What Are the Casting Methods for UHPC?

The casting method for UHPC must be selected according to the component shape, dimensions, reinforcement density, and site conditions. The core objective is to ensure that the highly viscous mix can fully fill every corner of the formwork, achieving dense and uniform compaction while avoiding uneven fiber distribution. In engineering practice, Qinglong Group mainly adopts several mainstream methods, including "conventional casting with vibration," "pump-up method," and "self-leveling grouting," and uses a "precast assembly" approach for special components to avoid the difficulties of on-site casting.

Conventional casting with high-frequency vibration is the most commonly used method. It is suitable for most beams, slabs, columns, and components with relatively simple shapes. Since the UHPC mix has strong cohesion and relatively poor self-flowability, it must be supplemented with powerful vibration. A high-frequency poker vibrator is typically used (with a frequency above 10,000 revolutions per minute), inserted quickly and withdrawn slowly, with evenly distributed insertion points. Vibration should continue until paste appears on the surface and no large bubbles emerge; over-vibration must be strictly avoided to prevent fiber floating and paste segregation. For thin-walled components, attached form vibrators can be used. This method places high demands on workers' operational experience.

Pump-up or pressure grouting is suitable for steel tube UHPC columns, narrow deep cavities, or complex joints with extremely dense reinforcement. The UHPC mix is injected from the bottom under pressure and rises slowly under pressure, which effectively expels air bubbles and ensures compactness. This method requires dedicated UHPC pumping equipment and places special requirements on the workability and pumpability of the mix proportion. Qinglong can provide technical support and specialized materials for such projects.

Precast assembly is the ultimate solution for highly complex shapes and high-precision requirements. In the factory, using steel molds and standard curing conditions, UHPC precast components of exceptionally high quality can be produced, such as double-curved panels, artistic components, and large cladding panels. On-site work is limited to hoisting, splicing, and joint treatment. This method maximizes the assurance of UHPC performance and appearance quality, offers fast construction, and has minimal impact on the site environment. Qinglong Group's core business is precisely the production and installation of high-quality UHPC precast components, providing architects with the most reliable industrialized approach to realizing complex creative designs.