Different Types of UHPC Casting Methods and Their Application Scenarios

As a revolutionary breakthrough in the field of new architectural decorative materials, Ultra-High Performance Concrete (UHPC) is reshaping the aesthetic and functional boundaries of modern architecture with its ultra-high strength, excellent durability, and outstanding design expressiveness. As an industry leader with 28 years of deep expertise in UHPC/GRC/GRG/GRP materials, Qinglong Group leverages its full-chain service capabilities to provide an in-depth analysis of the core types of UHPC casting technology and their application-matching logic, offering designers and owners expert-level solutions from concept to completion.

Three Core Types of UHPC Casting Technology and Their Process Characteristics

The casting method for UHPC must be precisely selected based on component form, project scale, and performance requirements. Currently, mainstream technologies can be divided into three major systems:

1. Conventional Casting Process: An Efficient Solution for Standardized Components Suitable for regular components such as flat wall panels and linear decorative moldings, this process adopts formwork casting combined with vibration densification. By precisely controlling the water-binder ratio (typically ≤0.2) and steel fiber content (2-5% by volume), it achieves mechanical performance with a 28-day compressive strength of ≥150MPa. Qinglong Group's production base in Nanning, Guangxi, is equipped with automated casting lines with a daily output of 3,000 square meters, meeting the batch demands of large real estate projects. A representative project—the UHPC curtain wall panels of a commercial complex—achieved 0.5mm-level dimensional accuracy control through this process.

2. Spray Casting Technology: A Powerful Tool for Forming Complex Curved Surfaces For complex shapes such as double-curved curtain walls and sculptural forms, the high-pressure spray casting process is adopted, in which UHPC material is applied to the mold surface as a high-velocity jet, with robotic arms enabling precise three-dimensional build-up. This technology shone in the renovation project of Century Plaza on Nanjing East Road, where the Qinglong team completed the integrated forming of light-transmitting UHPC components through the spray process, retaining the material's structural strength while achieving a visual effect with a light transmittance of 15%, winning the AALBORG WHITE Cup UHPC Architectural Engineering Innovation Award.

3. Precast Assembly Casting: Core Support for Industrialized Construction By pre-fabricating UHPC modular components in the factory and performing bolted connections or wet joint casting on site, construction efficiency is greatly enhanced. Qinglong participated in drafting the industry standard “General Technical Conditions for Non-Load-Bearing Components of Ultra-High Performance Concrete (UHPC),” which specifies the mechanical performance indicators and installation specifications for precast components. In a municipal utility tunnel project, its precast UHPC cover slabs achieved a 6-meter span with a reinforcement-free design, reducing weight by 40% compared to conventional concrete and increasing installation efficiency by 3 times.

Scenario-Based Applications: A Technology Selection Guide Matching Project Needs

The technical characteristics of different casting processes determine their suitability for different scenarios:

• Landmark Building Envelopes: Composite Solution of Spray Casting + Precast Assembly Cultural buildings such as grand theaters and museums often feature double-curved, free-form UHPC curtain walls, which require the spray process to achieve shape complexity while shortening construction schedules through precast modular installation. The GRC/UHPC composite exterior wall system created by Qinglong for the Dongguan Women and Children's Activity Center realized the design concept of “flowing rhythm” through this technology combination, winning the GRC Architectural Engineering Innovation Award.

• Municipal Infrastructure: The Cost-Effective Choice of Conventional Casting Structural components such as bridge guardrails and tunnel linings demand stringent strength and durability. The conventional casting process combined with steam curing (80°C, 48 hours) ensures that the material meets early strength standards. In a river-crossing bridge UHPC anti-collision guardrail project that Qinglong participated in, the impact resistance was improved by 200% compared to conventional concrete.

• High-End Interior Decoration: Textural Expression Through Fine Casting For areas such as artistic staircases and elevator door surrounds in commercial complexes, fine casting combined with surface polishing can achieve a delicate texture similar to natural stone. The UHPC spiral staircase created by Qinglong for a five-star hotel achieved a “mirror-grade” decorative effect through 0.1mm-level surface flatness control.

As a National High-Tech Enterprise and a participant in industry standard development, Qinglong Group has transformed 28 years of engineering experience into technical advantages, establishing a full-chain service system covering material R&D, digital design, intelligent production, and precision installation. Whether facing the extreme challenges of super high-rise curtain walls or the meticulous restoration of historical buildings, Qinglong remains committed to its mission of “creating beautiful architecture,” providing customers with optimal solutions for UHPC/GRC/GRG/GRP materials and promoting the innovative application of new building materials worldwide.