Formwork embedded type dam face permanent heat preservation protection module

Abstract

The utility model discloses a template embedded type dam face permanent heat preservation protection module. Comprising a heat preservation core layer, a facing anti-seepage protection layer is arranged on the side, close to a concrete pouring formwork, of the heat preservation core layer, an internal pressure-bearing protection layer is arranged on the side, close to dam surface layer crack limiting steel bars, of the heat preservation core layer, and a thermal broken bridge supporting keel is arranged in the heat preservation core layer; an anchoring device is arranged in the area between the internal pressure-bearing protection layer and the dam surface layer crack limiting steel bars. The modular prefabrication and construction method is adopted, the prefabrication and installation method of a single module is simple and efficient, details such as anchoring protection measures are fully considered, the engineering construction operability is high, convenience and high efficiency are achieved, and the construction time of the heat preservation layer is greatly saved.

Description

TECHNICAL FIELD

[0001] The utility model relates to water conservancy project dam concrete heat preservation protection technical field, especially a formwork inlay type dam face permanent heat preservation protection module. BACKGROUND

[0002] When constructing concrete dam in severe cold area, the poured concrete needs to be heat preserved in time to prevent the temperature of dam concrete surface from producing large amplitude caused by adverse factors such as cold wave, temperature drop, large temperature difference between day and night, reduce the temperature difference between inside and outside of concrete, and prevent cracking of dam caused by temperature stress due to large temperature difference.

[0003] Traditional heat preservation technology is to perform permanent heat preservation and protection work on concrete dam surface after formwork is removed. For example, Chinese patent CN102505664B - a method for resisting aging of dam concrete, first, permanent heat preservation is performed by covering polyethylene foam, heat preservation cotton, pasting benzene board or spraying polyurethane hard foam; then, a layer of anti-aging paint, polyurea or polymer mortar is covered on the surface of the heat preservation layer to resist extrusion, pulling and impact caused by freezing of reservoir water, aging and discoloration caused by solar radiation, and impact damage or fire caused by other construction operations; alkali-resistant glass fiber mesh or iron wire mesh is laid in the middle of the protection layer to enhance, and anchor bolts and other components are used to anchor them in the dam concrete; thus, permanent heat preservation and protection are realized on the concrete dam surface.

[0004] Although the traditional permanent heat preservation and protection scheme of dam surface plays a certain protective role on dam concrete, there are still some deficiencies to be improved and optimized from the perspective of engineering practice experience and effect, mainly in three aspects:

[0005] (1) Heat preservation and protection have hysteresis, and dam concrete has cracking risk;

[0006] The basis for implementing the traditional permanent heat preservation scheme is the clean dam surface after formwork is removed, and the formwork must be removed after the newly poured concrete is initially set and the strength growth meets the requirements of form removal, which leads to certain hysteresis of dam heat preservation. The early strength of dam concrete is low, and it is more prone to cracking under the action of temperature tensile stress, so it needs to be heat preserved and protected in time.

[0007] (2) Many on-site heat preservation and protection procedures, high-altitude cross operation is needed, and construction difficulty is great;

[0008] Traditional dam heat preservation protection system is composed of multiple processes to deal with the adverse effects of large temperature difference, high water pressure and ice formation in reservoir, and different processes contain multiple procedures, and the process is relatively complex. Secondly, there are many restrictions during construction, such as polyurethane spraying construction, or polyurea or anti-aging paint spraying construction, which requires a clean and dry base surface. On the other hand, heat preservation and protection construction and pouring cross operation, mutual interference, construction difficulty is greater, and there is a high security risk.

[0009] (3) Complex construction environment, many interference factors, quality is not easy to control;

[0010] Traditional dam surface heat preservation and protection construction is greatly influenced by human subjective factors, and the quality is not easy to control. Secondly, the site has strong wind all year round, and the polyurethane material is easy to be blown away and scattered everywhere during spraying operation on the dam surface, which not only wastes materials and pollutes the environment, but also makes the spraying thickness uneven and the quality difficult to control. When applying polymer mortar protective layer on the surface of the heat preservation layer, water flow should be avoided. After initial setting, timely watering and curing are needed to ensure the overall quality of the dam concrete heat preservation and protection system. The dam construction site environment is complex, with many interference factors, and the quality is not easy to control.

[0011] Therefore, the traditional heat preservation and protection construction of the heat preservation and protection scheme has a lag, which leads to the risk of cracking of the dam concrete; and the construction process and procedure are complex, and are greatly influenced by environmental interference factors, with great construction difficulty; most of the work needs high-altitude operation and cross operation, with high risk coefficient, which needs a new scheme to better protect the dam concrete.

[0012] In this context, some experts and scholars have proposed the concept of disassembly-free formwork, such as Chinese patent CN202222438817.X - thermal insulation structure integrated disassembly-free formwork installation system in the field of building, which proposes to use thermal insulation board core material and composite lightweight mortar protective layer to form disassembly-free formwork, fix the disassembly-free formwork on the outside of the inner membrane through a screw rod, and leave a gap between the inner formwork and the thermal insulation formwork; then cast in-situ concrete in the gap; finally, remove the external limiting screw rod. This method is suitable for external wall engineering of civil building engineering, but not suitable for large volume concrete pouring of dam in water conservancy engineering. There is also a Chinese patent with application number CN202410402902.1 - a dam surface concrete permanent intelligent thermal insulation formwork and its manufacturing and construction method, which solves the problem that spraying or pasting thermal insulation materials cannot cover the dam concrete in time by sequentially arranging a steel formwork, a hydrophobic protective layer, a transition layer, and an intelligent thermal insulation layer from the outside to the inside. The focus of this method is to monitor the temperature of the dam concrete surface, the internal temperature of the intelligent thermal insulation layer, and the environmental temperature using temperature sensors, and then control the voltage adjustment device to output a certain voltage on both sides of the intelligent thermal insulation layer, convert the electrical energy into heat energy using conductive phase materials, and thus regulate the temperature of the intelligent thermal insulation layer. However, it does not provide specific parameters and solutions for how to achieve it. Similarly, there is a Chinese utility model CN114892666B - a dam concrete permanent thermal insulation formwork structure and its construction method, which proposes a structure including a steel truss, a steel formwork, a thermal insulation formwork, and a reinforced beam. The steel truss and steel formwork are arranged first during dam pouring, then the thermal insulation formwork is fixed inside the formwork using reinforcing bars, and the external support structure steel truss and steel formwork are removed after the concrete pouring is completed.

