钢结构加工制作及安装方案.doc

陕西瑞森建设工程有限公司 嘉民西安电子商务产业园 地面施工专项方案 室外道路、仓库地坪 施工方案 陕西瑞森建设工程有限公司 2016年元月21日 钢结构加工制作及安装方案1. Production and Installation of Steel Structure1.钢结构制作与安装1.1 Personnel Plan1.1人员计划According to the characteristics of this project and the specific requirements of the construction, the initial on-site personnel plan is as follows:根据本工程特点及施工的具体要求， 初定现场人员计划如下：Type of work工种Number of people (people)人数（人）Type of work工种Number of people (people)人数（人）lifting worker起重工4workers for electrical repair电修工 2installers安装工20scaffolders架子工8welders焊工12general workers普工8workers for measurement测量工2painters油漆工10Managers管理人员6Total合计721.2 Main Tools and Equipment Plan1.2主要工具、机具计划According to the conditions and characteristics of this steel structure work, drawn up main tools and equipment as below table:根据本钢结构工程的情况及特点，拟定主要工具、机具如下表：No.序号Name名 称Types and Specifications型号规格Quantity数量Remarks备注1Truck Crane汽车吊16T1 set2Flatbed truck平板车10t1 set3Level水准仪S32 sets4Theodolite经纬仪J23 sets5H-beam assembly machineH型钢组立机Z12B1 set6Door-type SAW machine门型SAW机DC1500 AC1200 Door-type trolley gauge门型台车轨距：45000mm2 sets7Bilateral driven flame cutter双边驱动火焰切割机CG600B1 set8CNC drilling machineCNC钻孔机DMD06/201 set9H-beam straightening machineH型钢矫正机HYJ-800-G1 set10Hydraulic shearing machine油压剪床1 setMax=16mm11Radial drilling machine施臂钻床2 sets12Slotting machine开槽机ASLW35-TW1 set13Biaxial drilling machine双轴钻孔机DNK9001 set14Sawing machine锯床ST-60901 set15NC horizontal drilling machineNC水平钻孔机KAWASAKI TYPE：D-22 sets16CO2 welderCO2焊机20 sets17DC welder直流焊机15 sets18Angle grinder角向磨光机100mm4 sets19Stud machine栓钉机2 sets20Stacker堆高机8 sets2115t crane15吨天车2 sets2210t crane10吨天车6 sets23Straightly conveyed washing machine直通输送式喷洗机1 set1.3 Structural Welding and Stud Welding1.3结构焊接及栓钉焊接13.1 Steel Structure Welding1.3.1钢结构焊接1. Welding Procedure Qualification1、焊接工艺评定Determine reasonable welding parameters through welding procedure qualification, and make the steel and joint form used in qualification matching with it the actual welding.通过焊接工艺评定,确定合理的焊接工艺参数,制定焊接工艺规程评定所使用钢材、接头形式与实际焊接相符。Welding procedure qualification report is signed off by a competent welding engineer, and takes effect with the approval of the Chief Engineer. Welders must be certificated, and he must be re-tested if out of the position for more than 3 months. Welders must strictly enforce the welding process in the qualification, no modification of welding parameters. Every time a seam is welded, clean up tumors such as slag, spatter, and weld defects, trim the seam to delay the transition with base material.焊接工艺评定报告由主管焊接工程师签认，总工程师批准后生效。焊工持合格证上岗，脱离岗位3个月以上，应重新考核。焊工必须严格执行焊接工艺的评定，不得修改焊接工艺参数。每焊完一道焊缝，必须清除熔渣、飞溅、焊瘤等缺陷，修整焊缝与母材保持延缓过渡。2. Welding Requirements2、焊接要求Basic type and size of the welding groove should be selected according to the requirements of current Basic Forms and Sizes of Weld Grooves for Gas Welding, Manual Welding and Gas-shielded Welding(GB985-88) and Basic Forms and Sizes of Weld Grooves(GB986-88) based on the plate thickness and construction conditions.焊接焊缝坡口的基本型式与尺寸应根据板厚和施工条件按现行气焊、手工电弧焊及气体保护焊焊缝坡口的基本型式与尺寸（GB985-88）和埋弧焊焊缝坡口的基本型式与尺寸（GB986-88）的要求选用。Flange connections, bearing stiffeners, and sandwich beams welding adopt the both sides welding; butt weld of component boards adopts the root element method to make a full penetration. Weld grade is in the secondary level, and weld inspection is implemented according to national standards of Method for Manual Ultrasonic Testing and Classification of Testing Results for Ferritic Steel Wdlds. In the butt weld of rigid-frame beam, welding position between flanges and webs should be staggered over 200mm.