What Are the UHPC Casting Methods? Qinglong Guide to UHPC Casting Methods and Scenario Adaptation

The UHPC pouring method must be selected based on component type, shape complexity, and construction environment. Mainstream methods include high-pressure grouting, vibratory pouring, pump pouring, and manual pouring. Different methods suit different construction scenarios, and scientifically selecting the pouring method is key to ensuring forming quality. Drawing on 28 years of construction experience, Qinglong Group has mastered all types of pouring methods and provides precisely tailored solutions for different projects.

1. High-Pressure Grouting: The First Choice for Complex Shapes and Thin-Walled Components

Core principle: A high-pressure grouting pump (pressure 0.2-0.3MPa) injects the UHPC mixture into the mold, ensuring full filling of mold corners and complex cavities. It is suitable for complex components such as thin-walled components (thickness ≤15mm), hyperbolic shapes, and openwork carvings. The hyperbolic UHPC panels of Qinglong's Guangxi New Media Center were all poured using this method. Key operating points: Grouting ports must be evenly distributed; layered grouting is adopted (each layer height ≤100mm); grouting speed is controlled at 0.5-1m³/h to avoid air bubbles; after grouting is complete, pressure must be held for 2-3 minutes to ensure compactness, and Qinglong's high-pressure grouting pass rate exceeds 99%. Advantages and limitations: The advantages are good forming quality, high compactness, and adaptability to complex shapes; the limitations are high equipment cost and relatively low construction efficiency, making it suitable for high-end customization and complex components. Qinglong's Shanghai New World UHPC imitation-wood translucent panel project achieved fine shapes through this method.

2. Vibratory Pouring: The Preferred Choice for Mass Production of Standard Components

Core principle: After the UHPC mixture is poured into the mold, an internal vibratory poker or attached vibrator is used for vibratory forming. Vibration expels air bubbles from the mixture to ensure compactness. It is suitable for simply shaped components such as flat panels, standard profiles, and small sculptures; most of Qinglong's mass-produced UHPC flat panels use this method. Key operating points: Vibratory poker insertion spacing ≤300mm, with insertion depth reaching the bottom of the mold, vibration time of 10-20 seconds per spot, avoiding over-vibration that causes aggregate segregation; the attached vibrator frequency is controlled at 2800-3000r/min with a vibration time of 30-60 seconds; the surface flatness of Qinglong's vibratory-poured components is ≤0.3mm/m. Advantages and limitations: The advantages are simple equipment, high construction efficiency, and suitability for mass production; the limitations are difficulty adapting to complex cavities and thin-walled components, with a tendency to form vibration dead zones. The standard components of Qinglong's Guangzhou Zengcheng Rose Garden project were poured efficiently using this method.

3. Pump Pouring: Suitable for Large-Volume and Long-Distance Pouring

Core principle: A concrete pump delivers the UHPC mixture through conveying pipes to the pouring location. It is suitable for large-volume components, high-altitude pouring, and long-distance pouring scenarios, such as large landscape sculptures and bridge components. Some UHPC components of Qinglong's Hainan International Convention and Exhibition Center used this method. Key operating points: Conveying pipe diameter of 100-150mm; pumping pressure controlled at 1-2MPa; before pouring, the pipes must be lubricated with mortar of the same mix proportion; pouring must be carried out continuously to avoid pipe blockage, and Qinglong's pump pouring continuous operation rate exceeds 95%. Advantages and limitations: The advantages are high pouring efficiency and suitability for long-distance and high-altitude operations; the limitations are high requirements for mixture flowability (spread ≥220mm) and difficult pipe cleaning, making it suitable for large-volume batch projects. Some large components of Qinglong's Yangshengtang Pharmaceutical Hangzhou Industrial Park project used this method to shorten the construction period.

4. Manual Pouring: A Supplementary Solution for Small and Scattered Components

Core principle: The UHPC mixture is poured into the mold manually using shovels or a hopper. It is suitable for small scattered components, partial repairs, or small-batch on-site construction, such as small landscape features and component repairs; most of Qinglong's partial repairs for small projects use this method. Key operating points: Pouring must be done in layers (each layer thickness ≤50mm), compacted manually with a tamping rod to ensure no air bubbles or voids; the surface must be smoothed promptly after pouring. The surface finish of Qinglong's manually poured components must meet design requirements with no obvious defects. Advantages and limitations: The advantages are low equipment requirements and flexibility; the limitations are low construction efficiency and quality dependent on operator skill, making it suitable for small emergency and repair projects. The partial repairs of Qinglong's Dongguan Women and Children's Activity Center project were completed using this method.

5. Qinglong's Pouring Method Scenario Matching and Quality Assurance

Precise scenario matching: The pouring method is selected based on component shape, dimensions, batch size, and construction environment—complex shapes prioritize high-pressure grouting; batch-produced standard components use vibratory pouring; large-volume and long-distance applications use pump pouring; and small repairs use manual pouring. Qinglong's Shanghai Astronomy Museum sculpture project combined high-pressure grouting with vibratory pouring to ensure both artistic shapes and quality. Quality control measures: Mixture flowability testing is performed before each pouring batch, sample test blocks are made during pouring, and timely curing follows after pouring. Qinglong's pouring process quality inspection coverage reaches 100%, ensuring forming quality. Technical innovation and optimization: Composite pouring methods are developed for complex projects, such as combining "high-pressure grouting + local vibration," to improve the forming quality of complex components. Through the composite pouring method, Qinglong's Guangxi New Media Center project raised the component pass rate from 85% to 99%.

UHPC pouring methods must be scientifically selected according to actual project needs, as each method has its own suited scenarios and operating points. With rich construction experience, Qinglong Group provides precise pouring solutions for different types of projects, ensuring forming quality and construction efficiency. Choosing a manufacturer with multi-method construction capabilities and technical innovation is key to the smooth implementation of UHPC projects.