[0013] Although the above-mentioned patents propose some solutions for disassembly-free formwork, they are still at the initial conceptual stage. The application of specific problems in engineering needs further research, and there is no complete and effective technical system. For example, the dam has a large surface area, how to achieve seamless installation during arrangement; the thermal insulation performance of the thermal insulation material will be weakened after absorbing water, and there is no effective anti-seepage protection measure; the closed-cell structure of the thermal insulation material such as polyurethane rigid foam will be damaged after compression and deformation, and the thermal insulation performance will be significantly reduced, and the existing technology has defects in protecting the thermal insulation material. The dam concrete pouring process in water conservancy engineering is complex, and the above-mentioned solutions have great limitations, and there is no specific implementation plan for the material, structure, size, arrangement, and installation of disassembly-free formwork, which cannot adapt to the conditions and multiple demands of site construction, such as a castle in the air, which cannot be implemented in actual engineering at the moment. The main aspects are as follows:

[0014] (1) The material of the inner and outer protective layers directly affects the weight of the removable formwork structure. In a removable formwork field test carried out by a certain project, in order to ensure the strength and overall aesthetics of the panel, the weight exceeds 2000 kg. Due to the heavy weight of the self-formwork, the installation is difficult, slow, and even faces the scene of being unable to install and stopping work. Finally, during the concrete pouring, the connecting and fixing pull rod fell off and collapsed, which poses a great safety hazard.

[0015] (2) The compressive strength of the commonly used thermal insulation materials with excellent thermal insulation performance is relatively low compared to concrete. The single-bin pouring layer height of dam concrete is generally about 3m. When the concrete is poured and vibrated, a large lateral pressure and impact force of coarse aggregate will be generated. If there is no effective protection, the concrete will be extruded and deformed. Although the existing technology such as CN 114892666B - A dam concrete permanent thermal insulation formwork structure and its construction method considers the protection of impact force by arranging a protective layer in the inner layer of the thermal insulation material to offset the impact force of coarse aggregate. However, it lacks consideration of lateral pressure. The lateral pressure of the concrete first acts on the protective layer and then is directly transmitted to the thermal insulation material in the middle through the protective layer, which can cause compression deformation of the thermal insulation layer.

[0016] (3) The thermal insulation materials such as polyurethane rigid foam are mostly closed-cell structures. The pores are generally filled with low-boiling-point gases with lower thermal conductivity than air. The overall thermal conductivity is generally lower than air. Existing literature shows that the gas-phase thermal conductivity accounts for about 70% of the total thermal conductivity of polyurethane at a density of 50 kg / m³. If the thermal insulation layer is deformed under pressure, the closed-cell structure will be damaged, and its thermal insulation performance will be significantly reduced. Relevant test research shows that the reduction of thermal insulation performance is not linearly related to the thickness compression value. The existing technology lacks understanding of the weakening of the thermal insulation performance of the thermal insulation material after deformation, and the corresponding protection measures are also insufficient. A large-scale project in the northwest of China tried to use this technology ten years ago, but ultimately failed to achieve engineering application due to deformation and shedding of the thermal insulation layer.

[0017] (4) Thermal insulation materials have a certain water absorption, and the thermal conductivity increases significantly after absorbing water, greatly reducing the thermal insulation effect. The removable formwork is made by connecting and installing prefabricated blocks of different sizes in the bin. The joint part becomes a obvious leakage channel, and the existing technology does not provide effective structure and treatment methods. Secondly, the outer protective layer of the existing removable formwork is relatively thin, and there is no effective anti-seepage measure. Under the action of high water pressure, it is easy to leak itself, which will weaken the protection ability of the dam thermal insulation layer.

[0018] In summary, the conventional dam concrete heat preservation protection technology has defects and needs to be improved. The existing formwork removal technology scheme has great limitations in structure and other aspects, which leads to failure in the test stage, only some preliminary ideas and frameworks are proposed, no specific implementation parameters, technical indicators and construction methods are provided, which cannot meet the dam concrete pouring construction requirements and cannot be applied in the dam construction of water conservancy and hydropower projects. Therefore, it is particularly important to study the permanent heat preservation and anti-seepage protection technology suitable for dam concrete of water conservancy projects. Utility model content

[0019] The utility model discloses a formwork embedded dam surface permanent heat preservation protection module to solve the problems in the background art.

[0020] To solve the above technical problems, the utility model adopts the technical scheme of a formwork embedded dam surface permanent heat preservation protection module, including the heat preservation core layer, the heat preservation core layer is equipped with the facing anti-seepage protection layer on one side close to the concrete pouring formwork, the heat preservation core layer is equipped with the internal pressure bearing protection layer on one side close to the dam surface layer crack limiting steel bar, and the heat preservation core layer is equipped with the hot broken bridge support keel inside, and the region between the internal pressure bearing protection layer and the dam surface layer crack limiting steel bar is equipped with the anchoring device.

[0021] Preferably, the facing anti-seepage protection layer is sequentially provided with a hydrophobic anti-icing coating, a cement-based anti-seepage coating and a base protection layer from the side in contact with the concrete pouring formwork to the inside of the dam.

[0022] Preferably, the internal pressure bearing protection layer includes a second fiber cement board and a second steel wire mesh arranged in the second fiber cement board.

[0023] Preferably, the hot broken bridge support keel includes a first anchor nut arranged in the facing anti-seepage protection layer and a second anchor nut arranged in the internal pressure bearing protection layer, the first anchor nut and the second anchor nut are threadedly connected with the two ends of the heat insulation screw rod, and the thread directions of the first anchor nut and the second anchor nut are opposite.

[0024] Preferably, the heat insulation screw rod is provided with a groove or a step on the side close to the first anchor nut, and an outer limiting flange plate in contact with the facing anti-seepage protection layer is arranged in the groove or the step.

[0025] Preferably, the heat insulation screw rod is provided with a groove or a step on the side close to the second anchor nut, and an inner limiting flange plate in contact with the internal pressure bearing protection layer is arranged in the groove or the step.

