LNG墙体施工方案.doc

02009.10.6 张晓斌廖明强刘俊 b2009.9.25 张晓斌廖明强刘俊 a2009.9.2 张晓斌廖明强刘俊 版次 rev. 日期 date 编 制 prepared by 审 核 reviewed by 批 准 approved by cbi 业主/监理 owner/superviso r 修 改 说 明 提交供审核 revision description. ifc (issue for construction) 中中国国核核工工业业华华兴兴建建设设公公司司 chinachina nuclearnuclear industryindustry huaxinghuaxing constructionconstruction co.co. 福建福建 lnglng 一期新增一期新增 3#3#、4#4#储罐工程储罐工程 fjlngfjlng phasephase i i additionaladditional #3#3 andand #4#4 tankstanks projectproject 液化天然气低温储罐土建工程 lng cryogenic tank civil works 编码 code fjlng-co2-huax-014 文件类别 doc. type 方案method statement 文件名称 doc. title 福建 lng 罐混凝土墙体施工方案 method statement for the concrete wall of fjlng tank 版次rev 页码 page abcdefg 版次rev 页码 page abcdefg 011 112 213 314 415 516 617 718 819 920 1021 changechange recordrecord pagepage revisionrevisiondescriptiondescription ofof revisionrevision a a issueissue forfor reviewreview b b issueissue forfor reviewreview 0 0 ifcifc revisionrevision tabletable pagepagerevisionrevisionpagepagerevisionrevisionappendixappendixrevisionrevision aaa 1x26x1x 2x27x2x 3x28x3x 4x29x4x 5x30x5x 6x31x6x 7x32x7x 8x33x8x 9x34x 10x35x 11x36x 12x37x 13x38x 14x39x 15x40x 16x41x 17x42x 18x43 19x44 20x45 21x46 22x47 23x48 24x49 25x50 目目 录录 contentcontent 1.general 概述 .6 2.scope 范围.6 3.references 参考文献7 3.1.drawing 图纸7 3.2.specifications 规范11 4.construction preparation 施工准备.11 4.1.personnel 人员 .11 4.2.construction materials 施工主要材料 .11 4.3.construction equipment and tools 施工机具 11 5.construction methodology 施工方法 .14 5.1.construction sequence 施工顺序.14 5.2.survey control 测量控制15 5.3.installation of embedded parts 预埋件安装17 5.4.rebar fabrication and fixing 钢筋制作及安装21 5.5.pre-stressing duct erection 预应力管道安装.25 5.6.formwork erection 模板支设.25 5.7.striking of formwork 拆模37 5.8.horizontal construction joints treatment 水平施工缝的处理 38 5.9.concrete work 混凝土浇注工作.39 5.10.temporary construction opening 临时施工洞口41 6.contingency plans 应急方案42 7.controls 控制.42 8.access 通道.43 9.training 培训.44 10.safety plan for wall construction 墙体施工安全方案 .45 10.1.physical barrier to be installed 安装硬围护 45 10.2.climbing of doka formwork 多卡模板爬升.45 10.3.fall protection 防坠落保护.45 10.4.access and emergency access 通道和紧急通道.46 10.5.electrical safety measure 用电安全措施.46 10.6.bad weather plan 坏天气计划46 11.appendix 附件47 1. general 概述 this method statement is established to define construction method for the concrete wall of fjlng phrase 1 additional 3# and 4# tanks project. 此方案 适用于福建 lng 一期新增 3#和 4#储罐工程混凝土墙体施工方案。 2. scope 范围 variations of sequence or method may evolve as the work progresses, which will maximize efficiency and use of available equipment and resources. a revised method statement will be issued for variations in work practice. 施工顺序或方法会随工程进展而改动，以便最大化的提高资源使用效率。 the tank wall is circular on plan, tank height of 50054mm, 1000mm thick tapering down to 550mm thick at a height of 6750mm. the inner radius of wall is 41000mm, the outer radius is 41550mm, and the thickness of standard wall is 550mm. the concrete c50 will be used for the wall, reinforced with high yield steel reinforcement on the faces of the wall and cryogenic reinforcement just be used on the inner face of lift 2. 罐体 墙体为圆形, 罐高 50054mm, 在高度 6750mm 范围内，罐厚从 1000mm 渐变到 550mm. 墙体内径为 41000mm,外径为 41550mm,标准墙体厚度为 550mm。墙体使用 c50 混凝土， 墙体钢筋高屈服钢筋，第二层墙体内侧使用低温钢筋。 post tensioning is applied to horizontal and vertical pre-stressing ducts built into the walls. 预应力适用于墙体的水平和竖直预应力管道。 the description of tendon prestressing and duct grouting will be addressed in separated method statement. 预应力和孔道灌浆的描述参见单独的施工方案。 