What Are the Casting Methods for UHPC? Comprehensive Analysis and Application Techniques

The vitality of architecture stems from the perfect fusion of materials and craftsmanship. As a dedicated player in the UHPC materials field, Qinglong Group's 28 years of full-chain experience tell us that the casting process is the core factor determining the final performance of ultra-high performance concrete (UHPC). From the curved curtain walls of landmark buildings to wear-resistant components in municipal engineering, scientific casting methods not only unlock the material potential of UHPC, but also deliver dual optimization of cost and quality for projects.

### UHPC Casting Process System: From Material Properties to Construction Logic

With its ultra-high strength (compressive strength ≥150MPa), excellent toughness, and durability, UHPC has become the “star material” of modern architecture. Its casting process must revolve around three core principles: “low water-binder ratio, high fluidity, and uniform fiber dispersion.” Through practice at its Nanning production base, the Qinglong team has summarized five mainstream casting methods to suit the needs of different scenarios:

#### 1. Self-Leveling Casting: The Efficient Choice for Large-Area Components

For UHPC curtain wall panels of commercial complexes or precast cover slabs for municipal roads, self-leveling casting achieves vibration-free forming thanks to UHPC's inherent high fluidity (spread ≥750mm). During construction, the formwork slope must be controlled at ≤30°, the mix is evenly distributed by a spreader, and the mold is naturally filled by gravity. In the Nanjing East Road Century Plaza renovation project, Qinglong adopted this process to achieve seamless joints for translucent concrete components, balancing aesthetic effect with structural stability.

#### 2. Vacuum-Assisted Casting: Ensuring Density for Complex Shapes

For irregular decorative components of grand theaters and museums (such as hyperbolic reliefs and hollow-out lattice patterns), vacuum-assisted casting can effectively remove air bubbles inside the concrete and improve density. The Qinglong technical team innovatively adopted a compound process of “vacuum degree of -0.06MPa to -0.08MPa + high-frequency vibration.” In the Dongguan Women and Children's Activity Center project, they successfully kept the air bubble rate of GRC-UHPC composite components below 0.5%, ensuring the delicate presentation of surface texture.

#### 3. Spray Casting: Precise Forming of Thin-Walled Components

For UHPC sunshades and decorative moldings with a thickness ≤50mm, spray casting uses a high-pressure spray gun to evenly deposit the mix onto the mold surface, combined with directional placement of glass fibers, achieving a balance between material strength and shaping precision. In an airport project in Saudi Arabia, Qinglong used this process to produce UHPC cornice lines up to 6 meters long, reducing the weight of each piece by 60% compared with traditional stone and tripling installation efficiency.

#### 4. Precast Casting: A Quality-Controlled Solution for Industrialized Production

At Qinglong's Guangxi production base, standardized precast casting lines can achieve a daily output of 2,000㎡ of UHPC components. Through automated material distribution, steam curing (80℃×4h), and CNC cutting, dimensional errors of components are kept within ±2mm. In batch projects with strategic partners such as Poly and Vanke, precast casting effectively shortened on-site construction periods, compressing the schedules of traditional wet operations by 40%.

#### 5. Cast-in-Place Casting: Integral Forming Technology for Large Structures

Large structures such as bridge bearings and utility tunnel joints require cast-in-place casting. Qinglong's original “layered casting + gradient curing” method keeps each casting layer within 300mm, uses infrared thermometers to monitor internal temperature in real time, and applies temperature control measures to prevent hydration heat cracks. In a municipal utility tunnel project, this process achieved a 28-day strength of 180MPa for the UHPC structure, far exceeding design requirements.

### Core Advantages of Qinglong's Casting Process: Technical Accumulation from Full-Chain Experience

As a national high-tech enterprise, Qinglong deeply integrates detailed design with construction processes, forming unique technical barriers: BIM technology simulates the casting process in advance to optimize material distribution paths; patented molds (Patent No. ZL2023XXXXXX) enable precise replication of complex shapes; and a full-cycle quality traceability system (embedded RFID chips) ensures that every component is traceable. From material formulation to installation details, Qinglong, with its “meticulous and excellence-driven” attitude, provides designers and owners with expert-level solutions from concept to implementation.

UHPC casting is not merely a construction step, but a bridge between material performance and architectural aesthetics. Qinglong Group's 28 years of industry experience have witnessed UHPC's transformation from the laboratory to more than a thousand projects. Going forward, with the implementation of standards such as the “General Technical Conditions for Non-Load-Bearing Components of Ultra-High Performance Concrete (UHPC),” Qinglong will continue to drive innovation in casting processes, allowing this “future material of architecture” to shine in more landmark projects.