[0026] Preferably, the anchoring device includes an adjustable support rod provided between the internal pressure-bearing protective layer and the crack-limiting steel bars on the surface of the dam, and an anchor bar threadedly connected to the outer side of the second anchor nut.

[0027] Preferably, insertion holes for installing concrete casting formwork anchor bolts and concrete casting formwork support legs are provided in the concrete casting formwork, the surface anti-seepage protective layer, the thermal insulation core layer and the internal pressure-bearing protective layer. The concrete casting formwork anchor bolts are threadedly engaged with one end of the positioning cone, and the other end of the positioning cone is connected to the surface crack-limiting steel bars of the dam through a serpentine anchor bar; the concrete casting formwork support legs are fixedly connected to the concrete casting formwork bracket.

[0028] Preferably, one end of the thermal insulation core layer is higher than the end plane of the decorative anti-seepage protective layer and the internal pressure-bearing protective layer, forming a tenon structure; the other opposite end of the thermal insulation core layer is lower than the end plane of the decorative anti-seepage protective layer and the internal pressure-bearing protective layer, forming a tenon structure; each two adjacent template-embedded dam surface permanent thermal insulation protection modules are connected by the cooperation of the tenon structure and the tenon structure.

[0029] Preferably, the top surfaces of the uppermost thermal insulation core layer, the surface anti-seepage protective layer and the internal pressure-bearing protective layer are also provided with edge sealing protective covers.

[0030] Beneficial effects of the utility model:

[0031] 1. The structure of the utility model is scientific and reasonable, and fully considers the lateral pressure and coarse aggregate impact force when the concrete is vibrated into the warehouse. The load is evenly transferred from the internal pressure-bearing protective layer to the decorative anti-seepage protective layer through the thermal bridge support keel, and then transmitted from the decorative anti-seepage protective layer to the outer casting formwork. The internal thermal insulation core layer will not be squeezed and deformed.

[0032] 2. The utility model can calculate the size, thickness and other parameters of a single module according to the actual project conditions, which not only meets the load bearing capacity requirements, but also takes into account the structure and characteristics of the dam casting template, and has good engineering adaptability.

[0033] 3. The utility model can avoid the joints existing in modular construction through the mortise and tenon structure, and can realize modular seamless splicing installation, so that the dam's thermal insulation and anti-seepage protection layer becomes a whole, preventing the joints from becoming weak links in thermal insulation protection, and providing better thermal insulation and anti-seepage performance, thereby providing better protection for the dam.

[0034] 4. This system adopts modular prefabrication and construction methods. The prefabrication and installation methods of a single module are simple and efficient, and full consideration is given to details such as anchoring protection measures. The construction is highly operable, convenient and efficient, which greatly saves the construction time of the insulation layer.

[0035] 5、The utility model discloses more functions, in addition to the main heat preservation function, through cement base admixture is added in the surface seepage prevention protective layer, and the seepage prevention coating is arranged on the surface, and the hydrophobic ice layer is added in the water level change area, so that the system has heat preservation, seepage prevention and protection integrated structure and function.

[0036] 6、The utility model discloses a formwork embedded dam surface permanent heat preservation protection module, the internal pressure bearing protective layer has high structural strength and good folding resistance, can bear the lateral pressure generated during dam concrete pouring and vibration and the impact force of coarse aggregate in four-grade concrete, to prevent damage to the system.

[0037] 7、The utility model discloses a hot broken bridge support keel structure, which can evenly conduct the load of the concrete from the internal protective layer to the external protective layer through the hot broken bridge support keel structure during pouring, and further conduct to the concrete pouring formwork. Prevent extrusion deformation of the intermediate heat preservation core layer, and avoid the weakening phenomenon of the heat preservation performance of the heat preservation core layer after compression deformation; similarly, after the dam is completed and put into operation, the high water head pressure in the reservoir area can be reversely conducted to the dam concrete, which protects the heat preservation core layer well.

[0038] 8、Compared with the existing removable formwork technology, the material and structure adopted by the utility model do not penetrate to the outer surface, and a good broken bridge can be formed between the dam concrete and the external environment, reducing the adverse effects of environmental temperature on the dam concrete temperature.

[0039] 9、The modular prefabrication and installation technical scheme of the utility model not only can move the dam heat preservation and protection workload forward and complete the module prefabrication work in the factory building, but also is light in weight, modular in installation, convenient and efficient in construction, can well adapt to the dam concrete pouring construction, and realizes permanent heat preservation and dam concrete pouring synchronization.

[0040] 10、The utility model completes the prefabrication of the module in the factory building, without the interference of complex construction environment during on-site operation, better quality control and lower cost. Moreover, high-altitude cross operation is avoided, the safety factor is high, the heat preservation and protection workload can be greatly reduced, the individuality of the technology is promoted, and the economic benefit and social benefit are remarkable. BRIEF DESCRIPTION OF DRAWINGS

[0041] Figure 1 It is a structure diagram of a formwork embedded dam surface permanent heat preservation protection module.

[0042] Figure 2 It is Figure 1 An enlarged structure diagram of the surface seepage prevention protective layer.

[0043] Figure 3 It is Figure 1 An enlarged structure diagram of the internal pressure bearing protective layer.

[0044] Figure 4 For Figure 1 Enlarged structural diagram of hot bridge support keel;

[0045] Figure 5 For the structure diagram of the connection of the concrete pouring formwork, the concrete pouring formwork support and the embedded dam surface permanent thermal protection module;

[0046] Figure 6 For the schematic diagram of the embedded dam surface permanent thermal protection module of the upper and lower two layers of formworks connected with each other through the tenon structure and the mortise structure. DETAILED DESCRIPTION

[0047] The utility model will be described further in detail in combination with the drawings and specific embodiments.

[0048] Embodiment 1:

[0049] As Figures 1-6 shown: a embedded dam surface permanent thermal protection module, including thermal core layer 4, the thermal core layer 4 is close to the one side of concrete pouring formwork 6 and is equipped with the facing impermeable protection layer 1, the thermal core layer 4 is close to the one side of dam surface layer crack limiting steel bar 7 and is equipped with internal pressure bearing protection layer 2, and the thermal core layer 4 is internally provided with hot bridge support keel 3, and the area between internal pressure bearing protection layer 2 and dam surface layer crack limiting steel bar 7 is provided with anchoring device 5.

