Single-layer cold storage high-clearance sky surface heat preservation high-altitude operation-free method

Abstract

The invention relates to a high-clearance sky surface heat-preservation high-altitude operation-free method for a single-layer refrigeration house, and belongs to the technical field of building installation. According to the method, manufacturing of the cold storage roofing heat preservation layer is completed on the ground, and the heat preservation layer is integrally hoisted to the designed height and fixed to a roofing building by adopting an electric hoist group hoisting system capable of being hung upside down through a loop chain and combining a carrying pole beam, a linkage control box and an elastic guider. According to the method, through lifting point mechanical calculation, load balanced distribution and special tool configuration, the problems of safety risk and low efficiency of traditional high-altitude operation are solved, synchronous installation of the heat preservation layer and subsidiary facilities (such as lighting and air pipes) is achieved, the construction efficiency can be improved, the cost is reduced, and the construction safety is remarkably improved.

Description

Technical Field

[0001] This invention relates to the field of building installation technology, specifically to a method for high-clearance roof insulation of single-story cold storage facilities without high-altitude operations. Background Technology

[0002] In traditional single-layer cold storage roof insulation construction, regardless of whether it is a level II, III, or extra-high-altitude operation, the common practice is to...

[0003] Using aerial work platforms, scissor lifts, or scaffolding for material transportation and installation presents significant problems:

[0004] Safety concerns: Workers at heights are exposed to dangerous environments for extended periods, increasing the risk of falls.

[0005] Inefficiency: Construction requires repeated transport of materials and equipment to high altitudes; the procedures are cumbersome and reliant on manual labor, leading to extended construction periods; high-altitude welding and splicing operations are limited by environmental constraints, making large-scale construction difficult. Cost

[0006] High costs: It requires renting large-scale aerial machinery and building temporary facilities, which ties up a lot of capital; high-altitude operations are inefficient, require high skill and physical fitness from personnel, require a large investment of manpower, and are prone to additional losses due to rework or accidents. Summary of the Invention

[0007] The purpose of this section is to outline some aspects of embodiments of the present invention and to briefly describe some preferred embodiments. Simplifications or omissions may be made in this section, as well as in the abstract and title of this application, to avoid obscuring the purpose of these documents; however, such simplifications or omissions should not be construed as limiting the scope of the invention.

[0008] In view of the problems existing in the prior art, the inventors have proposed the present invention.

[0009] Therefore, the purpose of this invention is to overcome the shortcomings of the prior art and provide a method for high-clearance roof insulation of single-story cold storage without high-altitude operations.

[0010] To solve the above-mentioned technical problems, the present invention provides the following technical solution: a method for high-clearance roof insulation of single-story cold storage without high-altitude operations, comprising the following steps:

[0011] (1) Determine the coordinates and number of the lifting points of the group crane, and perform load balance calculations based on the cold storage roof insulation type, unit area weight, rated lifting capacity of electric hoists and mechanical parameters of the spreader beam.

[0012] (2) Prefabricate the insulated roof on the ground and install auxiliary facilities on the insulation layer;

[0013] (3) The insulation layer is hoisted to the design height as a whole by means of a spreader beam and a chain hoist group lifting system;

[0014] (4) The lifting speed and load of each electric hoist are adjusted synchronously by the linkage control box, and the horizontal displacement of the insulation layer is controlled by the elastic guide.

[0015] (5) After hoisting, the insulation layer is welded and fixed to the roof building, and the escape hatch is filled.

[0016] As a preferred embodiment of the single-layer cold storage high-clearance roof insulation non-high-altitude operation method of the present invention, wherein: the spacing between the group of hoisting points is determined according to the size of the cold storage and the weight of the insulation layer.

[0017] As a preferred embodiment of the single-layer cold storage high-clearance roof insulation non-high-altitude operation method of the present invention, wherein: the spreader beam is made of Q235A carbon steel 18a channel steel, and its maximum bending moment stress is less than the allowable stress of the material.

[0018] As a preferred embodiment of the single-layer cold storage high-clearance roof insulation non-high-altitude operation method of the present invention, the rated lifting capacity of the chain-mounted electric hoist is 2t, the lifting speed is ≤5m / min, the lifting height is ≤22m, and the number of linkage control consoles is 20-24.

