汽机基础顶板施工.doc

CSPC Nanhai Petrochemicals ProjectCSPC NANHAI PETROCHEMICALS PROJECTCSPC 南海石化项目CONSTRUCTION OF STG. FOUNDATION TABLE TOP汽机基础顶板施工WORK INSTRUCTION: WI-8710-8100-0082SEPCO Electric Power Construction Corporation山东电力基本建设总公司REV版次DATE日期REASON FOR ISSUE修订原因BY编制CHKD审核REVIEW审查APPR批准A03.Jan.2004Issued for ApprovalShi.QSSong.JD Cao.ALXiao.TPSheng.XGB19.Feb.2004Issued for ApprovalLu.XWSong.JD Cao.ALXiao.TPSheng.XGWI-8710-8100-0082Page 38 of 38汽轮机基础施工 Page 38 of 38升版记录Revision information版次Rev章节号Section No.主要修改内容Description of main changesBAll Section将中文翻译为英文。Translate Chinese into English. 7.2.2详见高支撑计算7.2.8条改为7.2.10条Change see detailed section 7.2.8 for high-support calculation into see detailed section 7.2.10.7.2.2增加剪力撑的布置Add arrgement of shear support. 7.2.4增加脚手架排距、跨距、步距。Add scaffolds row space, span and step space7.2.5增加拆模后螺杆处理方案Add the project of bolt cutting after backout.7.2.8.4增加测温点布置图Add measuring points location. 7.2.10.3增加整体稳定性验算Add total stability calculation7.2.10.4顶板节点处扣件抗滑力验算：Add the calculation on the sliding resistant power of joints: 目 录Contents 1.目的 Purposes2.范围 Scope3.职责 Responsibilities4.参考文件 References5.计量器具、工具、机械 Measuring instruments , tools , machinery 6.劳动力组织 Labor force 7.施工工序和施工方法 Construction procedure and plans8.附件 Attachment 1.范围 Scopes 本作业指导书适用于CSPC 南海石化项目Steam & Power生产区汽轮机基础顶板的施工。The work instruction applies to the steam turbine foundation apical plate construction of S&P for CSPC Nanhai petrochemicals project.2.目的 Purposes规定中SEPCO1在CSPC南海石化项目汽轮机基础施工中的施工工艺及标准，以有效的控制施工质量及施工进度。It stipulates the construction process and standard of SEPCO1 in steam turbine foundation construction for CSPC Nanhai petrochemicals project in order to effectively control the construction quality and construction progress.3.职责responsibility技术负责人 Technical principals 宋辉、陈群 Song Hui, Chen Qun施工负责人 Construction principals 许德利、李晓东、方瑞青 Xu Deli, Li Xiaodong, Fang Ruiqing 技术员 Technicians 宋吉东、石青松 Song Jidong, Shi Qingsong施工员Constructors 乔德修、姚元广、胡燕青、杨志猛、张立平Qiao Dexiu, Yao Yuanguang, Hu Yanqing, Yang Zhimeng, Zhang Liping 质检员 Inspectors 高见、王福全 Gao Jian, Wang Fuquan 测量员 Surveyors 张胜利、郑小峰、潘江涛 Zhang Shengli, Zheng Xiaofeng, Pan Jiangtao HSE员 HSE personnel 李新军 Li Xinjun 4.参考文件 References 4.1相关设计图纸 Relative design drawings ；4.1.1汽轮发电机顶板平面布置图（44-8320-8130-0101，REV.00）Steam turbine generator apical plate plane arrangement plan 4.1.2 汽轮发电机基础11剖面图（44-8320-8130-0102，REV.00）Steam turbine generator foundation drawing of section 114.1.3汽轮发电机基础22、33剖面图（44-8320-8130-0103，REV.00）Steam turbine generator foundation drawing of section 22、33 4.1.4汽轮发电机基础44、55剖面图（44-8320-8130-0104，REV.00）Steam turbine generator foundation drawing of section 44、55 4.1.5汽轮发电机基础顶板配筋图（44-8320-8130-0105，REV.00）Steam turbine generator foundation apical plate bar arrangement drawing 4.1.6汽轮发电机基础ZL-2纵梁配筋图Steam turbine foundation longeron bar arrangement drawing ZL-2 4.1.7汽轮发电机基础框架-1,2和3图（44-8320-8130-0108，REV.00）Steam turbine generator foundation frame drawing- 1,2,34.1.8汽轮发电机基础ZL-1纵梁配筋图（44-8320-8130-0109，REV.00）Steam turbine generator foundation longeron bar arrangement drawing ZL-1 4.2与施工图纸相关的设计变更文件；The design change document is correlative to the construction drawing ;4.3混凝土结构规范（SP-8320-8100-0002）Concrete structural specification （SP-8320-8100-0002）4.4 HSE扎脚手架（PR-8560-0000-1403）HSE binding scaffolding （PR-8560-0000-1403）4.5 GB50202-20024.6 GB50204-20024.7 JGJ130-20015.