[0050] Preferably, the facing impermeable protection layer 1 is sequentially provided with hydrophobic anti-icing coating 1.1, cement-based impermeable coating 1.2 and base protection layer 1.3 from the side in contact with the concrete pouring formwork 6 to the inside of the dam; the base protection layer 1.3 includes first fiber cement board 1.3.1 and first steel wire mesh 1.3.2 arranged in the first fiber cement board 1.3.1.

[0051] In this embodiment, the base protection layer is a fiber cement board pressed from raw materials such as fibers and cement, and the thickness is 10-50 mm. The thickness of the base protection layer in the facing impermeable protection layer is the same as that of the internal pressure bearing protection layer, and the thickness of the internal pressure bearing protection layer is calculated according to the lateral pressure of concrete.

[0052] XYPEX admixture is added in the slurry during pressing, and the addition ratio is 1%-3% of the cement amount, which can achieve good impermeability effect.

[0053] Preferably, the base protection layer is internally arranged with one or more layers of steel wire mesh, and the mesh size of the steel wire mesh is 2-4 cm, and the wire diameter of the steel wire mesh is 0.8-1.5 mm.

[0054] The inner part of the base protective layer is arranged with a plurality of first anchor nuts at intervals of 500 mm, and the material of the nuts is stainless steel, carbon steel or nylon. The inner diameter of the first anchor nut is 10 mm, and the height is 1 / 2 of the thickness of the fiber cement board. One side of the first anchor nut is flush with the inner surface of the base protective layer, and the other side is located in the center of the fiber cement layer and presses the steel wire mesh. First, the force borne by the first anchor nut is more evenly transmitted to the fiber cement board, preventing local stress from being too large and causing damage. Second, the height of the first anchor nut is only half of the fiber cement board, and the outer surface of the base protective layer is not damaged, maintaining the appearance and overall protective performance. Third, the inner surface is also not protruding, which facilitates the batch stacking and transportation of the prefabricated modules and reduces transportation costs.

[0055] One side of the base protective layer is a rough surface, and the other side is a smooth surface. The smooth surface faces outward, which can increase the flatness and aesthetics of the dam surface, reduce ice formation, and reduce the pulling force of the ice layer on the base protective layer. The rough surface faces inward, which can increase the adhesion between the base protective layer and the thermal core layer and enhance the durability of the overall structure.

[0056] A layer of cement-based anti-seepage coating is applied to the outer side of the base protective layer by brushing. The material of the cement-based anti-seepage coating is XYPEX concentrate, and the thickness of the anti-seepage layer is 1-2 mm. This further enhances the anti-seepage ability and prevents high water pressure from penetrating the base protective layer into the thermal core layer when used on the upstream face of the dam, thereby weakening the thermal insulation performance of the thermal core layer.

[0057] For the facing anti-seepage protective layer in the water level change area, in order to deal with the pulling damage caused by ice formation in cold regions, a layer of hydrophobic coating is applied to the outer side of the anti-seepage layer by brushing. The material of the hydrophobic coating is organic fluorocarbon resin or organic silicon oligomer, and the thickness of the hydrophobic coating is 0.1-0.5 mm. Through the penetration of the hydrophobic coating, a protective film can be formed on the surface of the base protective layer, preventing water penetration and protecting it from damage by the reservoir water, preventing and reducing surface icing, and improving its freeze-thaw resistance.

[0058] Preferably, the internal pressure-bearing protective layer 2 comprises a second fiber cement board 2.1 and a second steel wire mesh 2.2 arranged in the second fiber cement board 2.1.

[0059] The main function of the internal pressure-bearing protective layer is to protect the thermal core layer from damage caused by lateral extrusion force and impact force of aggregates during concrete placement and vibration, which requires the base protective layer itself to have good bending strength and impact resistance.

[0060] The internal pressure bearing protective layer is a fiber cement board made of fiber, cement and other raw materials. XYPEX admixture is added in the slurry during pressing, and the adding ratio is 1% to 3% of the cement amount, which can achieve good anti-seepage effect.

[0061] The thickness of the fiber cement board determines its bending strength and impact resistance, and must be greater than the lateral pressure during dam concrete pouring. The thickness of the fiber cement board is 20 to 50 mm, and the specific thickness is obtained by calculation.

[0062] According to the concrete pouring formwork guide ACI 347-04, when the concrete slump value is ≤175 mm, and the placement height is ≤4.2 m under normal vibration, and the placement rate is <21. m / h, the lateral pressure of the concrete is calculated according to the following formula.

[0063] ;

[0064] Among them, : the maximum lateral pressure of the concrete, unit kPa; : unit weight coefficient, ; : the density of the concrete, unit ; : chemical coefficient, the value is 1.2; : the pouring rate of the concrete, unit m / h; : the temperature of the concrete during placement, unit ℃; and through detection, the performance indicators of the 10mm thick fiber cement board are as follows:

[0065] Table 1 related technical parameters of 10mm fiber cement board

[0066]

[0067] As can be seen from Table 1, the bending strength of the 10mm fiber cement board is 12MPa.

[0068] Case 1: when ×10 -3 < 12, the thickness of the fiber cement board is 10mm;

[0069] Case 2: when ×10 -3 ≥ 12, the thickness of the fiber cement board is calculated according to the following formula,

[0070]

[0071] In the formula, : the thickness of the fiber cement board, unit m; ​​: The maximum lateral pressure of concrete, unit kPa.

[0072] The internal pressure bearing protective layer is internally arranged with one or more layers of steel wire mesh, the mesh size of the steel wire mesh is 2-4 cm, and the wire diameter of the steel wire mesh is 0.8-1.5 mm.

[0073] The internal pressure bearing protective layer is internally arranged with a plurality of second anchor nuts at intervals of 500 mm, and the positions and quantities of the second anchor nuts one-to-one correspond to the first anchor nuts in the facing impermeable protective layer.

[0074] The second anchor nut is made of stainless steel, carbon steel or nylon material. The inner diameter of the second anchor nut is 10 mm, and the height is the same as the thickness of the fiber cement board. The second anchor nut is arranged in the internal pressure bearing protective layer in a through arrangement, one side of the second anchor nut is flush with the inner surface of the internal pressure bearing protective layer, and the other side is flush with the outer surface. There is no protrusion on both sides, which facilitates batch stacking and transportation of prefabricated modules.

