GRC墙板施工组织设计之生产篇.doc

南京倍立达(集团)有限公司 NANJING BEILIDA (GROUP)CO.,LTD.地址:江苏省南京市秦淮区双龙街一号 Addr.: No1，Shuang Long Road， Qinhuai Zone of Nanjing,Jiangshu ProvinceTelFax-mail：工程名称： E-TECK FLAGSHIP BUILDING建设方： 镇江二建构 件 名 称：GFRC外墙板工程编号：设 计：审 核：日 期：张 数(共60张)： 64GRC质量保证计划GRC Production and Quality Plan for The Project in Republic of Trinidad & Tobago南京倍立达实业有限公司Nanjing Beilida Industrial Co., Ltd.前 言公司GRC生产和质量计划是依据BS EN1169:1999以及美国PCI MNL-130的相关标准要求制定的，对于GRC产品的检验和测试则是参照BS EN1170:1999的方法执行。为了使产品达到较高的品质要求，我们严格对GRC生产过程进行控制，同时实施全过程的跟踪记录。顾客对产品的特殊要求构成对本计划的补充。Foreword It is made according to the relevant standard of BS EN 1169:1999 and American PCI MNL-130, and the testing and inspection method of GRC product is based on BS EN1170:1999. In order to achieve higher quality , we strictly monitor the whole process of GRC production, and at the same time, the whole process tracking record has been kept. The custom fitting requirements are the supplement of this plan. 目 录TABLE OF CONTENTS1.0 原材料计划 Raw materal plan2.0 生产组织计划 Production Layout Plan3.0人力资源计划 Human resource plan4.0质量控制计划 Quality control plan5.0校准、测试计划 Calibration and testing plan6.0 GRC制作程序 GRC Production Procedure7.0 GRC产品的养护、搬运和贮存 Curing, delivery and storage of GRC Products(Air Cure)1.0 原材料计划1.0 Raw Material Plan1.1 原材料的标准要求1.1 Raw Material Standard 1.1.1 耐碱玻璃纤维 Alkali resistant glass fiber (AR Glass Fiber )GRC产品使用的玻璃纤维应该是专门开发和配制的连续耐碱纤维纱，耐碱玻纤材料可包括无捻粗砂，短切砂和网格布，长度最适宜的范围是2551，氧化锆含量16%。Alkali resistant glass fiber used in GRC should be the specified one, including chopped mat, fiber fabric the most appropriate length is 25mm to 51mm, the requirement of ZrO2 content 16% 1.1.2 水泥 CementGRC生产所用水泥应符合下列标准规范的相关要求：JC-T 659-2003 低碱度硫铝酸盐水泥应该正确地贮存水泥，保持干燥，避免品质降低。the cement used to GRC production should achieve the standard as follow: JC-T 659-2003 Standard Specification for Low-alkali sulphoaluminate cement Store the cement properly,keep it dry, avoid the quality destroying 1.1.3细集料 Fine aggregate 喷射GRC要求的最大颗粒尺寸为1.2mm，预混GRC要求的最大颗粒尺寸为2.4mm。两种工艺情况下，通过150微米孔筛子的细颗粒面分数应该低于砂子总质量的10%。 The max particle diameter for GRC spraying is 12mm, the ones that for premix GRC is 24mm. In both conditions, the weight of the ones that pass the sieve whose diameter is 150 micron should be blow 10% of the whole weight. 石英砂应该符合下列标准规范： 硅含量96%，水份含量2%，可溶盐含量1%，烧失量0.5%，硫酸盐最大0.4%，氯离子0.6%。Quartz sand should conform to standard as follows：Silicon content96%，water content2%，dissoluble salt content1%，LOI0.5%，sulfate max0.4%，chlorin0.6%。 1.1.4 水Water 水应该是清洁无杂质的。 The water should be clean.1.1.5 外加剂 admixture 由于外加剂能够提高GRC的性能，所以许可使用而且鼓励使用。应该按照供应者的推荐，严格使用外加剂，生产者必须保证外加剂的使用不会对最终产品有负面影响。外加剂应参考英国标准BS4887，BS5075，或符合ASTMC494或ASTMC260要求，如果GRC中含有钢筋、固定套管或相似的浇注部件，绝对不能使用氯化钙基的外加剂。 Admixture can improve the character of GRC, so it is encouraged to be used. But we should use it strictly following the recommendation of the supplier, making sure that it will not cause side effect to the product. we can refer to the standard of England like BS4887,BS5075, or ASTMC494 or ASTMC260. If there are steel cast-in product, calcium chloride is forbidden to use.1.1.6 丙烯酸聚合物 Polymer 当使用丙烯酸聚合物体系时，应该按照生产规程使用，并应符合下列技术规范。 