计量器具、工具及机械 Measuring instrument, tools and machinery 计量器具：全站仪、水准仪、钢卷尺、电子测温仪Measuring instrument: Whole station, water level, ribbon, electron thermometric instrument 工具：锤头、安全带、专用扳手 Tools: Hammerhead, safety belt, special spanner 机械：塔吊一台、汽车吊一台、混凝土泵车两台、搅拌车三台、砼振动器8台、7.5米振动棒6根、钢筋切断机2台、弯钢机3台、拉丝机1台（所有机械进厂前应进行认真检查，并报有关部门审查通过后方能进入现场施工）。Machinery: 1 tower crane, 1 car crane, 2 concrete pump vehicles, 3 agitator trucks, 8 concrete vibrators, 6 pieces of vibrating rod (7.5m), 2 rebar cutters, 3 steel benders, 1 wire draw bench (All machinery should be inspected carefully and reported to relative department for review before mobilizing into site ).6.劳动力组织 Labor force 技术员1人，施工员3人，测量员2名、质检员1名，HSE员1名，壮工20名，熟练操作工3名，驾驶员5人，电工2人，焊工2人，木工20人，钢筋工37人，瓦工（砼工）15人 ，架工15人1 technician, 3 constructors, 2 surveyors, 1 inspector, 1 HSE personnel, 20 laborers, 3 skillful operators, 5 drivers, 2 electricians, 2 welders, 20 woodworkers, 37 rebar benders, 15 concrete workers, 15 scaffolding men 7.施工工序和施工方法 Construction procedure and plans 7.1施工工序 Construction procedure 施工工序为： 测量放线 框架柱脚手架搭设框架柱钢筋绑扎（预埋件施工）框架柱钢筋、预埋件验收框架柱模板安装框架柱砼浇筑框架柱模板拆除框架柱脚手架拆除顶板（18米标高处）承力脚手架搭设，外侧防护脚手架搭设底模安装螺栓套管预埋顶板钢筋绑扎各类埋件预埋侧模安装质量验收 砼浇灌、养护混凝土强度达到100%后模板拆除按上述施工顺序施工12米标高处平台The construction procedure is: Measuring and marking putting up the skeleton pole scaffolding Binding skeleton pole rebar (embedded pieces construction ) Frame pole rebar , embedded pieces acceptance Frame pole template installation Frame pole concrete pouring Frame pole template removal Frame pole scaffolding removal put up the force bearing scaffolding (at 18m of the elevation) and outside protection scaffolding Bottom template installation embedding the bolt spool binding apical plate rebar embedding various embedded pieces side template installation quality acceptance concrete pouring , curing removing template till the concrete strength reaches up to 100% platform construction at the 12m of elevation according to aforementioned construction sequence 7.2施工方法 Construction plans 7.2.1测量放线 Measuring and marking 按施工图纸将柱位和汽机中心线在底板上表面进行标示，同时按施工方案将支模用脚手架各立杆准确定位，并用红油漆做出标记，以便于脚手架搭设；待顶板模板安装完毕后在模板表面将预埋件位置进行标示（由预埋件施工班组进行）。Mark the pole position and steam turbine central line on the surface of the bottom plate according to drawing, in the meanwhile, locate the template well and truly through each vertical pole of scaffolding according to the construction plans, then mark it with red painting in order to be convenient for putting up scaffolding; Mark the position of embedded pieces on the surface of template till the template installation of apical plate has completed (It is done by construction teams and groups for embedded pieces). 7.2.2模板支撑承力脚手架搭设 Put up the force bearing scaffolding of the template support 支撑架用484BS标准架杆搭设，立杆间距800mm，局部标高18.890米及18.780米区域板下立杆间距600mm。（详见高支撑计算7.2.10条）。禁止使用有明显变形、裂纹和严重锈蚀的钢管。Put up the bearing frame with the standard pole for 484BS, that vertical space is 800mm, The space between vertical poles under the regional plate whose partial elevation is 18.890m and 18.780m is 600mm. (See detailed section 7.2.10 for high-support calculation). Strictly prohibit using the steel tube which is distorted, cracked and rust. 脚手板选用厚50 mm宽225mm包铁箍木板，脚手板上不得有直径超过50mm的结节，且边结的直径不得超过脚手板宽度的一半。不得使用翘曲及开裂的脚手板，不得带有槽口、烧迹、油污或突出的钉子。不得使用烂板或过度损坏的脚手板。脚手板存放时高度不得超过20张。The hoop iron board in 50mm length, 225mm width applies to the scaffolding on which the diameter of nodule cant be over 50mm. And the diameter of side-knot cant be over half of the scaffolding width. No allowed to use rotten or overly damaged scaffold. The height of scaffold cant be over 20 pieces when storing. 