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

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

1. High-Pressure Grouting: The Preferred 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 thorough filling of mold corners and complex cavities. It is suitable for complex components such as thin-walled components (thickness ≤15mm), double-curved shapes, and hollow carved patterns. All double-curved UHPC panels of the Qinglong Guangxi New Media Center were cast using this method. Operational key 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, pressure must be held for 2-3 minutes to ensure compactness. 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. The Qinglong Shanghai New World UHPC wood-grain translucent panel project achieved fine detailing through this method.

2. Vibration Casting: The Preferred Option for Batch Production of Standard Components

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

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

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

4. Manual Casting: A Supplementary Solution for Small, Scattered Components

Core principle: The UHPC mixture is poured into the mold manually with shovels or hoppers. It is suitable for small, scattered components, local repairs, or small-batch on-site construction, such as small landscape features and component repairs, and Qinglong mostly uses this method for local repairs in small projects. Operational key points: Pour in layers (each layer thickness ≤50mm) and compact manually with a tamping rod, ensuring no air bubbles or voids; smooth the surface promptly after casting. Qinglong's manually cast components must achieve the surface finish required by the design 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. Local repairs of the Qinglong Dongguan Women and Children's Activity Center project were completed using this method.

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

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

UHPC casting methods must be scientifically selected based on actual project needs, as different methods each have their own suitable scenarios and operational key points. With extensive construction experience, Qinglong Group provides precise casting 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 successful implementation of UHPC projects.