[0019] As a preferred embodiment of the single-layer cold storage high-clearance roof insulation non-high-altitude operation method of the present invention, the elastic guide is installed around the insulation layer to limit the horizontal swing during the hoisting process, the lifting speed is not greater than 5m / min, the lifting height is within 22m or higher, and the uneven load difference is not greater than 20%.

[0020] As a preferred embodiment of the single-layer cold storage high-clearance rooftop insulation method without high-altitude operation described in this invention, the linkage control box displays the current data of each electric hoist in real time to monitor load balance. As a preferred embodiment of the single-layer cold storage high-clearance rooftop insulation method without high-altitude operation described in this invention, the insulation layer is fixed to the rooftop structure by welding or bolting.

[0021] As a preferred embodiment of the single-layer cold storage high-clearance rooftop insulation non-high-altitude operation method of the present invention, the auxiliary facilities include lighting, air ducts and pipes, etc., which can be pre-installed on the ground and then hoisted synchronously with the insulation layer.

[0022] As a preferred embodiment of the single-layer cold storage high-clearance roof insulation non-high-altitude operation method described in this invention, an escape hatch with a size of 600mm×600mm needs to be reserved before hoisting, and a slow-descent device support point needs to be set.

[0023] As a preferred embodiment of the single-layer cold storage high-clearance roof insulation non-high-altitude operation method of the present invention, wherein: in the load balance calculation, the load of a single lifting point does not exceed 80% of the rated load of the electric hoist, and the unbalanced load difference is ≤20%.

[0024] The beneficial effects of this invention are as follows: By prefabricating the insulation layer on the ground and hoisting it as a whole, high-altitude operations are completely avoided, eliminating the risk of personnel falling; the introduction of elastic guides effectively controls horizontal swaying during hoisting, preventing the insulation layer from colliding with the building structure and further ensuring construction safety; the use of a group hoisting system and linkage control technology enables the synchronous hoisting of the insulation layer and its ancillary facilities (such as lighting and air ducts), reducing the need for cross-operations among multiple trades; the ground prefabrication mode simplifies the construction process and shortens the construction period; there is no need to rent high-altitude work equipment, reducing mechanical investment; the modular design of special tools (such as spreader beams and mother-daughter ring hangers) supports rapid disassembly and reuse, reducing material waste and labor costs; the arrangement of hoisting points and balanced load distribution based on mechanical calculations ensures uniform stress on the insulation layer and avoids local deformation; the linkage control box monitors the load of each hoisting point in real time and dynamically adjusts the lifting speed, improving installation accuracy and structural stability; this invention can adapt to the needs of cold storage of different sizes and is also suitable for the complex construction environment of high-clearance, large-span cold storage, providing a universal solution for the industry. (See attached figures for details.)

[0025] Figure 1 This is a schematic diagram of the connecting sleeve of the present invention.

[0026] Figure 2 This is a schematic diagram of the lifting sleeve with male and female rings according to the present invention.

[0027] Figure 3 This is a partial perspective view of the cold storage machine panel insulated roof group hanging system of the present invention.

[0028] Figure 4 This is a partial perspective view of the hoisting system for the on-site spraying of polyurethane insulation onto the roof of a cold storage facility, as described in this invention.

[0029] Figure 5 This is a schematic diagram of the 18a channel steel connecting pipe sleeve of the present invention.

[0030] Figure 6 This is a schematic diagram of the roller elastic guide of the present invention. Detailed Implementation

[0031] To make the above-mentioned objects, features and advantages of the present invention more apparent and understandable, the specific embodiments of the present invention will be described in detail below with reference to the examples in the specification.

[0032] Many specific details are set forth in the following description in order to provide a full understanding of the invention. However, the invention may also be practiced in other ways different from those described herein, and those skilled in the art can make similar extensions without departing from the spirit of the invention. Therefore, the invention is not limited to the specific embodiments disclosed below.

[0033] Secondly, the term "an embodiment" or "embodiment" as used herein refers to a specific feature, structure, or characteristic that may be included in at least one implementation of the present invention. The phrase "in one embodiment" appearing in different places throughout this specification does not necessarily refer to the same embodiment, nor is it a single embodiment or an embodiment selectively excluded from other embodiments.

[0034] Example 1

[0035] Reference Figure 1-3 This embodiment provides a method for high-clearance roof insulation without high-altitude operation in a single-layer cold storage facility, specifically a roof assembled from prefabricated panels for a single cold storage unit.