梁柱端板的法兰式连接、支承加劲肋、夹层梁焊接采用双面焊缝，构件板材的对接焊缝采用碳棒清根方法使之焊透，焊缝等级为二级标准焊缝探伤按国家标准钢焊缝手工超声波探伤方法和探伤结果分级的标准执行；刚架梁对接焊缝时，翼缘与腹板对接焊缝位置应错开200mm以上。3. Welding Materials3、焊接材料Welding between Q235-B steel adopts E43XX welding rod, and welding between Q345 steel adopts E55XX welding rod; SMAW should be consistent with national standards of carbon steel (GB5117-95, GB5118-95), and automatic or semi-automatic SAW should comply with the provisions of Steel Wires for Welding (GB1300-77); Q345 adopts H10Mn with high manganese bound flux; Q235 steel adopts H08A with medium manganese oxide flux or manganese flux.Q235-B钢材间的焊接采用E43XX型焊条，Q345钢材间的焊接采用E55XX型焊条；手工电弧焊应采用符合国家标准碳钢焊条（GB5117-95、GB5118-95），自动或半自动埋弧焊的焊丝应符合焊接用钢丝（GB1300-77）的规定；对于Q345，采用H10Mn配合高锰型焊剂，对于Q235钢，采用H08A，配合中锰型或锰型焊剂。4. Welding4、施焊(1) The welding of main seam and long seam adopts manual welding and CO2 shielded welding; the welding of secondary seam and short seam adopts manual welding.（1）主要焊缝和长焊缝采用手工焊和CO2气体保护焊焊接，次要焊缝和短焊缝采用手工焊。(2) Weld seams within 24 hours after main components are assembled.（2）主要零部件焊缝组装后24小时内焊接。(3) Take effective measures when any of the following circumstances occurs in the welding environment, otherwise the welding is prohibited.（3）当焊接环境出现下列任一情况，须采取有效措施，否则禁止焊接。 wind speed over 4m/s. relative humidity over 85%. welding area of base metal wet. indoor temperature below 50C.风速大于4m/s。相对湿度大于85%。母材焊接区域湿润时。室内温度低于50C。(4) Striking in non-weld of base metal is strictly banned in the welding.（4）施焊时严禁在非焊缝母材处引弧。(5) Check seam locations for cracks. If any, remove it before the tack welding.（5）施焊前应检查定位焊缝是否有裂纹，如有裂纹应铲除重新定位焊。(6) After the completion of each layer welding, welders should clean up defects such as slag, splash, melting tumors, and entrapped slag.（6）焊工在每焊完一层后均应清除熔渣、飞溅、熔瘤、夹渣等缺陷。5. Welding Sequence5、焊接顺序Main seam before secondary seam; central seam before surrounding seam; short seam before long seam.先主要焊缝，后次要焊缝；先中间焊缝后周边焊缝；先短焊缝后长焊缝。6. Welding Inspection6、焊接检验(1) Visual inspection: All weld seams should take visual inspection to ensure that there is no defect like crack, non-fused slag, and unfilled crater.（1）外观检验，所有焊缝必须进行外观检查，不得有裂纹，未熔合夹渣、未填满弧坑等缺陷。(2) The detection of butt joints welding should be implemented according to the requirements of construction drawings and the regulations of Code for Acceptance of Construction Quality of Steel Structures (GB50205-2001), and non-destructive testing should be conducted in 24 hours after welding.（2）对接接头焊缝的检测按施工图的要求及钢结构工程施工及验收规范（GB50205-2001）的规定执行，无损检测在焊接后24小时进行。1.3.2 Key Points of Steel Component Welding1.3.2钢构件焊接要点The steel component welding should be conducted by two synchronous welders in a symmetrical, constant way; to reduce the amount of hydrogen diffused from seams and to prevent the cold cracks and HAZ delayed cracks, pave super low hydrogen electrodes for 24 bottom layers on the tip of the groove, and then low hydrogen electrodes. The welding adpots CO2 shielded welding and multi-lateral welding; weld 34 channels in each direction, and keep observing the verticality when change the direction. Stop welding immediately once found the steel component is deviating from a certain direction, weld some layers in the opposite direction, and restart synchronous, symmetrical welding after correcting the direction. Preheat the steel plates around the weld seams to 100150C before welding. Take measures to prevent wind and rain when make construction in rainy season.