Shenzhen Yirui Biotechnology Building

I. Basic Project Overview

This project is a major industrial investment project in Shenzhen in 2022 and a key industrial project in Bao'an District. It has a total construction area of ​​approximately 80,000 square meters and comprises two underground floors and two independent buildings above ground: an 8-story staff dormitory and a 6-story R&D and production plant. The building's functions include a biological R&D center, standardized production workshops, an information data center, office areas, staff dormitories, commercial facilities, a staff canteen, underground parking, and a full set of water and electrical equipment rooms.

Once completed, the project will improve the supporting facilities for the biomedical industry in Bao'an District, enhance the region's industrial carrying capacity and core competitiveness, and serve as a benchmark project for the UHPC irregular facade in Shenzhen Industrial Park.

II. Core Material: UHPC Ultra-High Performance Concrete

The exterior facade, ceiling, and elevator decorative columns of this project all utilize UHPC-reinforced ultra-high performance concrete. All materials have undergone third-party standardized testing, and all indicators exceed national and industry standards. The testing was conducted in accordance with national and industry standards including GB/T 50081-2019, GB/T 15231-2008, and T/CBMF 171-2022/T/CCPA30-2022. The measured core performance parameters are as follows:

1. Average compressive strength: 133.4 MPa (standard requirement: ≥120 MPa)

2. Bending proportional ultimate strength: 17.3 MPa (standard requirement: ≥11.0 MPa)

3. Bending strength: 25.3 MPa (standard requirement: ≥22.0 MPa)

4. Dry bulk density: 2.3 g/cm³ (standard requirement: ≥2.2 g/cm³)

5. Water absorption rate: 1.4% (standard requirement: <1.5%)

The material possesses core advantages such as ultra-high strength, low water absorption, impermeability, weather resistance, durability, and strong plasticity, enabling integrated molding of complex curved surfaces and hollow irregular shapes, thus meeting the needs of modern irregular building designs in industrial parks.

III. Implementation Process of Digital Design for Four Major Projects

The project features a complex design, including a large-area curved ceiling, double-curved elevator columns, and a gradient perforated facade. The entire design was developed using BIM digital modeling and was implemented across four key design areas:

1. Establishment of a complete BIM model of the entire building

In the early stages of the project, a complete 3D digital model was built, integrating the main building, UHPC facade, ceiling, elevator irregular components, and steel structure support system. This allowed for the early prediction of issues such as surface collisions, component size errors, and installation space conflicts, thereby reducing the rate of construction rework from the outset.

2. Detailed PD drawings for UHPC unit blocks

For tens of thousands of irregularly shaped UHPC panels and hollow ceiling components, each is individually numbered and separated, and PD production and processing drawings are issued for each component. Each component is marked with dimensions, hollow patterns, pre-embedded points, and installation numbers, so as to achieve standardized mass production in the factory and precise assembly on site according to the numbers.

3. Large-area curved ceiling surface positioning design

The project features a 435㎡ curved ceiling, entirely composed of irregular, multi-curved surfaces with no uniform, flat panels. BIM was used to extract the surface coordinates, precisely determining the curvature, elevation, and cutout arrangement of each ceiling component to ensure a smooth transition across the overall curved surface.

4. Elevator-shaped hyperboloid UHPC integrated connection

The elevator facade features streamlined, hyperboloidal, irregularly shaped UHPC decorative columns, which presented a significant construction challenge for the project. Through 3D surface layout, the curvature of the hyperboloids, floor elevations, and glass curtain wall finishing dimensions were uniformly coordinated to achieve a seamless, integrated design between the UHPC components and the glass curtain wall.

IV. End-to-End Production and On-Site Installation Solution

1. Custom manufacturing of irregular curved surface molds

The ceiling and elevator hyperboloid components are all made using a 1:1 solid wooden negative mold customization process. The factory replicates the building's curved surface shape 1:1 and manually polishes the curvature of the curved surface to ensure the accuracy and flatness of the curved surface after UHPC casting, thus solving the problem of forming irregular arc shapes.

2. Standardized production of UHPC components

Relying on its own UHPC prefabrication production workshop, irregularly shaped components are cast and cured in batches according to the PD component drawings, and connecting sleeves and reinforcing ribs are pre-embedded, eliminating the need for on-site installation of back steel frames and simplifying the subsequent on-site connection process.

