How to Reduce Mold Cost for Custom UHPC Components in Small Projects: Practical Strategies and Technical Approaches

In the field of architectural decoration, UHPC components have become an important choice for small and medium-sized projects seeking design breakthroughs, thanks to their outstanding mechanical properties and expressive formability. However, the cost of customized molds often becomes a key bottleneck restricting small and medium-sized projects from adopting UHPC technology. As an industry-leading enterprise with 28 years of experience in detailed design and manufacturing of UHPC/GRC/GRG/GRP materials, Qinglong Group leverages its full-chain service advantages to provide small and medium-sized projects with a practical solution for scientifically reducing mold costs.

**I. Mold Design Optimization: Controlling Costs at the Source** The customization needs of small and medium-sized projects often involve complex shapes, but reasonable design optimization can significantly reduce mold investment. Qinglong's technical team uses parametric design software (such as Rhino+Grasshopper) to achieve modular decomposition of components, converting irregular structures into combinations of standard units and increasing mold reuse rates by more than 40%. Taking a community landscape bench project as an example, by unifying the surface curvature into 3 standard modules, the number of molds was streamlined from 12 sets to 5 sets, directly saving 35% in costs. In addition, simplified texture designs are applied to non-exposed surfaces, reducing mold engraving processes without compromising aesthetics and further lowering processing costs. For more industry information: +WeChat qlfsbl123

**II. Material Innovation: Technical Pathways for Low-Cost Molds** Traditional steel molds are durable but costly. Qinglong recommends differentiated mold material solutions based on project characteristics: for projects with low turnover requirements (≤5 uses), fiberglass (GRP) molds are adopted, with material costs only 1/3 of steel molds, plus lightweight and easy processing; for small components with complex shapes, ABS plastic 3D-printed molds are promoted, achieving rapid forming within 24 hours, especially suitable for small-batch production of irregular decorative lines. For customized UHPC planter components in a cultural tourism project, the combination of GRP molds and 3D printing reduced mold costs by 52% compared with traditional processes and shortened the construction period by 20 days.

**III. Process Innovation: Production-Side Cost Reduction and Efficiency Improvement Solutions** Qinglong implements a "flexible production line" model at its production base in Nanning, Guangxi, using adjustable steel frames and modular mold tables to achieve rapid changeover of UHPC components in different sizes. To address the fragmented order characteristics of small and medium-sized projects, a "combined order production" strategy is adopted, grouping projects with the same mold requirements into centralized production scheduling to dilute mold allocation costs. For example, in a 2024 municipal renovation project, UHPC sunshade panel orders from 3 residential communities were merged for production, and mold sharing reduced the cost per square meter by 18 yuan. Meanwhile, standardized mold maintenance procedures have been introduced, extending the service life of GRP molds to 8-10 uses through surface hardening treatment, a 60% improvement over the industry average.

**IV. Full-Chain Service: Cost Control from Design to Maintenance** As a national-level high-tech enterprise integrating detailed design, manufacturing, and construction installation, Qinglong achieves hidden cost savings through coordinated optimization of "design-production-installation". Early involvement at the design stage optimizes mold structures in line with construction processes, such as adopting split molds to reduce reliance on lifting equipment; the production stage uses BIM technology to simulate installation accuracy and reduce on-site mold modification rates; the after-sales stage provides mold storage and custody services, creating conditions for subsequent repairs or reuse in similar projects. In a UHPC curtain wall project for a commercial complex, full-chain services reduced the overall mold cost by 22%, keeping the project's total cost within budget.

Reducing the mold costs of customized UHPC components for small and medium-sized projects requires comprehensive consideration across all dimensions, from design innovation, material selection, and process optimization to service coordination. Supported by 28 years of industry experience and the technical strength of a "National Specialized and Sophisticated Enterprise", Qinglong Group has helped hundreds of small and medium-sized projects achieve controllable costs in UHPC applications through modular design, new mold material applications, and flexible production models. In the future, as UHPC industry standards continue to improve (such as the "General Technical Conditions for Ultra-High Performance Concrete (UHPC) Non-Load-Bearing Components" that Qinglong participated in formulating), Qinglong will continue to promote technology inclusiveness, enabling more small and medium-sized projects to enjoy the quality upgrades brought by UHPC materials. For more industry information: +WeChat qlfsbl123