钢构件焊接时，由2名焊工对称同步等速焊接，为减少焊缝中扩散氢气量，防止冷裂纹和热影响区延迟裂纹的产生，应在坡口尖端部，用超低氢型焊条打底24层，然后再用低氢型焊条施焊。焊接采用CO2气体保护焊，方法为多道横向焊，每个方向焊接34道后，换一个方向焊接，并随时观测垂直度有无变化。如发现钢构件向某个方向发生偏差时，立即停止该方向的焊接，再在相反方向多焊几层，待纠偏调直后，再开始同步对称焊接。焊接前，必须首先对焊缝周围钢板预热至1001500C。雨季施工时，应采用挡风防雨措施。Heat treatment after welding can eliminate the residual stress and overflow the residual hydrogen. Specific practices: uniformly heat the area within 23 times the thickness of board in weld area, to 150200C with a gas welding torch within 30min; after preheating the weld seam, take measures to cool down the temperature of weld area slowly to room temperature.焊接后的热处理可以消除残余应力，同时还可以溢出残留氢。具体做法是在焊接区板厚的23倍范围内，用气焊枪均匀加热到1502000C，时间控制在30min以内，焊缝预热后，应采取措施使焊接区缓慢冷却到室温。Test the weld quality by ultrasonic flaw detector. Only qualified weld seam can carry out the next procedure; clear and repair the unqualified weld seam. Eliminate the weld defects with carbon arc air gouging before re-welding. One weld seam cannot be repaired more than twice, or the base metal has to be replaced.使用超声波探伤仪检焊缝质量，经检查合格的焊缝。可以进行下道工序；对不合格的焊缝应清除修补。修补用碳弧气刨将焊缝缺陷除掉，然后再重新施焊。一条焊缝修补不得超过两次，否则要更换母材。1.3.3 Welding Technology and Quality Assurance Measures1.3.3焊接技术及质量保证措施1. Welding Procedure Qualification1、焊接工艺评定Make welding procedure qualification or welding procedure qualification transformation according to national norms and standards.根据国家有关规范和标准进行焊接工艺评定或焊接工艺评定转化工作。2. Preparations before Welding2、焊前准备工作Check the accuracy of joints and groove assembly before welding, and the close degree of backing strap; repair unqualified joints and groove.焊前检查接头及坡口装配加工精度，背面衬垫紧贴度，对不合格要求的接头及坡口应进行修补处理。Remove the rust, iron oxide, oil and water from joints and groove before welding.焊前除去接头及坡口两侧铁锈、氧化铁、油污及水分等。Outdoor welding should take measures to prevent wind and rain; carbon dioxide shielded welding should be equipped with reliable windshield devices.外场焊接应有防风、雨措施，二氧化碳气体保护焊应有可靠挡风装置。3. Tack Welding3、定位焊Tack welding, generally 25mm long, adopts the electrode same with formal welding. Do not weld on seam intersections; no defects like cracks and blowholes.定位焊采用与正式焊接相同的焊条，定位焊一般长是25mm，定位焊不要在焊缝交叉处，定位焊不应有裂纹、气孔等缺陷。4. Run-on Plate and Blowout Plate4、引弧板及熄弧板Run-on plate and blowout plate should be set at both ends of all butt and fillet welds. The groove type and material of run-on plate and blowout plate are the same. Adopt gas cutting to cut off plates after welding, not break them with hammer.所有对接及角接焊缝的两端应设置引弧板及熄弧板，引熄弧板的坡口型式，材质均与工作相同，施焊后采用气割割除，不得用捶击断。5. Welding Procedures5、焊接程序Component welding adopts symmetrical welding method, carried out by welders of even number in regions at the same time.构件焊接采用对称焊接法,施焊时由双数焊工同时进行。Long seam uses the end-middle welding method and end-middle back welding method, or it can be welded by several welders simultaneously in partitions.长焊缝采用由中间向两端的分中焊接法及分中步退焊法，也可由数名焊工分区同时进行。6. Welding Quality Inspection6、焊接质量检验(1) Welding Appearance Quality Inspection（1）焊接外观质量检验Ripples of the seam should be uniform, without any defects such as crack, faulty fusion, crater, slag, overlap, blowhole, and undercut.焊缝的焊波均匀不得有裂纹、未熔合、弧坑、夹渣、焊瘤、气孔及咬边等缺陷。