[0075] Both sides of the fiber cement board are rough and have a matte surface, which facilitates good bonding with the polyurethane material of the thermal insulation core layer; and the extrusion and impact force generated during concrete pouring and vibration can be uniformly distributed, so that the overall pressure bearing of the thermal insulation protective system is more uniform, and the compressive performance and durability are increased.

[0076] Preferably, the hot broken bridge support furring 3 includes a first anchor nut 3.1 arranged in the facing impermeable protective layer 1 and a second anchor nut 3.2 arranged in the internal pressure bearing protective layer 2, the first anchor nut 3.1 and the second anchor nut 3.2 are threadedly connected with both ends of the heat insulation screw 3.3, and the thread directions of the first anchor nut 3.1 and the second anchor nut 3.2 are opposite.

[0077] Preferably, the heat insulation screw 3.3 is provided with a groove or a step on the side close to the first anchor nut 3.1, and an outer limiting flange plate 3.4 in contact with the facing impermeable protective layer 1 is arranged at the groove or the step.

[0078] Preferably, the heat insulation screw 3.3 is provided with a groove or a step on the side close to the second anchor nut 3.2, and an inner limiting flange plate 3.5 in contact with the internal pressure bearing protective layer 2 is arranged at the groove or the step.

[0079] The heat insulation screw is a double-thread structure with thin ends and a thick middle part, the diameters of the two ends are 10 mm, and the diameter of the middle part is 20 mm. The staggered table formed by the change of the diameter is used to clamp the limiting flange plate on the surface of the facing impermeable protective layer and the internal pressure bearing protective layer, and the stress area is increased to prevent local damage.

[0080] The material is nylon or basalt fiber composite rib, etc., which has the advantages of high strength, good heat insulation performance and strong corrosion resistance, forms a broken bridge structure, and prevents external environmental temperature changes from being conducted to the concrete inside through the screw rod.

[0081] The limiting flange plate is an iron or steel O-shaped gasket with an inner diameter of 10 mm, an outer diameter of 100 mm, and a thickness of 5 mm. The limiting flange plate can prevent the thermal core layer from deforming under pressure by limiting the deformation. In addition, the diameter of the gasket is significantly larger than the diameter of the heat insulation screw rod, which increases the stress area and prevents the inner and outer fiber cement boards from being damaged under local pressure.

[0082] The ends of the plurality of heat insulation screw rods are first inserted into the limiting flange plates, and then the limiting flange plates are screwed into the nuts of the surface impermeable protective layer and the internal pressure bearing protective layer, respectively, as a support framework to connect the inner and outer layers to form a whole.

[0083] The length of the heat insulation screw rod is calculated as follows: according to the thickness of the thermal core layer and the thickness of the fiber cement board , the total length of the heat insulation screw rod and the length of the thicker middle segment are calculated according to the following formula.

[0084] ;

[0085] ;

[0086] In the formula: is the length of the heat insulation screw rod, in meters; is the thickness of the thermal core layer, in meters; is the height of the first anchor nut, in meters; is the height of the second anchor nut, in meters; is the thickness of the outer limiting flange plate, is the thickness of the inner limiting flange plate, m.

[0087] When the concrete is poured, the lateral extrusion force and impact force generated by vibration first act on the internal pressure bearing protective layer. When the thermal core layer is subjected to a large load and may be compressed, the limiting flange plate close to the internal pressure bearing protective layer begins to bear the load, first transferring the load of the internal pressure bearing protective layer to the heat insulation screw rod, then transferring the load to the limiting flange plate close to the outer surface impermeable protective layer through the heat insulation screw rod, and finally uniformly transferring the load to the surface impermeable protective layer through the limiting flange plate. Through the heat broken bridge support keel structure, the thermal core layer in the middle can be well protected.

[0088] Preferably, the anchoring device 5 includes an adjustable support rod 5.1 arranged between the internal pressure bearing protective layer 2 and the dam surface crack limiting steel bar 7, and an anchor bar 5.2 threadedly connected to the outside of the second anchor nut 3.2.

[0089] Adjustable support rods are used to temporarily fix the dam surface permanent thermal insulation and anti-seepage protection modules arranged against the inner side of the concrete pouring formwork, one end is supported on the internal pressure bearing protective layer of the module, the other end is supported on the concrete base surface or crack limiting steel in the warehouse. Adjust the length of the adjustable support rod to keep the module close to the formwork, prevent the concrete from entering the warehouse and vibrating and causing displacement or overturning. When the concrete in the warehouse is poured to a certain height, the module is tightly attached to the formwork by relying on the lateral pressure of the concrete itself, and then the adjustable support rod is recycled and fixed with the next layer of module. The adjustable support rod in this embodiment can use a spring buckle type telescopic rod, and after adjusting each length, the length is locked by the cooperation of the spring buckle and the corresponding hole.

[0090] The anchor bar is a serpentine structure with a threaded end, the diameter of the thread matches the second anchor nut, and the length of the anchor bar is 15-50 cm. The material can be steel, iron, nylon and basalt fiber, etc.

[0091] After the dam surface permanent thermal insulation and anti-seepage protection module is installed and fixed, the threaded end of the anchor bar is screwed into the second anchor nut, and the serpentine tail end faces the warehouse. When the concrete in the warehouse is poured to the height of the anchor bar, the serpentine anchor bar is completely wrapped by the concrete. After the concrete solidifies, the serpentine anchor bar firmly fixes the dam surface permanent thermal insulation and anti-seepage protection module on the surface of the dam.