during construction of the wall, welding joints and deformation of inserts control shall be performed by the mechanical subcontractor in accordance with the relevant specification, other work shall be carried out by civil contractor. the mechanical subcontractor shall use the access and platform set by civil subcontractor for welding of inserts. 在罐筒体施工过程中，预 埋件焊接连接和变形控制措施工作由机械分包商按照相关规范执行，其余相关工作均 由土建分包商完成。机械分包商进入筒体执行预埋件焊接时，可利用土建分包商设置 的通道和操作平台。 construction will be 11 lifts of the following heights: 施工每层高度： lift noheight (mm)concrete dosage(m) 13375790 23375621 33800587 43800587 53800587 63800587 73800587 83800587 93800587 103775584 11-12275534 11 11-21100437 3. references 参考文献 3.1. drawing 图纸 general arrangement 总体安排 dd-dwg-ts-st-025101 tank ts-t-02-03 orientation 3#罐定位图dd-dwg-ts-st-025102-01 tank ts-t-02-04 orientation 4#罐定位图dd-dwg-ts-st-025102-02 outer paste on liner 衬里的外部粘贴材料dd-dwg-ts-st-025122 outer liner embed details 外罐衬里预埋件详图 dd-dwg-ts-st-025123-01 outer liner embed details at tco 临时洞口外罐衬里预埋件详图 dd-dwg-ts- st-025123-02 outer liner embed details 外罐衬里预埋件详图 dd-dwg-ts-st-025123-03 3“ outer bottom insulation purge n13 3“外罐底隔热层排气管 n13dd-dwg-ts-st-025192 outer liner embed details 外罐预埋件详图dd-dwg-ts-st-025139 2“ dia pres. equalization - n14a/b survey diameter line downwards, max. tolerance is 1/2000) to lead base slab center point to the height needed for total station erection. then survey radius and verticality of every piece of formwork with total station without prism (without prism could reduce man-made errors). during concrete pouring, do a circumferential survey every 1/3 height concrete poured and do some adjustment if necessary to control tank verticality, radian and diameter. as per wall construction requirement, survey and lead directional line up every two lifts. 在墙体施工阶段，使用测量专用塔架 （塔架制作参照附件附件 1414） 、激光垂准仪（向上一测回标准偏差 1/45000，向下对 径观测极限误差 1/2000） ，将底板上的圆心点引测到架设全站仪所需的高度，再 用全站仪通过无棱镜测量（使用无棱镜可以减少扶棱镜的人为误差）每一块模板 的半径和垂直度。砼浇筑过程中，每浇筑 1/3 高度进行一次全圆测量，发现问题 及时调整，直至浇筑完成，以此来控制储罐墙体的垂直度、弧度和直径。根据墙 体施工需要每两层将定向方位线向上引测一次。 survey is a key issue during the wall construction. survey points must be placed on each inner formwork panel (top and bottom). inner formwork panels shall be adjusted and fixed according to the surveyors instructions. verticality and position of the vertical inserts shall be checked once fixed onto the shutter. 建筑墙体最关键的 是要做好测量工作。测量点必须置于内模板上下，内模板则需根据测量员的指示 进行调整和固定。在把竖直预埋件装到模板前，需先检查预埋件是否竖直，位置 是否正确。 during pouring, surveyor shall continuously monitor the shuttering so that adjustment of formwork panels may be done during concrete pouring if required。 浇注时，测量员需时刻监视模板支撑，如需调整，则可在混凝土 浇注过程中进行。 after shuttering removal, full survey of the wall lift shall be performed in order to check all tolerances specified in the project specification. a formal written report shall be then submitted to the qc manager, construction manager, technical manager and the survey engineer for review and approval. 模板拆除后，全面检查分层表面是否符合 规范中规定的误差，且必须向质量控制经理，施工经理，技术经理以及测量工程 师递交书面报告以便复查评估。 5.3. installation of embedded parts 预埋件安装 5.3.1. general 总则 contractor shall provide all inserts used in the tank. the mechanical subcontractor shall weld the connection joints and adjust the deformation caused by welding. the civil subcontractor shall install and fix the inserts in accordance with the requirement of drawings and specification.承包商负责供应罐体所用全部预埋件，机械分包商负责焊接连接 和焊接变形校正，土建分包商负责根据图纸和规范要求将预埋件安装和固定。 principally, steel plate of inserts shall not be welded. spot welding can be used to weld the stud of inert and the fixing material with agreement of cbi representative. the embedment will not be welded on wall rebars. studs are not to be bent without approval by cbi. 