Vertical circulating cooling construction method for super-thick concrete wall

Abstract

The invention discloses a vertical circulating cooling construction method for an ultra-thick concrete wall, and relates to the technical field of concrete structure construction. The method comprises the following steps: prefabricating a vertical cooling loop formed by connecting U-shaped galvanized steel pipes in series, and mounting and fixing the vertical cooling loop in a steel reinforcement framework; an external circulating device is connected to form a closed circulating system, and a temperature sensor is arranged in the system; circulating cooling is started after concrete pouring, the monitored water inlet and outlet temperature difference is compared with a set threshold value, the water inlet temperature is dynamically regulated and controlled by replacing water in the water tank or adding an ice-water mixture, and precise temperature control is achieved. The U-shaped cooling pipes which are vertically arranged are particularly suitable for a special wall body structure forbidding transverse wall penetrating, uniform heat dissipation along the whole height of the wall body can be achieved, temperature cracks are effectively prevented, and the U-shaped cooling pipe has the advantages of being convenient and fast to install, reliable in temperature control and high in adaptability.

Description

Technical Field

[0001] This invention relates to the field of concrete structure construction technology, specifically a vertical circulating cooling construction method for ultra-thick concrete walls. Background Technology

[0002] With the development of large-scale infrastructure and special-function buildings, the application of ultra-thick concrete walls is becoming increasingly widespread. Due to the large amount of cement used and the concentrated heat of hydration, these walls accumulate internal heat during the hardening process, creating a significant temperature difference with the external environment. This can easily lead to temperature stress exceeding the tensile strength of the concrete, resulting in harmful cracks and endangering structural safety and durability.

[0003] Currently, temperature control for large-volume concrete typically employs pre-embedded cooling water pipes for internal water circulation and heat dissipation. However, traditional cooling pipe arrangements are mostly based on horizontal or serpentine coil designs, primarily suitable for horizontal structures such as dams and foundation slabs. For vertically towering structures like ultra-thick walls, traditional arrangements struggle to achieve uniform heat dissipation along the wall's vertical height, and the long cooling water flow and high resistance easily lead to uneven cooling. This is especially problematic in areas with special protection or airtight requirements, such as nuclear medicine shielding walls and diaphragm walls. Horizontal perforations in the walls are strictly prohibited, making traditional cooling pipe systems impossible to implement.

[0004] Therefore, existing technologies lack a circulating cooling construction method specifically designed for the structural characteristics of ultra-thick concrete walls, capable of achieving efficient, uniform, and controllable internal cooling under conditions where transverse wall penetration is prohibited. Summary of the Invention

[0005] To address the shortcomings of existing technologies, the purpose of this invention is to provide a method for vertical circulating cooling construction of ultra-thick concrete walls that can achieve high efficiency, uniformity, and controllability under conditions where lateral wall penetration is prohibited.

[0006] The technical solution adopted by this invention to solve its technical problem is:

[0007] A construction method for vertical circulating cooling of ultra-thick concrete walls includes the following steps: S1. Prefabrication and assembly of the cooling system: Prepare an external circulation device, which includes a water tank, a centrifugal pump installed outside the water tank, a submersible pump installed inside the water tank, and connecting pipes; use multiple prefabricated U-shaped galvanized steel pipes as cooling units, wherein each U-shaped galvanized steel pipe includes a closed elbow section at the bottom and two parallel vertical straight pipe sections; arrange the multiple U-shaped galvanized steel pipes with their vertical straight pipe sections perpendicular to the ground, and connect the top open ends of all U-shaped galvanized steel pipes in series through a horizontal galvanized steel pipe connecting pipe to form at least one independent vertical cooling circuit. S2. Cooling Circuit Installation and Fixing: After the steel reinforcement frame of the ultra-thick concrete wall is tied, the vertical cooling circuit assembled in step S1 is hoisted and placed inside the steel reinforcement frame, ensuring that the vertical straight pipe sections of the U-shaped galvanized steel pipe are distributed along the wall thickness direction, and that the top of the vertical straight pipe sections is higher than the predetermined height of the designed top surface of the wall; the vertical cooling circuit is then firmly tied and fixed to the steel reinforcement frame. S3. System Piping Connection: The inlet of the vertical cooling circuit is connected to the outlet of the centrifugal pump through a pipe; the return end of the vertical cooling circuit is led back to the water tank through a pipe; the inlet of the centrifugal pump is connected to the submersible pump in the water tank through a pipe, thus forming a complete closed-loop circulation system from the water tank through the pump, through the internal cooling circuit of the wall, and back to the water tank. S4. Temperature Monitoring Device Installation: Temperature sensors are installed at the bottom outlet and the return water inlet of the water tank to monitor the temperature of the supplied cooling water and the temperature of the return water flowing out of the wall cooling circuit in real time. S5. Concrete Pouring and Curing Start-up: After the formwork is erected, concrete is poured. After the concrete pouring is completed, the centrifugal pump and the submersible pump are started to circulate the cooling water in the closed-loop system. S6. Circulating Cooling and Intelligent Control: During concrete curing, circulating cooling is continuously performed. The inlet and outlet water temperatures are monitored by the temperature sensors installed in step S4, and the temperature difference is calculated. When the estimated temperature difference between the return water temperature and the internal concrete temperature exceeds a first set threshold, or the temperature difference between the return water temperature and the inlet water temperature exceeds a second set threshold, the inlet water temperature is adjusted by replacing the water in the water tank or adding an ice-water mixture to the water tank, so that the circulating water temperature is always within the preset control range.

[0008] Preferably, in step S1, the diameter of the U-shaped galvanized steel pipe and the spacing between adjacent U-shaped galvanized steel pipes are determined based on the design thickness of the ultra-thick concrete wall, the concrete mix ratio, and the temperature control calculation requirements.

[0009] Preferably, in step S2, the vertical straight section of the U-shaped galvanized steel pipe is five to ten centimeters higher than the designed top surface of the wall.

[0010] Preferably, in step S3, an exhaust valve is installed at the highest point of the vertical cooling circuit.

[0011] Preferably, in step S6, the first set threshold is 20 to 25 degrees Celsius, and the second set threshold is 10 to 15 degrees Celsius.

[0012] Preferably, the method further includes a post-curing treatment step: after the concrete curing is completed, the circulation system is shut off, the pipe openings exposed on the wall are sealed by pressure grouting, and the residual water in the U-shaped galvanized steel pipe is squeezed out.

[0013] The present invention, which adopts the above technical solution, has the following prominent features compared with the prior art:

[0014] The cooling circuit is formed by connecting prefabricated vertical U-shaped pipes in series, perfectly adapting to the vertical structure of ultra-thick walls and achieving uniform heat dissipation along the entire height of the wall, especially suitable for special working conditions where horizontal penetration through walls is prohibited. By setting temperature sensors at key points of the water tank inlet and outlet, the heat exchange status of the circulating water is monitored in real time, and the cooling water inlet temperature can be actively adjusted according to the set temperature difference threshold, effectively avoiding "cold shock" to the concrete and achieving dynamic and precise temperature control. The U-shaped galvanized steel pipes can be prefabricated in the factory, allowing for quick on-site assembly and good installation stability. The resulting closed-loop circulation system has a clear water path and relatively balanced resistance, ensuring the stability and reliability of the cooling effect. The use of conventional galvanized steel pipes results in lower costs. The circuit design is flexible, and the number, spacing, and arrangement of the U-shaped pipes can be adjusted flexibly according to the wall size and temperature control requirements, making it highly adaptable. Attached Figure Description

[0015] Figure 1 This is a schematic diagram of the main structure in an embodiment of the present invention;

[0016] Explanation of reference numerals in the attached diagram: 1. Water tank; 2. Centrifugal pump; 3. Galvanized steel pipe; 4. Control valve; 5. Temperature sensor; 6. Drain valve; 7. Submersible pump; 8. Extra-thick concrete wall. Detailed Implementation

[0017] The present invention will be further illustrated below with reference to specific embodiments. The purpose of this illustration is solely to provide a better understanding of the invention. Therefore, the examples given do not limit the scope of protection of the present invention.