[0092] Preferably, the concrete pouring formwork 6, the facing anti-seepage protection layer 1, the thermal insulation core layer 4 and the internal pressure bearing protective layer 2 are provided with insertion holes for installing concrete pouring formwork anchor bolts 8 and concrete pouring formwork support legs 9, the concrete pouring formwork anchor bolts 8 are threadedly connected with one end of a positioning cone 10, the other end of the positioning cone 10 is connected with the dam surface crack limiting steel 7 through a serpentine anchor bar 11; the concrete pouring formwork support legs 9 are fixedly connected with a concrete pouring formwork support 12. The current dam concrete pouring formwork must be fixed by anchor bolts, positioning cones and anchor bars. Through the concrete pouring formwork support legs 9 and the concrete pouring formwork support 12, the weight of the entire formwork and module can be supported, and through the concrete pouring formwork anchor bolts 8, the module and the formwork can be fixedly connected, which plays a certain supporting role and can prevent the module from falling into the warehouse. In order to make the formwork embedded dam surface permanent thermal insulation and protection module better adapt to the dam concrete pouring, according to the structural characteristics of the construction steel formwork, the concrete pouring formwork anchor bolt insertion holes and the concrete pouring formwork support leg insertion holes are reserved in each module, and the size and number thereof are determined according to the structure of the external formwork.

[0093] Preferably, as Figure 6As shown, the end of the heat preservation core layer 4 is higher than the end plane of the surface anti-seepage protection layer 1 and the internal pressure bearing protection layer 2, forming a tenon structure; the other end of the heat preservation core layer 4 is lower than the end plane of the surface anti-seepage protection layer 1 and the internal pressure bearing protection layer 2, forming a mortise structure; each two adjacent formwork embedded dam surface permanent heat preservation protection modules are connected through the cooperation of the tenon structure and the mortise structure.

[0094] In this embodiment, the heat preservation core layer is a polyurethane rigid foam heat preservation material or a benzene plate material or a polyethylene foam material, which is formed by pouring and extruding once. The thickness of the heat preservation core layer is determined according to the design requirements of the dam, and the thickness can be 3-15 cm.

[0095] According to the equivalent heat release coefficient of the heat preservation layer required by the design of the dam, the thickness of the heat preservation core layer is determined.

[0096] ;

[0097] In the formula: is the thickness of the heat preservation core layer, in meters; is the thermal conductivity, in W / (m·K); is the equivalent heat release coefficient, in W / m²·K; is the correction value: 1-1.2, when the adhesive joint is not air-tight, take =1.2.

[0098] According to the equivalent heat release coefficient required by the design of the dam, the thickness of the heat preservation core layer can be calculated by the above formula .

[0099] The heat preservation core layer, the surface anti-seepage protection layer and the internal pressure bearing protection layer form an integral whole, and a sub-mother tenon-mortise structure is formed around, and the depth of the groove and the length of the tenon are both 5 cm.

[0100] When the modular splicing and installation is carried out on site, first, the surface of the tenon and the mortise is brushed with adhesives such as foam glue and structural glue, then the tenon and the mortise of the adjacent modules are spliced one by one to realize seamless connection of multiple modules, and prevent the environmental temperature amplitude from having an adverse effect on the dam concrete through the joint.

[0101] Preferably, the top surface of the uppermost thermal core layer 4, the facing impermeable protection layer 1 and the internal pressure bearing protection layer 2 is further provided with an edge sealing protection cover 13. The edge sealing protection cover 13 is used to temporarily seal and protect the top surface of the uppermost module, which can prevent the concrete slurry from polluting the mortise and tenon structure of the module during pouring, and can also prevent the thermal core layer from being damaged when the dam is washed. The groove structure of the edge sealing protection cover corresponds to the tenon head of the module. After all the modules in the dam are assembled and fixed, the edge sealing protection cover is used to cover the tenon head of the module, which can prevent the concrete slurry from polluting the mortise and tenon structure of the module during pouring, and can also prevent the thermal core layer from being damaged when the dam is washed. The edge sealing protection cover is removed when the next dam permanent thermal protection and impermeable protection module is assembled.

[0102] Embodiment 2: A prefabrication method of a formwork embedded dam permanent thermal protection and impermeable protection module, which comprises the following steps:

[0103] Step 1: Parameter determination;

[0104] Step 1.1: Determine the thickness of the thermal core layer according to the equivalent heat release coefficient of the thermal insulation layer required by the dam design;

[0105] ;

[0106] In the formula: is the thickness of the thermal core layer, in meters; is the thermal conductivity, in W / (m·K); is the equivalent heat release coefficient, in W / m²·K; is the correction value: Take 1~1.2, when the adhesive joint is not air-tight, take =1.2;

[0107] Step 1.2: Calculate the lateral pressure of the dam concrete pouring, and recheck the shear strength of the fiber cement board of the facing impermeable protection layer and the internal pressure bearing protection layer to determine the thickness of the fiber cement board;

[0108] According to the concrete pouring formwork guide ACI 347-04, when the concrete slump value is ≤175 mm, and the placement height is ≤4.2 m under normal vibration, and the placement rate is <21.m / h, the lateral pressure of the concrete is calculated according to the following formula:

[0109] ;

[0110] In the formula : the maximum lateral pressure of the concrete, in kPa; : unit weight coefficient, ; : concrete density, in ; Chemical coefficient, value 1.2; Pouring rate of concrete, unit m / h; Concrete temperature during placement, unit ℃;

[0111] The bending strength of 1cm fiber cement board is 12MPa, when ×10 -3 <12, the thickness of fiber cement board is 1cm;

[0112] When ×10 -3 ≥12, the thickness of fiber cement board is calculated as follows:

[0113]

[0114] In the formula, : thickness of fiber cement board, unit m; : maximum lateral pressure of concrete, unit kPa; Step 1.3: according to the thickness of thermal insulation core layer and the thickness of fiber cement board , the total length of heat insulation screw and the length of the thicker segment in the middle are calculated as follows.

[0115] ;

[0116] ;

[0117] In the formula, : length of heat insulation screw, unit m; : thickness of thermal insulation core layer, unit m; : height of first anchor nut, unit m; : height of second anchor nut, unit m; : thickness of outer limiting flange, unit m, : thickness of inner limiting flange, unit m, m.

[0118] Step 1.4: determination of size and weight of single module.

[0119] ​The formwork 80% used in dam concrete pouring of water conservancy projects is large steel formwork with standard size such as multi-card formwork. For this part, according to the structural characteristics (size, size and number of positioning cone, position and length of supporting leg, etc.) of the large formwork, the single module is controlled to be a square or rectangle with a side length of 1000mm~3000mm according to the principle of equal division of single formwork. The weight of single formwork is controlled to be 50~500kg. The size of single heat preservation and anti-seepage protection module matched with the large formwork, the size and number of reserved positioning cone hole, the size and position of reserved formwork supporting leg insertion hole, etc. are obtained to realize large-scale installation in batches on the construction site.