3. High-precision on-site installation control

1. Curved ceiling: The four points of a single ceiling panel are not on the same horizontal plane. A total station and infrared instruments are used for cross-positioning to extract three-dimensional reference coordinates for precise alignment and installation.

2. Standard exterior wall panels: Strictly follow the PD numbered drawings and assemble in sequence after positioning the instrument at the baseline;

3. Elevator hyperboloid decorative column: The component is large, heavy and has a small installation space. It adopts the process of pre-embedded sleeve + on-site bracket support connection, strictly controls the fit between the component and the glass curtain wall, and simultaneously protects the surface of the finished product.

V. Overall Project Implementation Value

1. Industrial Value: As a key industrial benchmark project in Shenzhen, the high-end UHPC facade enhances the architectural identity of the industrial park and helps upgrade the image of the Bao'an District Biomedical Industrial Park;

2. Technical Demonstration Value: A rare domestic case of large-area double-curved surface and hollowed-out arc ceiling integrated UHPC industrial park implementation, providing a complete BIM detailing + prefabrication production + on-site installation solution for irregular facade projects in industrial parks;

3. Architectural Aesthetic Value: High-strength UHPC material enables a thin and curved surface design, while the gradient hollow ceiling paired with streamlined elevator decorative columns creates a modern, minimalist, and technologically advanced visual effect for the biomedical industrial park.

FAQ

Q1: Does the performance of the UHPC material used in this project meet the requirements of national standards?

A1: All test indicators are superior to national standards and industry association standards. The test report is issued in accordance with specifications such as GB/T 50081-2019, GB/T 15231-2008, and T/CBMF 171-2022. Core parameters such as compressive strength, bending strength, water absorption, and density all meet the standards. The material's compliance and durability are supported by complete test data.

Q2: How to ensure the overall smoothness of a large-area, irregularly curved UHPC ceiling?

A2: Accuracy is controlled in two steps. In the first step, BIM 3D modeling is used to extract the coordinate data of each curved surface. In the second step, the factory uses a 1:1 solid wooden negative mold to replicate the complete curved surface. After the components are prefabricated, the total station and infrared dual instruments are used on site for positioning to accurately control the elevation and curvature splicing gap of each ceiling piece.

Q3: What is the biggest challenge in the construction of UHPC decorative columns for elevators, and how can it be solved?

A3: The challenges are the large size and weight of the components, the limited space for installation and operation, and the need for precise fitting with the glass curtain wall. Solution: Pre-embed reinforcing ribs and connecting sleeves during the prefabrication stage, use architectural corbel supports for on-site fixing, and use BIM simulation to adjust the connection dimensions between the curved surface and the curtain wall before construction to reduce on-site splicing errors.

Q4: Why is the 1:1 wooden negative mold manufacturing process used for irregular curved UHPC components?

A4: The ceiling and elevator columns in this project are irregular free-form surfaces, and standardized steel molds cannot adapt to the varying curvatures; 1:1 wooden molds can be manually polished to create any arc shape, completely replicating the architectural design surface. The UHPC components after molding have smooth surfaces without corner deformation, adapting to complex irregular shape requirements.

Q5: What are the advantages of using UHPC exterior wall panels compared to ordinary curtain walls in industrial park buildings?

A5: ① Higher mechanical strength, impact and crack resistance, suitable for factory areas with high pedestrian and equipment traffic; ② Water absorption rate of only 1.4%, waterproof and weather-resistant, not prone to water seepage or efflorescence during long-term outdoor use; ③ Extremely malleable, can achieve hollow, hyperboloid, and streamlined irregular shapes, enhancing the recognizability of park buildings; ④ Controllable self-weight, prefabricated components can be assembled on-site, shortening the construction period of the park.

Q6: What key roles does BIM overall modeling play in this UHPC project?

A6: First, integrate the main building structure, UHPC curved components, steel structure, and curtain wall system in advance to identify spatial collision issues; second, disassemble tens of thousands of irregularly shaped components and issue part number drawings to achieve standardized production in the factory; third, extract precise coordinate data of the curved surface to provide three-dimensional data basis for mold making and on-site instrument positioning.

Q7: Is the UHPC irregular facade difficult to maintain in the later stage?

A7: The UHPC in this project has extremely low water absorption and a dense, non-porous surface, making it less prone to dirt accumulation, water seepage, and moss growth. The material itself is UV resistant and weather-resistant, requiring only daily rinsing with water. There is no need for frequent renovation or repair, and the long-term maintenance cost is far lower than that of stone or ordinary concrete curtain walls.

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