[0018] like Figure 1As shown in the figure, this embodiment provides a construction method for vertical circulation cooling of ultra-thick concrete walls, including the following steps: S1. Prefabrication and assembly of cooling system: Prepare an external circulation device, which includes a water tank 1, a centrifugal pump 2 set outside the water tank 1, a submersible pump 7 set inside the water tank 1, and connecting pipes; use multiple prefabricated U-shaped galvanized steel pipes 3 as cooling units, wherein the U-shaped galvanized steel pipe 3 includes a closed elbow section at the bottom and two parallel vertical straight pipe sections; arrange the multiple U-shaped galvanized steel pipes 3 with their vertical straight pipe sections perpendicular to the ground, and connect the top open ends of all U-shaped galvanized steel pipes 3 in series through a horizontal galvanized steel pipe 3 connecting pipe to form at least one independent vertical cooling circuit.

[0019] S2. Cooling circuit installation and fixing: After the steel reinforcement cage of the ultra-thick concrete wall 8 is tied, the vertical cooling circuit assembled in step S1 is hoisted and placed in the internal space of the steel reinforcement cage, ensuring that the vertical straight pipe sections of the U-shaped galvanized steel pipe 3 are distributed along the wall thickness direction, and the top of the vertical straight pipe section is higher than the predetermined height of the designed top surface of the wall; the vertical cooling circuit is firmly tied and fixed to the steel reinforcement cage.

[0020] S3. System Piping Connection: Connect the inlet of the vertical cooling circuit to the outlet of the centrifugal pump 2 through a pipe; lead the return water of the vertical cooling circuit back to the water tank 1 through a pipe; connect the inlet of the centrifugal pump 2 to the submersible pump 7 in the water tank 1 through a pipe, thereby forming a complete closed-loop circulation system from the water tank 1 through the pump, through the internal cooling circuit of the wall, and back to the water tank 1.

[0021] S4. Temperature monitoring device installation: Temperature sensors 5 are installed at the bottom outlet of the water tank 1 and the return water inlet of the water tank 1, respectively, to monitor the temperature of the supplied cooling water and the temperature of the return water flowing out of the wall cooling circuit in real time.

[0022] S5. Concrete Pouring and Curing Start-up: After the formwork is erected, concrete is poured; after the concrete pouring is completed, the centrifugal pump 2 and the submersible pump 7 are started to allow the cooling water to circulate in the closed-loop circulation system.

[0023] S6. Circulating Cooling and Intelligent Control: During concrete curing, continuous circulating cooling is carried out; the temperature sensors 5 installed in step S4 monitor the inlet and outlet water temperatures and calculate their temperature difference; when the estimated temperature difference between the return water temperature and the concrete inside the wall exceeds the first set threshold, or the temperature difference between the return water temperature and the inlet water temperature exceeds the second set threshold, the inlet water temperature is adjusted by replacing the water in the water tank 1 or adding an ice-water mixture to the water tank 1, so that the circulating water temperature is always within the preset control range.

[0024] In step S1, the diameter of the U-shaped galvanized steel pipe 3 and the spacing between adjacent U-shaped galvanized steel pipes 3 are determined based on the design thickness of the ultra-thick concrete wall 8, the concrete mix ratio, and the temperature control calculation requirements.

[0025] In step S2, the vertical straight section of the U-shaped galvanized steel pipe 3 is five to ten centimeters higher than the designed top surface of the wall.

[0026] In step S3, an exhaust valve is installed at the highest point of the vertical cooling circuit.

[0027] In step S6, the first set threshold is 20 to 25 degrees Celsius, and the second set threshold is 10 to 15 degrees Celsius.

[0028] The method also includes a post-curing treatment step: after the concrete curing is completed, the circulation system is shut off, the pipe openings exposed on the wall are sealed by pressure grouting, and the residual water in the U-shaped galvanized steel pipe 3 is squeezed out.

[0029] A control valve 4 is installed on the water inlet pipe of water tank 1, and a drain valve 6 is installed on the water outlet pipe of water tank 1.

