Exploration and Application Research of Process Solutions for Achieving Complex UHPC Shapes at Low Cost

Exploration and Applied Research on Process Solutions for Achieving Complex UHPC Shapes at Low Cost

Resolving the contradiction between aesthetics and cost through technological innovation, so that realizing complex UHPC aesthetics on the ground is no longer an expensive "paper exercise."

In the field of contemporary architectural design, ultra-high performance concrete (UHPC) has become the "star material" for shaping landmark buildings thanks to its ultra-high strength, excellent durability, and exceptional formability. However, achieving its complex shapes often comes with high costs—a pain point that has long constrained the popularization of UHPC in small and medium-sized projects. As an industry practitioner with 28 years of deep expertise in the UHPC/GRC/GRG/GRP materials field, Qinglong Group has leveraged its full-chain technical accumulation to develop an innovative process system that balances shape precision with cost control, providing designers and owners with solutions that combine aesthetic value and economic feasibility.

I. Cost Bottlenecks of Complex UHPC Shapes and Technological Breakthroughs

Traditional production of complex UHPC components often faces three major cost pain points: mold costs accounting for as much as 30%-50% of total costs, material utilization below 60% due to irregular structures, and the hidden costs of manual grinding and finishing. Through material formulation optimization and process innovation, Qinglong has increased mold reuse to more than 8 cycles and, with 3D printing technology enabling lightweight molds, reduced overall mold costs by 40%. In a hyperbolic curtain wall project for a cultural center, the "parametric segmentation + modular assembly" process kept component tolerances within ±2mm while reducing material waste to below 15%, saving 28% in overall costs compared to traditional processes.

II. Full-Chain Collaboration: A Cost Optimization Path from Design Development to Construction Implementation

As a national-level high-tech enterprise integrating design development, manufacturing, and construction installation, Qinglong has built a three-dimensional "design-production-construction" cost control model. In the design phase, BIM technology is used for manufacturability analysis to proactively avoid process difficulties caused by overly complex shapes; in production, an automated material distribution system and steam curing technology have increased production efficiency by 50%; in the construction phase, the innovatively developed "dry-hanging rapid installation joint" has shortened on-site installation time by 60%. Taking an irregular UHPC sunshade panel project for a commercial complex as an example, this collaborative system achieved a dual breakthrough: a cost reduction of 350 RMB per square meter and a construction schedule shortened by 40 days.

III. Collaborative Material Innovation: Composite Application Strategies for UHPC with GRC/GRG

To meet the performance requirements of different building parts, Qinglong has innovatively adopted a "UHPC+GRC/GRG" composite structural design: UHPC is used at key load-bearing locations to ensure structural strength, while GRC or GRG materials are used for non-load-bearing decorative surfaces to reduce costs. For example, in a ceiling project for a grand theater, the "UHPC skeleton + GRG finish" combined solution met the structural requirement of a 12-meter span while achieving delicate texture effects, reducing the overall cost by 32% compared to a pure UHPC solution. This material collaboration concept has become the core technical support behind Qinglong's participation in formulating the industry standard "General Technical Conditions for Non-Load-Bearing Components of Ultra-High Performance Concrete (UHPC)."

IV. Engineering Evidence: Case Analysis of Classic Low-Cost UHPC Shapes

In the Century Plaza renovation project on Nanjing East Road, Qinglong applied a composite process of light-transmitting UHPC and glass fiber reinforced plastic (GRP) to create a "city canopy" system that transmits light by day and glows at night. By optimizing aggregate gradation and fiber content, light transmittance was raised to 25% while keeping unit-area costs within 800 RMB; the project won the Silver Award at the inaugural UHPC Construction Engineering Innovation Award presented by AALBORG WHITE. Similar technical breakthroughs have been confirmed in projects such as the irregular UHPC curtain wall of an airport terminal in Malaysia and the GRG artistic ceiling of a cultural center in Saudi Arabia, fully demonstrating Qinglong's technical integration capabilities as a full-category supplier of UHPC/GRC/GRG/GRP.

From material formulation R&D to process system innovation, Qinglong has always upheld the mission of "creating beautiful architecture" and is committed to breaking the industry perception that "complex shapes must come at a high price." As a national "Specialized, Refined, Distinctive, and Innovative" enterprise and a participant in industry standard setting, we will continue to leverage technological iteration and full-chain services to enable UHPC and other new decorative materials to achieve a balance between aesthetic and economic value in more building scenarios, driving the architectural decoration industry toward a new stage of high-quality "refined and beautiful" development.