连接件采用与48架杆配套的BS标准系统连接件。连接件 妥善存放，保持清洁。 The connecting piece is compliance with the BS standard system and matches with the48 scaffolding pipe . Keep the connecting piece properly and cleanly. 板下纵横立柱通过九道水平连杆连成一体，第一道为扫地杆，第二道水平连杆设于汽机基础底板面上1800mm处，以上七道每间隔1000mm设置一道，局部高度可稍作调整，以满足板模支设为准；The crossbar vertical pole under the scaffold makes one through nine rows of horizontal link rod , the first row is ground pole , the second horizontal link rod is set 1800mm above the foundation bottom plate of steam turbine , set a row at intervals of 1000mm for other seven rows of link rod, Adjust the partial height in order to meet the template installation;搭设前必须对进场的钢管、底座、连接件、脚手板等配件进行严格的检查，禁止使用规格和质量不合格的钢管及配件。The fittings such as steel tube, backseat, connecting piece, scaffolding must be inspected strictly prior to put them up, prohibit using the unqualified steel tube and fittings. 架体搭设施工工序：摆放扫地杆逐根竖立立杆随即与扫地杆扣紧装扫地小横杆并与立杆或扫地杆扣紧安第一步大小横杆（与各立杆扣紧）第二步大小横杆第三步大小横杆连接立杆加设剪刀撑Construction procedure of putting up scaffolding: Put the ground pole set up the vertical pole piece by piece and piece and fastening with the ground pole meanwhile installing small ground cross bar and fastening with vertical pole or ground pole installing the first step of big and small cross rod (fastening with each vertical pole) the second step of big and small cross rod the third step big and small cross rodconnecting vertical pole and set the bridging 脚手板铺设时注意铺平铺稳，且并排不得少于三块脚手板，脚手板两端用8号退火铁丝与脚手架管绑牢。脚手板采用对接平铺，在对接处，与其下两侧支承横杆的距离应控制在100200mm之间。铺板严禁出现端头超过支承横杆250mm以上未作固定的探头板。每层脚手板皆设置踢脚板，高度150mm，并与脚手架钢管绑扎固定。Lay the scaffolding level and steady and there are at least three pieces of scaffolding board side by side, bind two ends of scaffold firmly with No.8 annealed wire and scaffolding pipe. Tile the scaffolding in a butt joint way, the distance between the joint and the bearing rail at the both sides of the joint should be controlled within 100200mm. The end of plank cant exceed the bearing rail by over 250mm. Lay the mopboard for each bed of scaffolding and the height of the mopboard is 150mm. In addition, fix them on the steel tube of scaffolding through binding. 支撑体系搭设前须清理完地面杂物，保障立杆、扫地杆的位置准确；斜杆与地面成45度60度角；扣件夹紧钢管时开口处的最小距离不应小于5cm。To clean out the ground sundries before putting up the support system, ensuring the exact position of vertical pole and ground pole; The branch bar strut makes an angle of 45 degrees 60 degrees with ground; The minimum distance of opening should be not less than 5cm when the fastening device is clamping the steel tube.脚手架立杆垂直度偏差应不大于1/300，且最大垂直偏差应不大于50mm。水平杆的水平偏差应不大于1/250，且全架长的水平偏差不大于50mm。The verticality deviation of scaffold vertical pole should not be more than 1/300，and the maximum verticality deviation should not be more than 50mm. The horizontal deviation of level bar should not be more than 1/250，furthermore, the level deviation of the whole scaffolding shouldnt be more than 50mm。构造措施 Structural measures ：为提高支撑系统的整体稳定性和抗倾覆能力，在支撑立柱间须用水平连杆将其连为一体，搭设时注意水平杆接头应错开，尤其注意立柱在纵横方向都要加设剪刀撑。剪力撑沿竖直方向连续布置，四边与中间每隔四排支架支架立杆应设置一道纵向剪力撑，两端与中间每隔四排支架立杆从顶向下每隔2步设一道水平剪刀撑，每道剪刀撑宽度不小于4跨，且不小于6m。剪刀撑搭接长度应0.8m，搭接部分的结扎不少于2道，且结扎点间距应0.6 m。杆件在结扎处的端头伸出长度不小于0.1 m。Make it one through the horizontal link rod between the support vertical post and the joint of horizontal pipes shall be staggered in order to improve the integral stability and anti-overturning ability, especially to pay attention to set the bridging in the crossbar direction of vertical pole, which arranged continually in the vertical direction.