[0030] The cooling circuit is formed by connecting prefabricated vertical U-shaped pipes in series, perfectly adapting to the vertical structure of ultra-thick walls and achieving uniform heat dissipation along the entire height of the wall, especially suitable for special working conditions where horizontal penetration through walls is prohibited. By setting temperature sensors at key points of the water tank inlet and outlet, the heat exchange status of the circulating water is monitored in real time, and the cooling water inlet temperature can be actively adjusted according to the set temperature difference threshold, effectively avoiding "cold shock" to the concrete and achieving dynamic and precise temperature control. The U-shaped galvanized steel pipes can be prefabricated in the factory, allowing for quick on-site assembly and good installation stability. The resulting closed-loop circulation system has a clear water path and relatively balanced resistance, ensuring the stability and reliability of the cooling effect. The use of conventional galvanized steel pipes results in lower costs. The circuit design is flexible, and the number, spacing, and arrangement of the U-shaped pipes can be adjusted flexibly according to the wall size and temperature control requirements, making it highly adaptable.

[0031] The above description is merely a preferred embodiment of the present invention and does not limit the scope of the present invention. All equivalent changes made based on the description and drawings of the present invention are included within the scope of the present invention.

Claims

1. A method for vertical circulating cooling construction of ultra-thick concrete walls, characterized in that, Includes the following steps: S1. Cooling System Prefabrication and Assembly: Multiple prefabricated U-shaped galvanized steel pipes are arranged with their vertical straight sections perpendicular to the ground. The top open ends of all the U-shaped galvanized steel pipes are connected in series through a horizontal galvanized steel pipe connecting pipe to form at least one independent vertical cooling circuit. S2. Cooling Circuit Installation and Fixing: The vertical cooling circuit is placed inside the steel reinforcement frame of the ultra-thick concrete wall and fixed, ensuring that the vertical straight sections of the U-shaped galvanized steel pipes are distributed along the wall thickness direction, and that the top of each vertical straight section extends above the designed top surface of the wall. S3. System Piping Connection: The inlet end of the vertical cooling circuit is connected to the outlet of the centrifugal pump, and the return end of the vertical cooling circuit is led back to the water tank. The inlet of the centrifugal pump is connected to a submersible pump installed in the water tank via a pipe, forming a closed-loop circulation system; S4, Temperature monitoring device installation: Temperature sensors are installed at the bottom outlet and the return inlet of the water tank, respectively; S5, Concrete pouring and curing start-up: After the concrete pouring is completed, the centrifugal pump and the submersible pump are started to circulate the cooling water in the closed-loop circulation system; S6, Circulation cooling and intelligent control: The inlet and return water temperatures are monitored by the temperature sensors. When the temperature difference between the return water temperature and the estimated temperature difference between the concrete inside the wall exceeds a first set threshold, or the temperature difference between the return water temperature and the inlet water temperature exceeds a second set threshold, the water temperature in the water tank is adjusted.

2. The vertical circulating cooling construction method for ultra-thick concrete walls according to claim 1, characterized in that, In the prefabrication and assembly steps of the cooling system, the diameter of the U-shaped galvanized steel pipe and the spacing between adjacent U-shaped galvanized steel pipes are determined according to the design thickness of the ultra-thick concrete wall, the concrete mix ratio, and the temperature control calculation requirements.

3. The vertical circulating cooling construction method for ultra-thick concrete walls according to claim 1, characterized in that, In the installation and fixing steps of the cooling circuit, the vertical straight section of the U-shaped galvanized steel pipe is five to ten centimeters higher than the designed top surface of the wall.

4. The vertical circulating cooling construction method for ultra-thick concrete walls according to claim 1, characterized in that, In the system piping connection step, an exhaust valve is installed at the highest point of the vertical cooling circuit.

5. The vertical circulating cooling construction method for ultra-thick concrete walls according to claim 1, characterized in that, In the cyclic cooling and intelligent control step, the first set threshold is 20 to 25 degrees Celsius, and the second set threshold is 10 to 15 degrees Celsius.

6. The vertical circulating cooling construction method for ultra-thick concrete walls according to claim 1, characterized in that, It also includes post-curing treatment steps: after the concrete curing is completed, the circulation system is shut off, the pipe openings exposed on the wall are sealed by pressure grouting, and the residual water in the U-shaped galvanized steel pipe is squeezed out.

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