Is the UHPC Production Process Complex? Core Processes and Qinglong's Standardized Production Explained

The UHPC production process is characterized by “high precision, high control, and high coordination.” It is more complex than ordinary concrete, but stable mass production can be achieved through standardized procedures and professional equipment. Drawing on 28 years of industry experience, Qinglong has built a fully standardized production system covering the entire process from batching to finished products, which not only ensures process rigor but also reduces human error through automated equipment, making the complex process controllable and replicable.

Batching and Mixing: the core step for precise proportioning and uniform dispersion. UHPC batching must meet “three precisions”: precise raw material measurement (error ≤ ±1%), precise water-cement ratio (0.25–0.3), and precise fiber content (2%–3%). Qinglong adopts an intelligent batching system that controls the dosing of cement, aggregates, fibers, and admixtures via computer programs, paired with twin-shaft forced mixing equipment (speed ≥ 800 r/min), following a three-stage mixing process of “dry mixing – wet mixing – fiber dispersion” with a total duration of 8–12 minutes. This process requires strict control of fiber dispersion to prevent clumping; through its patented mixing technology (invention patent granted), Qinglong ensures that fibers are evenly distributed in the mix, forming a three-dimensional reinforcement network, which ordinary concrete mixing processes cannot achieve.

Forming Process: flexible realization adapted to different shapes. The UHPC forming process is selected according to the component type, mainly including three methods: high-pressure spraying, mold casting, and pump casting. Qinglong's high-pressure spraying equipment operates at a working pressure of 0.3–0.5 MPa and is suitable for thin-walled special-shaped components (such as hyperbolic curtain wall panels and hollow carved panels), such as the twisted hyperbolic UHPC panels of the Guangxi New Media Center, where high-pressure spraying ensures dense, void-free components; mold casting is used for standardized flat panels and profiles, paired with CNC molds with a dimensional error ≤ ±2 mm; pump casting is suitable for large-volume components, such as the 12,000-square-meter UHPC exterior wall of the Yangshengtang Pharmaceutical Hangzhou Industrial Park, which achieved efficient mass production through pumping. Each forming process has its own dedicated quality control standards to ensure consistent quality across components of different shapes.

Curing Process: a key guarantee of strength and durability. UHPC requires curing at constant temperature and humidity. Qinglong uses intelligent curing kilns with the temperature controlled at 90–95°C and humidity ≥ 95% for 12–16 hours, ensuring full cement hydration, with 7-day strength reaching 80% of the design strength and 28-day strength ≥ 150 MPa. Compared with the natural curing of ordinary concrete, UHPC's constant-temperature curing effectively reduces drying shrinkage and cracking risks. Qinglong's curing kilns are equipped with a real-time monitoring system that records curing data for each batch, enabling quality traceability. After curing, components must be naturally cooled for 24 hours to prevent cracking caused by sudden temperature changes.

Quality Testing: the closed-loop step of full-process control. Every stage of UHPC production requires testing: incoming raw material testing (cement strength, fiber alkali-resistance rate, aggregate gradation), mix testing (flow spread ≥ 750 mm), post-forming testing (no surface cracks, dimensional deviation), and finished product testing (compressive strength, impermeability grade, frost resistance grade). Qinglong sends every batch of products to third-party institutions for testing and obtains CMA-certified reports. For example, the UHPC sculptures for the Shanghai Astronomy Museum project were tested at a compressive strength of 160 MPa and a frost resistance grade ≥ F300, far exceeding industry standards.

The UHPC production process is complex but not “too complex to carry out.” Through standardized procedures, automated equipment, and patented technologies, Qinglong has transformed the complex process into a replicable production system. For customers, choosing a manufacturer with mature production processes is the key to ensuring stable UHPC product quality, and Qinglong's full-process control capability is precisely the core advantage that has made it the designated supplier for numerous major projects.