基础顶板立柱单根钢顶撑承受荷载较大，为避免应力集中对支承层结构砼产生冲切破坏，须在立柱下面铺架板。In view of the bearing load of single steel shore strut for vertical post of foundation apical plate is quite big, lay the scaffolding board under the vertical post in order that the stress cant punch the structural concrete of support layer. 基础顶板下承力架倒数第二道水平连杆与钢管立柱间用双扣件贴紧锁牢。Keep it closely and lock it up firmly through double fastening device between the reciprocal second row of level link rod of force bearing support under the foundation apical plate and vertical post of steel tube.在基础顶板支撑体系搭设完后，须对支撑体系进行专项检查，合格后才可转入下一工序的施工。浇筑基础顶板的砼时，安排专人观察模板及其支撑系统的变形情况，发现异常及时加固处理，以免发生质量和安全事故。Do the special inspection of support system after putting up the support system of foundation apical plate, then turn to the next working procedure if it passes the examination. Send special person to observe the distortion condition of template and its support system when pouring the concrete of foundation apical plate. To reinforce in time if there are something abnormal happened to prevent from the quality and safety accident.注意事项 Attentive items ：所有搭拆脚手架的工人均须经过培训取证才能上岗，非专业架工严禁施工。All scaffold men should be trained and get relative certificates before they are on duty, Strictly prohibit the non-special scaffolding men doing construction. 架工必须在至少三块脚手板组成的平台上操作。除非装有永久可靠的防坠设备，架工不得登上钢管进行操作，架工专用扳手须有安全绳，防止坠落。The operation platform must be made up of at least three pieces of scaffold board except that there are permanent and reliable falling protection equipments on the operation platform. The scaffold man cant mount the steel tube to operate. The special spanner used by scaffolding man should have the safe rope in order to prevent it from falling. 在作业中，严禁随意拆除脚手架的基本构架杆件、整体性杆件、连接件。如确因操作需要临时拆除时，必须经主管人员同意，并采用相应措施，且在作业完毕后，及时予以恢复，非专业架工禁止私拆及改动架体。Dont disassemble the basic truss member of framework, comprehensiveness member of framework, connecting piece of scaffolding without permission during working. Dont assemble them without permission unless get the approval from the governor. In the meanwhile, take relative measures to remove them. In addition, recover in time after the work complete. Strictly prohibit the non-special scaffolding man from disassembling and changing scaffolding body. 架工操作处高于1.8米时就必须设置“上空施工”的警示牌，并于作业完毕时将其摘除，必要时须设置专门警戒区域。Hang the warning card saying “ Construction high above” at the place of 1.8m away from the ground where the scaffolding man operates, and pick it off after completing the work. Set the special warning area if necessary.在施工作业中，工人必须正确佩戴PPE，有坠落危险处，高度超过1.8米时，须佩戴全身束双挂式安全带，且安全带的固定点要牢靠，并做到高挂低用。注意自我安全保护及他人的安全，避免发生碰撞、闪失和落物。严禁在架上嬉闹和坐在栏杆上等不安全处休息。Workers should wear the PPE properly in construction. In addition, fasten the full-body and double-hook safe belt and, the fixed point of safe belt must be reliable when the height is over 1.8m away form the ground. Hang the safety belt up higher and using it lower. Pay attention to self-protection and other elses safety in order to protect from being hit, accident and falling object. Strictly prohibit from resting in unsafe place.脚手架所用的管材和板材须水平放置，保持洁净，不得将其竖靠在脚手架上。Place the pipe and plate used for scaffold in level place and keep them clean. Dont lean them upright against the scaffold. 脚手架在未完工状态时须在脚手架底层加设标签予以警示：“脚手架不合格，禁止使用”标示牌。并在入口处放置“危险，请勿走近”标签。