预埋件 安装原则上不允许在预埋件钢板上施焊或引弧，在 cbi 代表同意时可将固定用金 属材料与预埋件上锚固筋点焊，并且不与墙体钢筋焊接，没有 cbi 的批准预埋件 禁止弯折。 5.3.2. vertical inserts 竖直预埋件 vapour barrier inserts will be fixed with fitments that were previously installed through formwork to ensure that the insert is held in position firmly during concreting operations. 隔汽预埋件通过一 个穿透模板的固定件进行固定以保证在混凝土作业过程中不会移位。 the vertical insert shall be fixed temporarily by steel wire after hoisted to place by tower crane to keep the deviation of location and verticality within the design requirement. the joint of inserts shall be welded by the mechanical subcontractor, and then inserts shall be checked and qualified before lifting and installing the inner formwork. use steel clamps and tie rods to pull the insert closely contact the surface of formwork. refer to detail 1 of appendix 1.the tie rod will pass through pre-drilled holes in the formwork and held the insert in position using a washer and wing nut. the wing nut will be hand tightened until the insert position is fixed by use of total station and then fully tightened. 垂直预埋件用塔吊吊至安装位置后可用铁丝进行临 时固定，使埋件位置和垂直度偏差满足设计要求。埋件连接处由机械分包商进行 焊接，然后由测量人员对埋件进行检查，符合规范要求后，即可将内模板提升安 装，通过穿透模板的螺杆和钢夹具将埋件拉动紧贴内模表面。见附件见附件 1 1 中详图中详图 1 1。螺杆穿过模板上预先钻透的孔并用垫片和蝶形螺母使埋件就位，蝶形螺母先 用手拧紧，在全站仪检查位置准确后再最终紧固。 if it is found that there is a gap between the insert and formwork, the insert will be pushed into contact by way of a rebar which one end is covered with c50 concrete block. refer to detail 2 of appendix 1.如 果发现预埋件与模板之间留有空隙，须用一端套有 c50 混凝土块的钢筋将预埋件 压紧，使两者接触。见附件见附件 1 1 中详图中详图 2 2。 5.3.3. horizontal inserts 水平预埋件 the first horizontal insert is located at a level of +515mm above the pile cap, its segmental components will be held in place by tying the stud welded on the rear face to the rebar by civil subcontractor. the segments shall be welded together by the mechanical subcontractor prior to concreting. 第一层水平预埋件埋于底板之上+515mm 标高处。土建分 包商通过将焊于预埋件背面的锚固钉与附近钢筋捆绑来固定预埋件。在混凝土施 工前由机械分包商将各部件焊接成一个整体。 should it be found necessary to push the horizontal strips to the formwork face, this will be done by concrete spacer between the insert strip and the rebar or by use of threaded rod and plate.水平板条必须抵 至模板面，则须在预埋件板条和钢筋间放置混凝土隔离块，或者使用螺杆和钢板。 the second horizontal insert is located at 4867mm above the pile cap. its segmental components will be positioned by using steel clamps. refer to appendix 2 after welding together, it will be pulled to closely contact the surface of formwork by using clamps and tie rod through the formwork. refer to appendix 2. the last joint will be welded until the adjusting work is finished and the tolerance meets the requirements of specification. 第二件水平预埋件应安装在底板之上 4867mm，用钢夹具将其逐个定位详见附件附件 2 2。在焊接后，用夹钳和螺杆穿过模板 将其拉到紧贴模板面详见附件 2。调整完毕且误差符合规定后方可焊接最后的接 缝。 the third horizontal insert is located in the top of lift 10. due to the weight of this component, the vertical inserts will support it.第 三个水平预埋件的位置在第 10 层顶部。考虑到此部件的重量，竖直预埋件可以 将其支撑住。 the sequence of installation of horizontal inserts shall be as follows: 水平预埋件安装顺序如下： a) the vertical insert shall be installed and fixed on the rebar net firmly by steel clamps. 竖直预埋件应安装于钢筋网上，用钢夹具固定； b) the component of horizontal insert shall be hanged to sit on the top of vertical inserts and connected by welding and fixed on the rebar net by steel clamps. 单个水平预埋件吊装放置在竖直预埋件之上并 互相焊牢，用钢夹具固定于钢筋网上； c) after the location and radius checked and qualified, joints between adjacent components shall be welded as soon as possible except the last one. 