Analysis of Mold Cost Proportion in Total Cost and Influencing Factors for Perforated UHPC Shapes

Molds are the "genetic code" of UHPC artistic forms, and their cost control directly determines the balance between project economics and aesthetic value.

In contemporary building envelope design, hollow-out UHPC (Ultra-High Performance Concrete) has become the "finishing touch" of landmark buildings thanks to its perfect fusion of mechanical performance and artistic expression. However, the customized production of such components relies on the support of precision molds, and the share of mold costs in the total budget often becomes a focal point of concern for owners and designers. As an industry-leading enterprise with 28 years of full-chain experience in UHPC/GRC/GRG/GRP, Qinglong Group will present a professional analysis from three aspects: cost composition, influencing factors, and optimization strategies.

I. Cost Share Analysis of Hollow-Out UHPC Form Molds

In the cost composition of hollow-out UHPC components, mold costs typically account for 20%-40%, significantly higher than ordinary concrete components (5%-15%). Taking a hyperbolic hollow-out curtain wall project at a cultural center as an example, the cost share of aluminum alloy molds with parametric design reached 35%, mainly due to the machining difficulty of irregular structures and their customized nature. Through cost data statistics from 300+ projects, Qinglong Group found that when the hollow-out ratio exceeds 50% or the form complexity reaches Grade G3 (hyperbolic surface + hollow-out texture), the mold cost share will exceed 40%, becoming a key factor constraining project economics.

II. Key Factors Affecting Hollow-Out UHPC Mold Costs

1. Form Complexity and Precision Requirements: The topological structure of hollow-out patterns directly affects mold machining difficulty. Linear hollow-outs can use modular steel molds, reducing costs by 25%; while non-linear hollow-out patterns generated parametrically require CNC precision machining, with mold unit prices reaching 8,000-15,000 RMB/㎡. In the light-transmitting concrete project at Century Plaza on Nanjing East Road, in which Qinglong Group participated, a single set of hollow-out texture molds with 0.2mm precision cost over 600,000 RMB.

2. Mold Material and Reuse Rate: Although steel molds require a high initial investment (3 times that of wooden molds), they can be reused more than 50 times, making them suitable for mass production; fiberglass (GRP) molds are suitable for complex curved surfaces, but their reuse rate is only 15-20 times. Through standardized mold interface design, Qinglong's production base has increased the proportion of universal modules to 40%, effectively reducing per-use costs.

3. Production Process Synergy: Adopting 3D printing rapid prototyping technology can shorten the mold development cycle by 50%, but increases material costs by 30%. The "digital mold + robotic engraving" technology jointly developed by Qinglong and universities has enabled low-cost mass production of complex hollow-out forms, and the related achievements have been applied to award-winning projects such as the Dongguan Women and Children's Activity Center.

III. Mold Cost Optimization Paths from a Full-Chain Perspective

As a national high-tech enterprise, Qinglong Group proposes an integrated "design-production-construction" cost control solution: at the design stage, BIM parametric optimization of hollow-out textures reduces the proportion of non-standard mold parts; in production, modular molds and replaceable inserts raised the mold reuse rate to 65% for a commercial complex project; on the construction side, precise layout reduces material waste, comprehensively lowering allocated mold costs by 18%. In addition, the industry standard "General Technical Conditions for Non-Load-Bearing Components of Ultra-High Performance Concrete (UHPC)", which Qinglong participated in formulating, provides a standardized basis for mold cost accounting.

The mold cost control of hollow-out UHPC forms is essentially a synergy of technological innovation and engineering experience. With 28 years of deep expertise in the UHPC/GRC/GRG/GRP materials field and the mission of "creating beautiful architecture", Qinglong Group helps designers transform creativity into practical and economical solutions through digital design, lean production, and full lifecycle services. In the future, with innovations in mold materials and the development of intelligent construction technology, hollow-out UHPC will achieve a win-win of artistic value and cost-effectiveness in more landmark projects.