[0120] For the remaining part of the small formwork, special-shaped formwork, etc., according to the size, position and number of this part of the formwork, for the large number and consistent size, the module is designed and produced according to the size of the small formwork, and then transported to the site for installation. For the small amount and different size, the standard module is cut on site with cutting machine and other tools to realize the installation and fixation inside the special-shaped formwork.

[0121] Step 2: Manufacturing of decorative anti-seepage protection layer

[0122] Step 2.1: Mix the raw materials such as XYPEX admixture, cement, fiber and filler according to a certain proportion, and send them into the mixer for stirring to ensure that various raw materials are fully mixed to form a uniform paste.

[0123] Step 2.2: Pour the mixed paste into the mold to half height, then put the steel mesh into the paste in the mold, keep the steel mesh in the middle position of the paste; then arrange and fix the first anchor nut in a square four-corner shape on the steel mesh, and ensure that the distance between adjacent bolts is 500mm; finally, pour the mixed paste into the mold to the standard height (the thickness of the fiber cement board determined in step 1.2), and use the 7000-ton flatting machine and pressing machine for flattening and pressing treatment, and curing forming.

[0124] Step 2.3: Cut the fiber cement board according to the size determined in step 1.4, and reserve the insertion holes of the concrete pouring formwork anchor bolt and the concrete pouring formwork supporting leg at the corresponding position to obtain the base protection layer.

[0125] Step 2.4: Apply 1~2mm SABRE (XYPEX) anti-seepage material on the smooth surface of the base protection layer to obtain the cement-based anti-seepage coating.

[0126] Step 2.5: Apply a layer of hydrophobic coating on the surface of the anti-seepage coating. The material of the hydrophobic coating is organic fluorocarbon resin or organic silicon oligomer, and the thickness of the hydrophobic coating is 0.1~0.5mm to obtain the hydrophobic ice-repellent coating.

[0127] Step 3: Internal pressure bearing protective layer manufacturing

[0128] Step 3.1: Mix the raw materials such as XYPEX admixture, cement, fiber, and filler according to a certain proportion, and send them into the mixer for stirring to ensure that the various raw materials are fully mixed to form a uniform slurry.

[0129] Step 3.2: Pour the mixed slurry into the mold to half the height, then place the steel mesh in the slurry in the mold, keeping the steel mesh in the middle of the slurry; then arrange and fix the second anchor nut in a square four-corner shape on the steel mesh, ensuring that the distance between adjacent bolts is 500mm, and the arrangement position corresponds to the first anchor nut; finally, pour the mixed slurry into the mold to the standard height (the thickness of the fiber cement board determined in step 1.2), and use a 7000-ton flattening machine and a pressing machine for flattening and pressing treatment, and curing to form.

[0130] Step 3.3: Cut the fiber cement board according to the size determined in step 1.4, and reserve the insertion holes of the concrete pouring mold anchor bolts and concrete pouring mold support legs at the corresponding positions to obtain the internal pressure bearing protective layer.

[0131] Step 4: Insulation core layer pouring and extrusion

[0132] Step 4.1: Insert two limiting flanges into the two ends of the heat insulation screw.

[0133] Step 4.2: Place the rough surface of the decorative impermeable protective layer parallel to the rough surface of the internal pressure bearing protective layer, screw the threaded segments of the multiple heat insulation screws into the first and second anchor nuts, respectively, and connect the decorative impermeable protective layer and the internal pressure bearing protective layer to form a whole. Then seal the four sides with a template, leaving only one pouring port to form a 6-sided sealed pouring mold.

[0134] Step 4.3: Use the pouring and extrusion one-step forming process to fill and compact the interior of the mold with polyurethane rigid foam insulation material; after setting, remove the four surrounding templates.

[0135] Step 4.4: Use power tools, electric saws, and other tools to drill through the insulation core layer according to the pre-reserved concrete pouring mold anchor bolts and concrete pouring mold support leg insertion holes on the decorative impermeable protective layer and the internal pressure bearing protective layer, and the hole diameter is the same as the protective layer.

[0136] Step 4.5: Use electric saws and hand saws to cut and trim the four sides, forming a son-mother mortise and tenon structure according to the principle of top-down correspondence and left-right correspondence, which forms a seamless connection when multiple modules are spliced and installed.

[0137] Embodiment 3: A construction method of a template-embedded dam face permanent thermal protection module, comprising the following steps:

[0138] Step 1: Transportation and hoisting;

[0139] According to the dam concrete pouring progress, the template-embedded dam face permanent thermal protection module prefabricated in the factory is transported to the site warehouse in batches. Then according to the daily concrete storage area, these modules are transported to the storage surface by cable crane.

[0140] Step 2: Template-embedded splicing and installation;

[0141] Step 2.1: After the concrete pouring formwork is erected, the above-mentioned module is arranged in close contact with the pouring formwork, and a balance pad layer is laid between the inner side of the concrete pouring formwork and the outer surface of the module. The balance pad layer can be foam rubber pad, plywood, polyethylene film, PET film and EVA film, etc. Firstly, it plays a buffering role for the surface protection layer of the module during concrete pouring, preventing it from being broken under pressure; secondly, it prevents the release agent, oil stains on the concrete pouring formwork from polluting the surface protection layer, avoiding the adhesion of the two during form removal. When arranging, the positioning cone and the formwork support leg are pulled out from the reserved hole to the warehouse.

[0142] Step 2.2: According to the corresponding principle of the sub-mother mortise and tenon structure, the splicing and installation of adjacent modules are carried out. Before splicing, the surface of the tenon is uniformly coated with adhesive such as structural adhesive and foam adhesive, and then the tenon is inserted into the corresponding mortise to ensure seamless connection between the adjacent modules above, below and on the left and right.

[0143] Step 2.3: The spliced and installed modules are fixed on the concrete surface or the surface layer of the crack control steel bar in the warehouse by using support rods, cushion blocks and the like, to prevent the modules from shifting or deviating from the concrete pouring formwork and falling into the warehouse during concrete pouring and vibrating.

