What Are the Key Steps in the Factory Prefabrication Stage of UHPC Curtain Wall Panel Production?

The factory prefabrication stage of UHPC curtain wall panels consists of eight key steps: detailed design, mold preparation, raw material batching, mixing and vibration, steam curing, demolding and trimming, quality inspection, and packaging for shipment. Through automated production lines and refined management and control, Qinglong sets strict parameter standards for every step, ensuring product precision and stable performance, with a prefabrication pass rate of over 99%.

1. Preliminary Preparation Stage: Detailed Design and Mold Preparation

Preliminary preparation is the foundation of prefabrication quality, primarily ensuring precise shaping and process feasibility. Detailed design: Based on the original design drawings, BIM modeling, clash detection, node optimization, and split design are carried out to define the curtain wall panel dimensions, thickness, and embedded part positions, with production detail drawings issued. Qinglong's detailed design error is ≤±0.5mm, ensuring compatibility with on-site installation. Mold preparation: Mold materials (steel molds, GRP molds, silicone molds) are selected according to the shape, and molds are CNC-machined to ensure dimensional accuracy of ≤±0.3mm; the mold surface is coated with release agent (thickness ≤0.1mm). Qinglong uses GRP molds for double-curved curtain wall panels, achieving a shape fidelity of 99%. Embedded part installation: Embedded parts (stainless steel hangers, anchor bars) are fixed according to the positions specified in the detailed design, ensuring position deviation of ≤±2mm. Qinglong's embedded parts are firmly secured to the molds to prevent displacement during pouring.

2. Core Production Stage: Batching, Mixing, and Vibration

The core stage determines the strength and density of the UHPC matrix. Raw material batching: Cement, quartz sand, steel fibers, mineral admixtures, high-efficiency water reducer, and water are precisely weighed according to the formula, with batching error ≤±0.1%. Qinglong uses an automated batching system to ensure mix ratio consistency. Mixing process: First, the dry materials (cement, quartz sand, mineral admixtures) are mixed for 2-3 minutes; then the water reducer and water are added and mixed for another 2-3 minutes; finally, steel fibers are added and mixed for 1-2 minutes, with a total mixing time of 5-8 minutes, ensuring uniform fiber dispersion (coefficient of variation ≤5%). Qinglong's twin-shaft forced mixer improves mixing uniformity by 30%. Vibration molding: The mixture is poured into molds and vibrated for 3-5 minutes on a high-frequency vibrating table (frequency ≥2500 times/min), supplemented by an internal vibrator for edges, corners, and embedded part areas, ensuring density (≥2.4g/cm³). Qinglong's vibrated UHPC is free of air bubbles and voids, with a flat surface.

3. Post-Processing Stage: Curing, Trimming, Inspection, and Shipment

Post-processing ensures stable product performance and compliant appearance. Steam curing: After casting, components rest for 2-4 hours before entering the steam curing room, following the curing curve of "temperature rise (10-15°C/h) → constant temperature (80-85°C, 48 hours) → cooling (≤10°C/h)", ensuring the 7-day strength reaches over 80% of the design strength. Qinglong's curing room maintains temperature and humidity accuracy of ±1°C and ±2%, allowing full hydration. Demolding and trimming: After curing, components are demolded, flash and burrs are cut off, and surface defects are ground down to ensure surface flatness ≤1mm/m. Qinglong uses automated cutting and trimming equipment with trimming precision ≤±0.5mm. Quality inspection: Each piece is inspected for dimensional deviation (length ≤±2mm, thickness ≤±1mm), appearance quality (no cracks or air bubbles), and mechanical properties (sampling tests for compressive and flexural strength). Qinglong's inspection coverage rate is 100%, and defective products are strictly prohibited from shipment. Packaging for shipment: Component surfaces are covered with waterproof film, corners are wrapped with anti-collision strips, and components are stacked by type in layers with clear labeling. Qinglong's packaging damage rate is ≤0.1%, ensuring safe transportation.