Research and engineering application of intelligent concrete pouring surface control model for roller-compacted concrete gravity dams

Abstract Hydropower projects in complex environments with variable meteorological conditions significantly impact the placement surface environment of roller-compacted concrete gravity dams. Effective monitoring and real-time adjustment of the placement surface microclimate are crucial to minimize concrete temperature rebound. Current practices often lack rigorous parameter optimization for spray systems, leading to inefficient cooling. This study proposes an intelligent placement surface control system integrating traditional spray technology, simulation models, and field data. Field experiments at a dam in southwestern China, conducted from June to September 2023 with hourly data collection, demonstrated that intelligent spraying reduced placement surface temperatures from 28 °C to 23 °C, lowered concrete temperature from 31.2 °C to 26.7 °C, and decreased dam body tensile stress from 0.5 MPa to 0.25 MPa. The system effectively mitigates temperature rebound and cracking risks, providing intelligent support for dam construction with an operational energy consumption of 8 kWh per hour. The spray machine in this system achieves a median volumetric diameter (MVD) of 100–150 μm for atomization droplets, enhancing cooling efficiency.