Concrete Heating Systems

Alp Concrete Heating Systems are designed to keep the thermal temperature of the mass concrete poured at outside temperature below zero at desired level.

Temperature is one of the most important factors which has a negative effect on the quality of concrete. Undesired temperatures also leads to problems in processes of mixing, placing and curing.

When the temperature of the concrete decreases;

• Loss of consistency increases,
• Setting time becomes irregular,
• Bleeding rate and time become unstable,
• Cracking tendency caused by plastic and drying shrinkage increases,
• Cold joint formation risk increases,
• Controlling air content becomes difficult,
• Aesthetic appearance deforms.

Like as high temperature, low temperature also affects the strength of concrete adversely. Therefore, adverse effects of temperature on the concrete should be observed and necessary measures should be taken.

Up until now, this problem has been solved by adding hot water to mixing water of the concrete or heating the surface of concrete with various techniques. However, the method of adding hot water to mixing water or heating the concrete on the surface have been found insufficient to obtain the desired quality of special concretes, particularly at air temperatures below zero.

The method of “heating in the concrete form” developed by our company is based on heating the concrete when it is poured into the concrete form and the works performed with this method have ensured obtaining the high quality concrete in accordance with the norms.

Alp Concrete Heating Systems used for heating the concretes specified by special norms in construction of dams, bridges and power plants heats the concrete but not the mixing water.

After cast irons are laid, polyurethane pipes selected in accordance with the criteria for the concrete to be used are laid inside the concrete form. Polyurethane pipes are placed in the concrete form in accordance with the designed project. Upon completion of concrete casting, the hot water obtained in concrete heating group flow through polyurethane pipes and the concrete is heated within the calculated period.

The system is fully automated and provides required temperature and volume values. It also provides reports at requested intervals.

Volumes and temperatures at inlet and outlet headers of the system can be separately set, measured and reported. The system was tested in cooling the special norm mass concretes of Osman Gazi Bridge included in Gebze-İzmir Highway Project and got full marks.

The concrete cooling systems manufactured for the first time for Osman Gazi Bridge Project is composed of cold water stream line and cold water return line. Each line at the return header supplies water at required temperature and volume respectively. Operation intervals of cooling group, stream and return temperatures and volumes in the lines are monitored and reported by the automation system.

The number of lines in stream and return headers, temperature, flow rate and operating intervals can be set having different values based on your project.

The signature under the Alp Concrete Cooling Systems designed by Alperen Mühendislik belongs to Turkish engineers. The system was designed, conceptualized, automated and manufactured by Turkish engineers.

Properties of Alp Concrete Heating System:

• The concrete heating system is designed as a portable package heating device which heats the cast concrete in accordance with required norms and values and its structure is suitable for field operations under outdoor weather conditions.
• Concrete heating system is manufactured in different capacities as needed.
• The system can produce hot water at desired flow rate.
• The system can produce hot water at desired temperature.
• The system measures and reports stream and and return temperatures of heating water.
• The system has a durable structure to be used under worksite conditions.
• The system has advanced automatic control system and special Alp automation software.
• The system is easy-to-install and portable.
• The system is designed as a package unit which takes a small space.
• Outer surface of system cabin is made of electrostatic painted modular panels. Each part of the cabin is easily accessible.
• Capacity control of the heating group is made proportionately. Performance values of heating group comply with ARI Standard 550/590-98.
• The compressors used in heating group are leaning, semi-hermetic, single screwed and can be serviced on site. Compressor parts are easily accessible for maintenance and repair. Operating life of compressor bearings is minimum 100.000 hours. When more than one compressor is used in the heating group, heating fluid circuit of each compressor is designed independently from each other. The economizer of the compressor is located outside the compressor to simplify the structure of the compressor and it is gas-heated.
• Temperature of water flow from each outlet line of the system is 700C ± 1 and the capacity is 1 ± 0,1 m3/h. These values can be checked visually at any time and reported by the system at will.
• The pumps in the system are redundant.
• Pipe connections of stream and return lines in the system are made of materials suitable for use under worksite conditions and they are easy-to-use.
• The equipment used in the system operate in compliance with the automation system.
• Condensers and fans of heating group of the system are designed to operate under worksite conditions.
• The fans used in the system are statically and dynamically balanced according to ISO 1940-G 6.3. The fans are mounted to custom-made slots in the manner not to vibrate. Connections of the motor and other electric luminaries are extended to a connection box of minimum IP65 protection class on the plant.
• The evaporator and condenser coils of the system are made of aluminum wing hydraulically spread over the copper pipe.
• The batteries in the system are subjected leakage test at 150 psig and pressure test at 450 psig.
• Condenser fins are resistant to corrosion caused by external factors. Condenser fans are in IP54 class and their operating temperature is between – 40C and + 55C. High efficiency and low sound condenser fans are used.
  Control system of the cooling group is placed in a panel not affected by external factors with a locked cover (IP54). Power and operating panels are placed in different compartments for safety and control. There are protection elements for each compressor and each condenser fan.
• There are high and low pressure cut-out switches and freeze thermostat for each cooling circuit and cut out switch and time counter indicating the operating time for each compressor in cooling group.
  Threaded valves are used in the range of DN15 – 40 and flanged valves are used for bigger diameters. Valves are sized in accordance with system requirements. Control valves with standard Kv values which provide equal percentage flow curve are used. All valves comply with pressure class PN16.
• Valves with on-off function are used in pipe diameter. All valve motors are selected to allow pressure cut-off.
• There is a test pump in the system to control stream and return lines. Design and use of this pump is suitable for field work.
• All electrical cable inputs and outputs of the system comply with IP 65 standard.
• Power supply connections of the system are designed and manufactured to operate under worksite conditions.
• Joints of the system are impermeable. Outer sides are connected with rivets or nuts and bolts resistant to corrosion and outdoor weather conditions.
• The system is suitable for worksite conditions and portable.
• The system operates with electric power. It also operates with natural gas at will.
• There are carrying handles for winching the system. These handles are placed in the manner so that the ropes will not damage the device during winching.
• There is a chassis made of steel in minimum at the bottom of the heating system. There are carrying slots and handles on this chassis for carrying and placing.
• All volume and temperature values in the system can be monitored on the screen and reports can be received at desired intervals.
• Temperature and volume reports received from the system are displayed both in tabular and graphical form.
• The automatic control system allows users to access the system data via local network within the facility and through standard internet browser programs on the internet outside the facility if the connection is provided.
• All kinds of labor, material and software required for the functional operation of the automatic control system are provided by us.
• Assemblies of mechanical equipment are made, calibrated and approved in our factory.
• Electrical supply board, automation panels and related consumables are assembled properly in the system.
• The system includes password protection to access data, functions and features of the system.
• The automatic control system has the infrastructure that allows information flow and generating different scenarios.
• The reports are kept in a PC and reviewed by the user if necessary.
• The received data can be easily viewed by the user in graphical environment without needing any additional program.
• A standard Internet browser allows unlimited number of users securely access the system through the network.
• Authorization levels have been created by assigning different names and passwords to each user in the graphical user interface environment.
• Animated graphics such as rotation of the blades of the operating fan are defined.
• Instant data on diagrams are automatically renewed without interference of users.
• A separate home page can be defined for each user. Users can be prevented from accessing the diagrams outside their own pages.
• Past data diagrams can be viewed and selection can be made in desired date and time interval.
• Each point connected to the system has been tested for functionality.
• Operator training is provided in your facility and on the installed system. The training is provided by our expert staff who have the necessary knowledge about the hardware and software of the system.
• Our concrete heating systems are guaranteed for 2 years against all kinds of manufacturing defects.

Related Photos;