安装位置及半径检查并确认合格后，尽快焊接各个相邻部件的接 缝，直至留下最后一个接缝； d) the inner formwork panels shall be installed from the opposite location of the last joint to two sides and the inserts shall be pulled to contact the face of formwork by steel clamps. 内模板从最 后一个接缝的对面开始向两边安装。用钢夹具将预埋件拉至紧贴模板面。 e) the last joint can be welded only after the location and radius of horizontal insert is checked and qualified. 水平预制件的位置与半径 都已经过检查并确认合格后方可焊上最后的接缝。 5.3.4. inserts for pipe rack and escape ladder 管道及逃生梯预埋件 the inserts for pipe rack and escape ladder shall be installed and fixed on the rebar net firmly by steel clamps. the method for fixing is similar as the horizontal inserts.管道及逃生梯预埋件应用钢夹具安装并固 定于钢筋网上，固定方法与水平预埋件相似。 5.3.5. cleaning of inserts after pouring 浇筑后预埋件清理 after concreting, immediately use steel brush to clean the slurry and other wastes on inserts. 当混凝土浇筑完毕后应立即用钢刷清理预埋件表面的 灰浆及其他杂物。 5.4. rebar fabrication and fixing 钢筋制作及安装 5.4.1. general 概述 reinforcement shall be cut or bent as shown in the bar bending schedule. 钢筋都应照钢筋下料单所示进行切割或弯曲。 this operation will be carried out on site, and will be inspected full time by our representative. 这一操作应现场进行，由我方代表全程监督。 each bundle of bars shall be clearly tagged with bar mark number and size. 每捆钢筋上都有标签，明确标出该捆钢筋的数量与尺寸。 all cry-bar will be cut and painted at the ends with red paint for distinguishing. 切割低温钢筋时在两端涂上红色油漆以示区别。 the wall reinforcement will be pre-fabricated into mats, comprising separate inner and outer mats. from second lift, install rebar by prefabricated rebar mat. generally speaking the rebar mat width will be 12000mm which is the standard rebar length, and the height of rebar mat can refer to appendixappendix 9 9: wall vertical rebar splicing sketch. 先将 墙体钢筋制成彼此独立的内外两种钢筋片。从第 2 层起墙体钢筋用预制网片形式 进行安装, 总的来说，内外墙钢筋片的宽为一个 12000mm 的标准钢筋长度，高度 可参见附件附件 9 9：墙体竖向钢筋搭接示意图 buttresses will be fixed in-situ as the layout of rebar does not lend itself to pre-fabrication. 现场安装扶壁柱钢筋. to prevent lateral drift of the rebar system alternate vertical bars of the wall section will be set in a regular pattern to the left or right of the bar below. 为防止钢筋结构的侧向移动, 墙体部分的相互交错的 钢筋将按照规则的方式放置在钢筋下方的左侧或右侧。 all horizontal bars will be straight with alternate mats placed above or below the adjacent mat to avoid the mats climbing. 所有相邻的水平钢 筋网相互交替布置，以避免钢筋网往上爬升。 a schedule of mats will be prepared showing the location of each type. 编制钢筋网表，标明显示出每种类型的位置。 the first lift of the wall will be fixed in-situ as the layout does not allow for prefabrication. stirrups will be placed between the inner and outer mats to maintain the geometry of the wall. 按照布置图 不允许预制，墙体的第一层钢筋将在现场固定。 拉筋将设置在内外钢筋网之间 以维持墙体的几何性。 5.4.2. pre-fabrication area 预制场地 fabrication of wall mats will be carried out on a rack and on elevated ground adjacent to the tank. 在临近罐体的一块平整场地上，按照一定间隔 布置条形垫块，进行墙体钢筋网片制作。 5 rebar mat forms (refer to appendix 3 for fabrication drawing) will be fabricated near tower crane for fabricating rebar mat as per designed wall radian.现场在塔吊附近准备制做 5 个网片制作模板（拟加工的 钢筋网片制做模板见附件附件 3 3）用于钢筋网片的制作，按照墙体设计的弧度制做墙 体钢筋网片。 on completion of rebar fabrication of each mat, the mat will be checked for acceptance of fabrication only and signed off by qc. once signed off a tag showing installation location will be attached to signify the mat is acceptable for incorporation into the works. another inspection will be carried out after the matt has been installed in position. 在钢筋网制作完成后，质量控制部门将检查预制情况 并签字，附上标签标示出安装位置，表示钢筋网可用于施工，网片安装完毕将进 行安装的验收。 completed mats will be lifted from the storage area to the wall by tower crane with lifting beam after cleaning. 钢筋网的清洁后，将用塔吊 从储存区域提升到墙体处。 