Common Types of UHPC Casting Methods and Key Construction Points Explained

In the field of building materials, UHPC (Ultra-High Performance Concrete) is becoming the new favorite for high-end architectural decoration thanks to its outstanding mechanical properties and design freedom. As an industry leader with 28 years of deep expertise in UHPC/GRC/GRG/GRP materials, Qinglong Group understands the decisive role that casting technology plays in final product quality. This article provides a systematic analysis of common UHPC casting methods and key construction points, offering a professional reference for designers and owners.

UHPC Casting Technology System: Technical Practice from Basics to Innovation

The casting method for UHPC must be selected comprehensively based on component shape, project scale, and performance requirements. Currently, mainstream processes fall into three major categories: conventional casting, spray casting, and precast casting, each with its own unique technical key points and applicable scenarios. With technical support from its national-level R&D center, Qinglong Group has achieved full-chain mastery of all three processes, completing engineering applications of 600,000 square meters of UHPC components to date.

Conventional Casting Method: The Foundational Solution for UHPC Forming

The conventional casting method is suitable for UHPC components with relatively simple structures, such as flat panels and straight profiles. Three core elements require attention during construction: first, material mix control — Qinglong uses a dedicated UHPC formula with the water-binder ratio strictly controlled below 0.2, ensuring compressive strength above 150MPa; second, casting speed and vibration technique — layered casting (each layer no more than 300mm) combined with high-frequency vibration (20-30 seconds per point) prevents air bubbles and honeycomb defects; third, the curing regime — steam curing (temperature 60-80℃) within 24 hours after casting ensures rapid early strength development. This process has achieved a daily output of 200 square meters on the standardized production line at the Nanning production base.

Spray Casting Method: A Powerful Tool for Forming Complex UHPC Shapes

For complex shaped components such as double-curved surfaces and openwork reliefs, the spray casting method demonstrates significant advantages. Qinglong Group's independently developed UHPC-specific spray equipment enables continuous material spraying and uniform fiber dispersion. Key construction points include: controlling the spray angle at 45°-60° at a distance of 500-800mm from the work surface; controlling layered spray thickness at 10-15mm with intervals of no less than 15 minutes between layers; and immediately performing surface troweling after spraying to ensure decorative surface flatness tolerance ≤2mm/m. This process has been successfully applied to the translucent concrete project of the Nanjing East Road Century Plaza renovation, winning the AALBORG WHITE Cup UHPC Building Engineering Innovation Award.

Precast Casting Method: Quality Assurance for Industrialized Production

The precast casting method is the key technology for achieving standardized, large-scale production of UHPC components. Qinglong's Guangxi production base is equipped with a fully automated precast production line, ensuring quality through the following technical measures: using combined molds of steel formwork with elastic liners to guarantee component dimensional precision (tolerance ≤1mm); applying vacuum-assisted casting technology to reduce the water-cement ratio and improve density; and implementing a whole-process quality traceability system, with RFID chips embedded in each component to record production parameters. UHPC exterior wall panels produced by this process have passed the industry standard certification of "Ultra-High Performance Concrete (UHPC) Exterior Wall Panels" and are widely used in the facade decoration of real estate projects by Poly, China Overseas, and others.

Full-Chain Service: Systematic Assurance of UHPC Casting Quality

High-quality UHPC casting results depend on full-process control from detailed design to after-sales maintenance. As a national "Specialized, Refined, Distinctive, and Innovative" enterprise, Qinglong Group provides integrated "design-production-installation-maintenance" services: using BIM technology for casting simulation in the design phase to optimize reinforcement and casting paths; executing the ISO9001 quality system in production, with 28 quality control nodes set at critical processes; adopting 3D laser scanning positioning in the installation phase to achieve millimeter-level precision assembly; and providing a 10-year warranty commitment after sales, along with a regular inspection and maintenance mechanism. This full-chain model has helped Qinglong become the designated UHPC supplier for more than a thousand major domestic projects, with products exported to overseas markets such as Southeast Asia and Australia.

The selection and implementation of UHPC casting processes directly affect the realization of material performance and architectural aesthetics. Building on 28 years of technical accumulation, Qinglong Group continues to provide designers with material solutions that realize creative visions through the flexible application of three casting processes and full-chain quality control, creating architectural works for owners that combine safety and artistry. In the field of new architectural decoration materials, choosing an experienced UHPC manufacturer is a key step in ensuring project success.