(2) Seam Internal Quality Inspection（2）焊缝内部质量检验Confirm the weld quality grade according to the drawings and related specifications, and make ultrasonic flaw detection on seams over grade 2 according to required proportion.根据图纸及有关规范确认焊缝质量等级，对于二级以上的焊缝按规范要求的比例进行超声波探伤。 (3) Quality Objectives of Welding Construction（3）焊接施工的质量目标One-time pass rate of self-test flaw detection is 100%; one-time pass rate of supervision and owner inspection is 100%.自检探伤一次合格率为100%，监理、业主检查一次合格率为100%。1.4 Steel Structure Painting, Rust and Fire Protection1.4钢结构油漆、防锈和防火1.4.1 Requirements on Steel Structure Painting, Rust and Fire Protection1.4.1钢结构油漆、防锈和防火要求Surface of all steel components should adopt the sand blasting method to clear dirt, grease, and burrs throughtly, and remove the rust by reaching Sa2.5 level of sand blasting. Steel menbers surface should be sprayed with fire-retardant coating. It needs to meet professional requirements of construction after the treatment, and to reach specified fire endurance - second grade of fire resistance rating.所有钢构件表面应采取喷砂方法，彻底清除脏物、油污、毛刺，严格除锈，喷砂应达Sa2.5级。钢构件表面需喷防火涂料处理，要求处理后满足建筑专业的要求，达到规定的耐火极限耐火等级二级。 1.4.2 Painting Methods and Devices1.4.2涂装方式及设备1. Airless spray: Recommended. Need an airless spray device of high flow and high pressure; the width of nozzle is 0.790.97mm (3138thou).1、无气喷涂：推荐使用，需要大流量、高压力比的无气喷涂设备，喷嘴宽幅0.790.97mm(3138thou)。2. Brushing/ rolling: Acceptable.2、刷涂/滚涂:可接受使用。3. Sand blasting should reach Sa2.5 level, and be conducted in closed workshop with constant temperature and humidity.3、喷砂应达Sa2.5级，恒温恒湿封闭车间进行。1.4.3 Painting Environmental Conditions1.4.3涂装环境条件1. Painting Principles1、涂装原则Painting construction must be carried out in accordance with the painting specification or the guidance of technical engineers.涂装施工必须按照油漆说明书要求或技术工程师的指导进行。2. Environmental Conditions2、环境条件Make sure the following conditions during the whole process of painting:在涂装的全过程中，应确保以下环境条件：(1) Keep steel surface clean and dry; maximum relative humidity is not over 85%;(2) Minimum temperature of steel surface is not less than 50C;(3) Steel surface temperature should be at least above the dew point temperature;(4) Avoid strong winds and direct sunlight for 23 days after spraying.（1）钢材表面清洁、干燥，最大相对湿度不超过85%；（2）钢板表面最低温度不低于50C；（3）钢板表面温度应至少高于露点温度；（4）在喷涂后23天内应避免强风和阳光直射。1.4.4 Component Surface Treatment before Painting1.4.4涂装前构件表面处理Make sandblasting rust removal on steel surface after eliminating sharp edges, ragged scraps, welding slag and greasy dirt.钢材表面清除尖锐棱角、刺屑、焊渣及油污后进行喷砂除锈。1.4.5 Painting1.4.5涂装1. Painting Process Parameters1、涂装工艺参数(1) Air pressure 0.40.6MPa(2) Nozzle selection 0.1730 or 0.2020 (depending on paint)(3) Gun distance 300500mm gun(4) Operating speed 1m/s（1）空气压力 0.40.6MPa（2）喷嘴选择 0.1730或0.2020(视不同涂料定)（3）喷枪距离 300500mm（4）运行速度 1m/s2. Painting Inspection2、涂装检验(1) Coating visual inspection（1）涂层外观检验Paint coatings are not allowed with peeling, lifting, miss painting, and lamination defects. Painting should be uniform, smooth, plump, and shiny.涂料涂层不允许有剥落、咬底、漏涂、分层缺陷。涂层均匀、平整、丰满、有光泽。(2) Coating Thickness Measurement（2）涂层厚度测量Coating thickness is measured by electronic pachymeter.涂层厚度测量采用电子测厚仪测量其厚度。(3) Coating Repair（3）涂层修补Remove rust by pneumatic grinders, and then repair painting according to its location; for small area, paint by hand to ensure the coating thickness.涂层修补可采用风动打磨机除锈，然后根据其所处的位置的涂层配套补上各度油漆，对面积较小可用手涂，并保证该处涂层厚度。