5.4.3. buttress rebar 扶壁柱钢筋 the buttress reinforcement will not be prefabricated. first, install inner rebar mat, then install outer vertical rebar, then outer horizontal rebar and tie bar at last. 扶壁柱钢筋不进行预制，在内侧钢筋 网安装之后，安装外侧竖直钢筋，再安装外侧水平钢筋，最后安装拉筋。 5.4.4. erection mats 钢筋网片安装 the sequences of erection have been addressed in section 5.4.1 above. 安装顺序已在章节 5.4.1 中列出。 the rebar mats will be installed by nearby tower crane. the angle of installation, elevation and weight of rebar mats will be marked on mats. 钢筋网片用附近的塔吊进行安装，每个网片上标示出网片安装的角度、标 高和网片的重量 two horizontal beams will be fabricated for lifting rebar mats. refer to appendix 4 for detailed drawing and lifting beam strength calculation.制作两个用于钢筋吊装的横吊梁，具体见附件附件 4 4：包括横吊梁强度：包括横吊梁强度 计算书。计算书。 fix rebar mat on lifting beam with 2 guy ropes for balancing rebar mats during being lifted up and put down.将钢筋网片固定于横吊梁上，并 设置 2 根牵引绳用于控制钢筋网片的在空中的摆动。牵引绳仅在钢筋网片上升和 下降阶段用于牵引钢筋网片。 mats will be hoisted to a position slightly above and in front of their final destination.钢筋网吊至悬于待装位置的前上方，稍稍高出。 the mats will be lifted along a radial line until contact is made with the mat or cage into which it meshes and then lowered into contact with the concrete of the previous pour. the mats will be tied as necessary to the starter bars from the previous pour on completion of tying all vertical bars to starter bars the construction supervisor will give instruction to the rigger that the lifting beam can be released. hse measures refer to relative jha for details. 沿径向升降钢 筋网片，待钢筋网接触到所接合的另一钢筋网，再降低高度使其慢慢达到规定高 度。钢筋网全部垂直筋需要与下一层插筋绑扎在一起后，工长才能告知起重指挥 可以松开起重臂，安全控制措施请参照相应的 jha。 5.4.5. technique control for rebar mats erection 钢筋网安装技术控制措施 check serial numbers, positions and quality of rebar mats prior to installation. unqualified and unclearly marked rebar mats should not be installed before modification and acceptance. 网片安装前对网片的编 号、位置、质量符合性进行检查，对于制作不合格的和标示不清楚的网片在进行 整改验收后才能进行安装。 check wall starter bar prior to rebar mat installation. adjust improper spacing for smooth connection to rebar mat. 网片安装前对墙体 插筋进行检查，对间距等不合适的地方进行调整，以便与网片钢筋顺利搭接。 check rebar mat fixing to ensure it meets hse requirements. 检查网片的 加固情况，使之满足 hse 的要求。 do not loose lifting hook until rebar mat connects to starter bars firmly and fixed, assigned person to be well trained for hook loosening. 钢筋网片与墙体插筋对接时要从水平钢筋一侧移动到位，与插筋绑 扎牢固并进行加固后才能去掉吊钩，拆卸吊钩将有专门训练的人员完成。 hse measure refer to relative jha for details.具体安全措施参见相应的 jha。 5.5. pre-stressing duct erection 预应力管道安装 please refer to prestressing duct installation procedure for detailed construction method 具体施工方法参见相关的预应力管道安装程序。 5.6. formwork erection 模板支设 5.6.1. type 类型 the selected type of formwork is doka type 150 climbing formwork. the major components of the formwork system are: refer to appendix 5 所选 模板为doka150爬升模板。 模板系统主要由以下组成：见附件附件5 5 18mm thick plywood 18mm 厚的胶合板 forming woods 模板木材 doka formwork beams h20-n 多卡模板梁 h20-n steel walings type ws10 钢支撑 ws10 5.6.2. pre-assembly of formwork panels 模板组装 the method of pre-assembly of panels is briefly described below. the assembly of the panels will be carried out upon instruction given by a doka engineer. 以下为模板组装介绍。模板组装将在多卡模板讲师进行指导后 进行。 profiling of the forming timbers, to be carried out on site 现场进行 木材的压型 placement of steel walers 钢围檩安装 fixing of the forming timbers to the steel walers 把造型木固定到围檩 上 fixing of the formwork beams 安装木工字梁 placing of plywood on doka formwork beams 胶合板安装到木工字梁上 fixing of others items as the platform and lifting arrangements 平台 和吊装使用的其他部件安装 the forms will be assembled in a prepared area adjacent to the tank, each formwork on the inside or outside to be painted with unique number. 罐体附近区域组装模板,内、外模将喷漆编号用以区分。 5.6.3. placement and align