[0036] Cold storage specifications: Internal dimensions 75.6m × 21m × 20m; insulation layer is composed of 250mm thick polyurethane machine-made panels; total weight 1587.6m³. 2 ×20.86kg / m 2 = 33.1 tons.

[0037] Implementation steps

[0038] Calculation and verification of lifting point coordinates: The proposed assembly panel specifications are 7m × 1.2m × 0.25m.

[0039] Longitudinal spacing: Based on the length of the cold storage of 75.6m, 3 rows of hanging points are designed, with a row spacing of 7m except for the distance from the wall of 3.5m. The total span covers 63 machine-made panels.

[0040] Lateral spacing: The cold storage is 21m wide and designed with 8 rows of hanging points. The row spacing is 9.6m except for the 4.2m distance from the wall, corresponding to 3 machine-made panels.

[0041] Mechanical verification: The spreader beam is made of 18a channel steel, subjected to a uniformly distributed load q = 145 kg / m, with a maximum bending moment M = 1682 kg·m at mid-span and a maximum stress σ = 1191.2 kg / cm². 2 Less than the allowable stress of Q235A 1250 kg / cm² 2 .

[0042] Equipment configuration and installation:

[0043] Electric hoists: 24 electric chain hoists with a rated lifting capacity of 2t are selected, with a maximum load of 1444.36kg per lifting point (<2t×80%=1600kg).

[0044] Spreader beam connection: An M16 mushroom bolt is installed through the center of each machined plate, and it is connected to the channel steel through a cold-drawn connecting sleeve to ensure uniform load transfer.

[0045] Elastic guides: Two roller guides are installed on each of the four sides of the insulation layer. The magnetic base is attached to the surface of the roof insulation board. The spring preload is set to 300N to effectively limit horizontal swaying.

[0046] Technical effects:

[0047] Efficiency improvement: The total construction period for ground assembly has been shortened from the traditional 20 days to less than 10 days.

[0048] Cost savings: Reduce aerial work platform rental costs by tens of thousands of yuan and reduce labor costs by more than 50%.

[0049] Safety: No high-altitude operations throughout the entire process, with a zero accident rate.

[0050] Example 2

[0051] Reference Figure 1-4 This embodiment provides a method for high-clearance rooftop insulation of a single-story cold storage facility without high-altitude operations. Specifically;

[0052] Cold storage parameters: internal net dimensions 39.6m × 22m × 20m, insulation layer is 250mm thick polyurethane sprayed on-site, total weight 871.2m³. 2 ×32kg / m 2 = 27.9 tons.

[0053] Implementation steps:

[0054] Skeleton design and painting process:

[0055] Upper and lower chord frame: The upper chord is welded from 40×40×4 angle steel at 1100×1100mm, and the lower chord is welded from 30x30x3 angle steel at 1100×1100mm. A 250mm high support frame is formed by Φ18 nylon rods. 0.426mm thick V-shaped pressed color steel sheet.

[0056] Spraying parameters: Polyurethane density 35kg / m3~38kg / m3, layered spraying thickness 50mm / 5 times, interval 30 minutes.

[0057] Optimization of lifting points and load distribution:

[0058] Longitudinal spacing: Designed with 5 rows of hanging points, with a row spacing of 4.4m, covering a cold storage width of 22m (22÷4.4=5).

[0059] Lateral spacing: Designed with 4 rows of hanging points, with a row spacing of 9.9m, covering a cold storage length of 39.6m (39.6 ÷ 9.9 = 4).

[0060] Concentrated load verification: Single suspension point load 1393.92 kg, maximum bending moment of the spreader beam 1703.68 kg·m, stress σ=1205 kg / cm² 2 The safety reserve factor is greater than 2.

[0061] The technical benefits achieved include: reduced construction time and labor costs by more than half compared to high-altitude operations; and high safety with a zero accident rate.

[0062] Material utilization rate: Ground spraying reduces high-altitude losses.

[0063] This invention addresses three major pain points in traditional cold storage roof insulation construction through systematic innovation: the risks of working at heights, low efficiency, and high costs. By calculating the load of the spreader beam and dynamically adjusting the lifting points, a balance between structural safety and economy is ensured. Standardized toolkits, including flexible guides and linkage control boxes, are formed to adapt to the needs of cold storage facilities of different sizes. Pre-installation of lighting and ventilation ducts on the ground reduces overlapping work at heights and shortens the construction period by more than 30%. The design of reserved openings and deceleration devices balances construction safety with convenient later transportation.