(4) Coating Protection（4）涂层保护In the sections completed painting, it is not allowed to directly use rope for tying in the lifting transportation. No collision, no coating scratch. Components should be stacked highly to prevent from water. Minimize the operation of electric welder. Lifting transportation should be carried out after components painting.对已涂装完毕的节段在起吊运输时不允许直接用钢丝绳捆扎，避免涂层损伤。严禁碰撞擦伤涂层。构件堆放要垫高，避免接触水。尽量减少电焊机火工作业。吊运应在构件涂层实干后进行。1.5 Steel Structure Installation1.5钢结构安装1.5.1 Steel Structure Lifting1.5.1钢结构吊装1. Overall Concept of Lifting1、总体吊装构想In order to achieve objectives of progress, quality, safety and economic, it is supposed to organize a consecutive construction, according to the characteristics of this steel structure work.根据本钢结构工程的特点，为实现进度、质量、安全及经济目标，拟组织依次施工。This steel structure is composed of three installation areas: warehouse W-1 (A D/110), warehouse W-1 (AW/121), and warehouse W-1 (AE/120).本工程钢结构部分分W-1仓库（AD/110）、W-1仓库（AW/121）、W-1仓库（AE/120）三个安装区。 Regions are independent from each other, and they are respectively constructed according to logical sequence. Install support, roof beams, tie beams, purlins, and corner brace between columns after adjustment, and make successive installation along the extension of axis after forming a stable structure.各个区域相互独立，先后逻辑顺序，施工时分别分区域进行。调整后安装柱间支撑、屋面梁、系梁、檩条、隅撑、形成稳定结构后方可延轴线逐次安装。(1) Regions are independent from each other, and they are respectively constructed according to logical sequence. According to the actual situation of engineering structures, first install the steel columns, and then life beams. After placing the structure, install support and other associated components timely to ensure the stability of structure.（1）各个区域相互独立，先后逻辑顺序，施工时分别分区域进行。根据工程结构实际情况，首先，安装钢柱，钢柱安装完成之后，即可进行吊装梁。结构就位完毕后应及时安装支撑和其他连系构件，保证结构的稳定性.(2) Overall installation sequence: columns liftingsupport installation between columnsinstallation of rigid support between columnssteel girders liftinginstallation of rigid support between steel girdersinstallation of horizontal support（2）总体安装顺序：柱子吊装柱间支撑安装柱间刚性支撑安装钢梁吊装钢梁之间的刚性支撑安装安装水平支撑2. Steel Columns Lifting2、钢柱的吊装(1) Embedded Anchor Recheck（1）预埋锚栓复检Steel columns in this project are connected on the original concrete pillars, so recheck the foundation of embedded parts first. Use parallels to make verticality adjustment and elevation, set one theodolite on vertical and horizontal axis to control the vertical degree, and use water level to check the axis position and elevation before steel column lifting. Lift steel columns in place by 16t car, and then set four ropes in four directions to ensure the stability.本工程由于是在原混凝土柱子上连接钢柱所以应先对安装的预埋件底座进行复检，复检时用垫铁调整柱垂直度、标高，在纵横控制轴线上各布设1台经纬仪控制垂直度，用水准仪控制标检查好轴线位置、标高等后方可进行钢柱吊装。钢柱在现场用16t汽车吊吊装就位。钢柱吊装到位后，四个方向拉设四根缆风绳来保证稳定。3. Steel Beams Lifting3、钢梁吊装A single piece of steel beam is light, so lifting can be done by car in conventional methods. Roof beam lifting is conducted from one end of the plant to the other end, and the support system between roof beams should be installed during the process.钢梁单件重量均较小，因此，利用汽车吊采用常规方法即可完成吊装。屋架梁的吊装则由厂房一端向另一端推行，在推进过程中，应将屋架梁之间的支撑系统同时安装完毕。The assembling nodes of roof beam are in such a great amount that its stability is poor. Therefore, use cross hanging methods to ensure the safety of components during the lifting process. Assembly of roof beams adopts vertical methods, and the camber and lateral bending are strictly inspected during the assembling process.由于屋架梁拼装节点多，因此其稳定性较差，为保证吊装过程中构件的安全性，采用铁扁担的吊装方法。屋架梁的拼装