Add a label at the bottom of scaffold giving the warning: “ Unqualified scaffold, dont use it” if the scaffold has not been completed. And lay the label at the entrance saying “ Dangerous, Please keep it off ”. 除非经HSE人员检验合格，脚手架须以红色标签标示“脚手架不合格，禁止使用”，经认证人员检验合格后负责将标牌更色为黄或绿色标示牌。Mark the scaffold with red label for “ Unqualified scaffold not allowed to use” unless the HSE personnel inspects them and approve. Chang it into the yellow or green nameplate after the inspectors checking it and approve. 脚手架竣工后，不得将零散管材、构件、架板或工具遗留在架上。Dont leave the scattered pipe, component, scaffold board or tools on the scaffold after the scaffolding construction complete.每班工人上架作业时，须先行检查有无影响安全作业的问题存在，在排除和解决后方可开始作业。在作业中发现有不安全的情况和迹象时，须立即停止作业进行检查，解决后才能恢复正常作业；发现有异常和危险情况时，须立即通知所有架上人员迅速撤离。Firstly examine whether there are any problem impacting safety work or not prior to start working. Stop to examine if there are unsafe situations and evidence and, then recover the normal work by resolving it; Inform of all personnel on the scaffold immediately and move away if something abnormal and dangerous happens. 在任何情况下，严禁自架上向下抛掷材料物品和倾倒垃圾。In any case, dont chuck the material and pour down rubbish from the scaffolding to the ground.脚手架须经常检查，尤其在大风、暴风雨等天气过后。Check the scaffolding regularly, especially after heavy wind or rainstorm and so on. 脚手架的拆除须按自上而下的程序进行，先拆脚手板，再拆小横杆，然后拆大横杆，最后拆立柱及剪刀撑。在拆除过程中，凡已松开连接的杆配件须及时拆除运走，避免误扶和误靠已松脱连接的杆件。拆下的杆配件以安全的方式运出和吊下，严禁向下抛掷。在拆除过程中，作好配合、协调作业，禁止单人进行拆除较重的杆件等危险性的作业。To disassemble scaffold from above to below, the scaffold board is the first, then the small cross bar, and then the big cross bar, the vertical post and bridging are removed at last. Disassemble and carry away the unstuck and connected bar fittings in order to avoid holding and leaning against the unstuck and connected member of framework by mistake. Ship out and suspend down the disassembled bar fittings in a safely way and dont throw it down. Strictly prohibit disassembling the heavier member of framework and such these hazardous work solely in the course of disassembling. 7.2.3框架柱操作平台脚手架搭设 Putting up the scaffold of the skeleton post operation platform 框架柱操作平台脚手架搭设平面布置图见（附图2）。 The arrangement drawing of putting up the skeleton post operation platform ( See attached diagram 2).该部分脚手架采用BS标准架管进行搭设，高度为12米，分为三个独立部分，每个部分可施工二根框架柱，搭设、拆除步骤和注意事项与模板支撑承力脚手架相同，搭设要求按JGJ130-2001和PR-8560-0000-1403程序的要求进行，由于该脚手架顶部高度未超过15米，属常规交脚手架搭设，在满足双排脚手架构造要求的情况下，不需进行受力计算。The partial scaffolding whose height is 12m adopts the BS standard scaffolding pipe to put up. It is divided into three parts independently, and there are two pieces of skeleton post for each part. The building and removing step and the noticing proceedings are the same as the step of force bearing scaffold of template support. The building requirement should accord to the procedure JGJ130-2001 and PR-8560-0000-1403.The top height of scaffolding is no over 15m, a standard scaffolding, it is no need to calculate the stress if it meets the structural requirement of double-row scaffold.7.2.4顶板外侧防护脚手架搭设 Build the protecting scaffold outside of the apical plate顶板外侧防护脚手架搭设布置图见（附图1、2）。The arrangement drawing of building the protecting scaffold outside of the apical plate (see attached diagram 1, 2 ).该部分脚手架采用BS标准架管进行搭设，高度为14米。顶板外侧双排防护脚手架排距1.2m，跨距1.4m，步距1.8m。The partial scaffold adopts the BS standard pipe to build and the height is 14m. For the double-row guarding scaffolding outside of the top slab, its row space is 1.2m, span is 1.4m, and step