[0064] This invention is applicable to fields with high requirements for cleanliness and safety, such as food cold chain and pharmaceutical warehousing. In addition, the group lifting principle of this invention can be extended to scenarios such as large factory roof installation and ship section construction.

[0065] Compared to traditional methods:

[0066] index This invention Traditional high-altitude operations Construction period Shorten by 50%-60% Long cycle Safety accident rate 0％ 0.5%-1% per year Comprehensive cost Reduce by 5-10% High proportion of equipment leasing Environmental protection Reduce material waste High-altitude spraying results in high losses.

[0067] It should be noted that

[0068] Several things that need to be done well.

[0069] 1. The determination of the location and number of lifting points for a group of cranes should be synchronized with the planning and design of the project.

[0070] After an engineering project is put into operation, its usability, practicality, rationality, advanced technology, and cost-effectiveness largely depend on the scientific and rational nature of its planning. This high-altitude operation method suggests that the insulation professionals be involved in the planning stage of the project to jointly ensure the smooth operation of the group hoisting. Relevant parameters of the group hoisting, such as coordinates, quantity, and load, should be submitted to the design department in a timely manner, and hooks should be pre-installed during construction. Furthermore, the construction department should be required to mark contour lines and cold storage insulation surface lines at 2-meter intervals along the walls and columns after plastering, for easy reference during group hoisting operations.

[0071] 2. This method of avoiding high-altitude operations mainly involves raising the roof insulation of a single-story, high-clearance cold storage facility to the designed height after the ground level is completed, thus essentially eliminating the need for high-altitude work. The specific methods for fabricating the insulation layer, fixing it to the roof structure, and integrating it with the wall insulation are still largely determined by the established practices or best practices of each professional unit.

[0072] 3. The attachment of electric hoists or hoist traction chains, operator safety belts, and slings to the pre-installed hooks on the roof surface is problematic. Since the compressive strength of the insulated roof surface, whether machine-made or sprayed on-site, is relatively low and insufficient to withstand the pressure of aerial work platforms or lifting platforms, and because ground-level construction doesn't involve being flush with the ground but rather supported at a suitable height using a support structure similar to a crib, this high-altitude work method recommends that the above three items be pre-attached using an aerial work platform or mobile four-post aluminum alloy lifting platform before the roof insulation layer is installed (since chain hoists are easy to install and remove, the chain can be attached first, and then connected to the hoist during group lifting operations).

[0073] 4. A minimum clearance of 1.6m should be maintained for the hanging components. Since the hanging components have a certain length and the electric hoist has a minimum retraction distance, the clearance between the insulated roof and the building roof hook should be at least 1.6m.

[0074] The five specialized tools for non-high-altitude operations are equipped with CC-type turnbuckles and shackles, primarily to increase fulcrums and facilitate flexible hoisting. For example, when used as fulcrums for hoisting safety belts, if a hoist malfunctions during group operations, the CC turnbuckle and shackles can be used to immediately replace the hoist. At the end of the group operation, the CC turnbuckle and shackles can replace the hoist, and the hoist can be removed, transforming the insulated roof into a large operating platform. Additionally, the turnbuckles can fine-tune the height of the insulated roof, facilitating coordination with wall insulation construction and benefiting the connection of large cold storage units to secondary and tertiary insulation panels.

[0075] <II> Preparatory work to be done before the assignment.

[0076] 1. Prepare a written hoisting plan. This high-altitude operation method believes that since the hoisting content is relatively simple, it is sufficient to fill in a special plan preparation form. However, the operators and relevant personnel must read it carefully, make sure the content is clear, and sign it.

[0077] 2. If only a traction chain is to be pre-attached, the hoist and chain should be assembled and the electrical wiring connected.

[0078] 3. Carefully inspect the condition of the equipment and site, especially the electric hoist chain for any twisting, knotting, or piling up. Check for any misalignment or overturning of the lower hook of the lifting chain, whether the lifting sprocket and guide wheel are properly engaged with the chain, whether the upper and lower hooks are secure, and whether all connecting fulcrums are securely connected.

[0079] 4. Check if the current and voltage are normal, and whether all personnel involved in operations and logistics are in place.

[0080] 5. Whether the emergency response plan has been implemented.