[0144] Step 2.4: The threaded end of the multiple serpentine anchor bars is screwed into the second anchor nut of the internal pressure-bearing protective layer, and the other end faces the warehouse. When the concrete is poured, the serpentine anchor bar forms a whole with the dam body, firmly fixing the template-embedded dam face permanent thermal protection and impermeable protection integrated system module.

[0145] Step 2.5: The top surface of the uppermost module is temporarily sealed and protected by using an edge sealing protective cover, which prevents the concrete slurry from polluting the sub-mother mortise and tenon structure of the module during pouring, and prevents the damage to the thermal core layer during the warehouse.

[0146] Step 3: Inspection and plugging;

[0147] Step 3.1: when the concrete pouring form is removed after the concrete pouring, the concrete pouring form anchor bolt connected with the positioning cone is unscrewed, and the concrete pouring form is lifted upwards along the surface of the module; after the upper form support and panel are installed, the concrete pouring form support leg of the lowermost form support is taken out from the insertion hole, and finally the finishing impermeable protective layer of the concrete dam surface of the bin is exposed.

[0148] Step 3.2: the person is hung on the support of the upper form by using a hanging ladder and the like, and then descends to the dam surface to check and seal; first, the positioning cone hole and the form support leg insertion hole are sealed by using polyurethane foaming material, when the sealing is 1cm away from the surface, the sealing is carried out by using polymer mortar, then 1-2mm of XYPEX impermeable material is brushed on the surface, and finally a layer of hydrophobic material with a thickness of 0.1-0.5mm is brushed, and the permanent thermal insulation and impermeable protective layer of the concrete dam surface of the bin is arranged.

[0149] Step 3.3: when the form of the next bin is erected, the protective cover on the top surface of the installed module is removed, the new module is spliced and installed on the top of the installed module according to the sub-mother mortise and tenon structure, and then the above steps are repeated, when the dam pouring is completed, the form embedded dam permanent thermal insulation and protection module of the whole dam surface is arranged, and the protection of the whole life cycle of the dam concrete is realized.

[0150] The above embodiment is only a preferred technical solution of the utility model, and should not be regarded as a limitation of the utility model, and the protection scope of the utility model should be the technical solution recorded in the claims, including the equivalent replacement solution of the technical features of the technical solution recorded in the claims as the protection scope. That is, the equivalent replacement improvement in this range is also within the protection scope of the utility model.

Claims

1. A form-liner embedded dam face permanent thermal protection module comprising a thermal core (4) characterised in that: The facing anti-seepage protective layer (1) is sequentially provided with a hydrophobic anti-icing coating (1.1), a cement-based anti-seepage coating (1.2) and a base protective layer (1.3) from the side in contact with the concrete pouring formwork (6) to the inside of the dam.

2. A form-liner embedded dam face permanent protection module according to claim 1, characterized in that: The facing anti-seepage protective layer (1) is sequentially provided with a hydrophobic anti-icing coating (1.1), a cement-based anti-seepage coating (1.2) and a base protective layer (1.3) from the side in contact with the concrete pouring formwork (6) to the inside of the dam.

3. A form-liner embedded dam face permanent protection module according to claim 1, characterized in that: The facing anti-seepage protective layer (1) is sequentially provided with a hydrophobic anti-icing coating (1.1), a cement-based anti-seepage coating (1.2) and a base protective layer (1.3) from the side in contact with the concrete pouring formwork (6) to the inside of the dam.

4. A form-liner embedded dam face permanent protection module according to claim 1, characterized in that: The heat broken bridge support keel (3) includes a first anchor nut (3.1) arranged in the facing anti-seepage protective layer (1) and a second anchor nut (3.2) arranged in the internal pressure-bearing protective layer (2), and the first anchor nut (3.1) and the second anchor nut (3.2) are threadedly connected with both ends of the heat insulation screw rod (3.3), and the thread directions of the first anchor nut (3.1) and the second anchor nut (3.2) are opposite.

5. An in-form, in-situ dam face permanent protection module according to claim 4, wherein: The heat insulation screw rod (3.3) is provided with a recess or a step on the side close to the first anchor nut (3.1), and an outer limiting flange plate (3.4) in contact with the facing anti-seepage protective layer (1) is arranged in the recess or the step.

6. The template embedded permanent thermal insulation protection module for dam surface according to claim 4, characterized in that: The heat insulation screw rod (3.3) is provided with a recess or a step on the side close to the second anchor nut (3.2), and an inner limiting flange plate (3.5) in contact with the internal pressure-bearing protective layer (2) is arranged in the recess or the step.

7. An in-form, precast, permanent formwork and thermal protection module according to claim 1, characterized in that: The anchor device (5) includes an adjustable support rod (5.1) arranged between the internal pressure-bearing protective layer (2) and the dam surface layer crack limiting steel bar (7) and an anchor bar (5.2) threadedly connected with the outer side of the second anchor nut (3.2).

8. An in-form, in-situ dam face permanent protection module according to claim 1, characterized in that: The concrete pouring formwork (6), the facing anti-seepage protective layer (1), the heat insulation core layer (4) and the internal pressure-bearing protective layer (2) are provided with insertion holes for mounting concrete pouring formwork anchor bolts (8) and concrete pouring formwork support legs (9), the concrete pouring formwork anchor bolts (8) are threadedly connected with one end of a positioning cone (10), the other end of the positioning cone (10) is connected with the dam surface layer crack limiting steel bar (7) through a serpentine anchor bar (11), and the concrete pouring formwork support legs (9) are fixedly connected with a concrete pouring formwork support (12).

9. An in-form, precast, permanent formwork and thermal protection module according to claim 1, characterized in that: The end of the heat preservation core layer (4) is higher than the end plane of the surface anti-seepage protection layer (1) and the internal pressure bearing protection layer (2), forming a tenon structure; the other end of the heat preservation core layer (4) is lower than the end plane of the surface anti-seepage protection layer (1) and the internal pressure bearing protection layer (2), forming a mortise structure; each two adjacent formwork embedded dam surface permanent heat preservation protection modules are connected through the cooperation of the tenon structure and the mortise structure.

10. An in-form, precast, permanent formwork and thermal protection module according to claim 1, characterized in that: The top surface of the uppermost heat preservation core layer (4), the surface anti-seepage protection layer (1) and the internal pressure bearing protection layer (2) is further provided with an edge sealing protection cover (13).

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