[0081] 6. Operators must fasten their safety belts.

[0082] <III> During the operation:

[0083] 1. Each operator should take their position, connect the power supply, and rotate the electric hoist forward and backward once to check if the rotation is flexible. Each electric hoist should be pre-tightened, and the tension should be consistent.

[0084] 2. Perform a trial lift, raising the hoist to about 1 meter and then stopping for a comprehensive inspection. Pay attention to whether the chain and hoist are normal, and whether the levelness is even.

[0085] 3. During operation, strictly follow the principle of making minor adjustments every 2 meters of elevation. Do not attempt to lift the object quickly in one go. Prevent "slanted pulling" and ensure "stable start, stable operation, and stable position".

[0086] 4. End of hoisting. After hoisting is completed, promptly insert and tighten the turnbuckles to replace the electric hoist. Remove the electric hoist and other tools and equipment safely from the site.

[0087] 5. Fill in the escape routes.

[0088] <iv> Do a good job in safety work.

[0089] (1) Operators must have a strong sense of responsibility and dedication, and must undergo training and assessment in the "Crane Operator" program and obtain a certificate before starting work.

[0090] (2) Operators must wear safety belts when working, have a high level of safety awareness, and always be aware of safety.

[0091] It should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A method for high-clearance roof insulation of single-story cold storage facilities without high-altitude operations, characterized by: Includes the following steps: (1) Determine the coordinates and number of the lifting points of the group crane, and perform load balance calculations based on the cold storage roof insulation type, unit area weight, rated lifting capacity of electric hoists and mechanical parameters of the spreader beam. (2) An insulated roof can be prefabricated on the ground, and auxiliary facilities can be pre-installed on the insulation layer; (3) The insulation layer is hoisted to the design height by means of a spreader beam and a chain hoist group system that can be inverted; (4) The lifting speed and load of each electric hoist are adjusted synchronously by the linkage control box, and the horizontal displacement of the insulation layer is controlled by the elastic guide. (5) After hoisting, the insulation layer is welded and fixed to the roof building, and the escape hatch is filled.

2. The method for high-clearance roof insulation of a single-story cold storage facility without high-altitude operations as described in claim 1, characterized in that: The spacing between the hoisting points of the group cranes is based on the size of the cold storage and the insulation layer per meter. 2 The weight and the weight of the lifting gear are determined.

3. The method for high-clearance roof insulation of a single-story cold storage facility without high-altitude operations as described in claim 2, characterized in that: The spreader beam is made of Q235A carbon steel 18a channel steel, and its maximum bending moment stress is less than the allowable stress of the material.

4. The method for high-clearance roof insulation of a single-story cold storage facility without high-altitude operations as described in claim 1, characterized in that: The rated lifting capacity of the chain hoist is 2t, the lifting speed is ≤5m / min, the lifting height is ≤22m, and the number of linkage control consoles is 20-24.

5. The method for high-clearance roof insulation of a single-story cold storage facility without high-altitude operations as described in claim 1, characterized in that: The elastic guide is installed around the insulation layer to limit horizontal sway during hoisting, with a lifting speed not exceeding 5m / min, a lifting height of 22m or higher, and a non-uniform load difference not exceeding 20%.

6. The method for high-clearance roof insulation of a single-story cold storage facility without high-altitude operations as described in claim 1, characterized in that: The linkage control box displays the current data of each electric hoist in real time to monitor load balance.

7. The method for high-clearance roof insulation of a single-story cold storage facility without high-altitude operations as described in claim 1, characterized in that: The insulation layer is fixed to the roof structure by welding or bolting.

8. The method for high-clearance roof insulation of a single-story cold storage facility without high-altitude operations as described in claim 1, characterized in that: The ancillary facilities include lighting, air ducts, etc., which can be pre-installed on the ground and then hoisted simultaneously with the insulation layer.

9. The method for high-clearance roof insulation of a single-story cold storage facility without high-altitude operations as described in claim 1, characterized in that: An escape hatch with dimensions of 600mm×600mm must be reserved before hoisting, and a descent device support point must be installed.

10. The method for high-clearance roof insulation of a single-story cold storage facility without high-altitude operations as described in claim 1, characterized in that: In the load balance calculation, the load at a single lifting point shall not exceed 80% of the rated load of the electric hoist, and the difference in unbalanced load shall be ≤20%.

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