混合物类型： 含水塑性聚合物体系 聚合物类型： 丙烯酸基 固含量： 4555% 外观： 物奶白，奶油状，无结块 最低成膜温度： 712 抗紫外线： 好 耐碱性： 好 When using polymer, we follow the following rules Compound type： water contained polymer Polymer type： crylic aid Solid content： 4555% appearance： milky, creamy,no agglomeration minum solid temperature 712 ultraviolet resistant： good alkali resistant： good 1.1.7 颜料Pigment 可以使用粉状颜料或分散体系以生产彩色GRC，颜料应符合BS1014或要求，买方必须理解颜色发生的变化，必须在可接受的变化范围内与生产者达成一致。 We can use pigment or separation system to produce GRC with colour, and the pigment should conform to BS1014. The clients should understand the variation of the colour, and reach an agreement with the manufacturer within an acceptable range.1.2 原材料的使用规定rules for raw material application GRC所有使用的材料必须符合规范的要求，进口材料需要有制造商的使用说明等证明文件，还要提供必要的检测试验报告。每收到一批原材料，负责人应检测品名、包装情况、重量、发货日期和有效期限，然后，盖QC章并把发货日期和有效日期露在包装外面。为了保证收到正确的原料，必须作好适宜的储存和检测。 All the materials used to produce GRC must be up to the standard of the rules, and the imported materials must attach the specification and certificate provided by manufacturer, including the testing report. When receiving a batch of raw material, the man at charge should check the name, the package, the weight, the date and the expire date, stamping on it, leaving the receiving date and exprire date outside. It should also be stored properly.2.0 生产组织计划 Production Schedule (已作另外提交Production Schedule would be submitted separately)3.0 人力资源计划（附图）Human Resource Plan（Picture attached）4.0 质量控制计划Management Quality Plan4.1 概要General description4.1.1 范围 Scope这一计划适用于GRC生产整个过程的控制和检验This standard is applied for all general inspection of whole GRC product manufacture process.4.1.2 应提前了解客户关于GRC产品方面的特殊要求，并根据客户要求调整该计划，确保顾客满意。 Give priority to customers special requirement on GRC product.4.2 材料的检验标准 Inspection of standard material4.2.1水泥 cement1) 概要Generala. 在GRC中用到两种类型的水泥：硅酸盐水泥和硅酸盐白水泥Two types of cements used in BLD: grey cement and white cement.b. 水泥的强度等级：42.5，42.5R或者更高（符合中国国家标准GB175-1999要求，28天的抗压强度达到42.5MPa） Intensity grade of grey cement: 42.5, 42.5R or above (National standard GB175-1999).c. 在选择某一品牌前，应获取生产商该品种水泥的物理性能和化学组成测试报告，如顾客有要求还须取样送检。 Before choosing one cement brand, you should acquire the physical properties test and chemical composition test for the product, and should be sent to be tested if the customer required.2)水泥进料检验的内容 Inspection items of cementa. 包装上要有：生产日期（一定要是三个月之内的）；包装条件，强度等级 Appearance: date of production (limitation in 3 months); packing condition; indicating of intensity grade.b. 重量检测（抽查） Weight inspection (selected) 抽查率：2%（如果数量是100袋，选择两袋检验并记录）MIN selected rate: 2% (If quantity is 100bags, select 2 bags to inspect and record) 重量检验的标准偏差：2%硅酸盐水泥：50kg1kg白水泥：40kg0.8kgDeviation standard of weight inspection: 2%: Grey cement: 501 kg White cement: 40 0.8 kg3) 当发现超出偏差范围时，重新选择4%的定量重新检验，如果选定了50%数量达不到标准，把这些材料退还给供应商。 When find discrepancy. Reselect 4% for inspection, if there are 50% bags of selected quantity fall short of standard; return this lot material to supplier.4.2.2 石英砂 Sand1) 概要 General a. 使用石英砂（硅砂）生产GRCBLD used quartz sand (silica sand) for GRC productb. 在选择某一品牌的石英砂供应商之前，应取样测试化学组成（要求：见1.1.3的规定）Before choosing one quartz send supplier, 5 kg sample should be chosen and send to HK QCC laboratory for chemical composition test (requirement: SiO2 content 96%, NaCl content 0.06% (or 600ppm)2) 石英砂进厂检验内容 IQC inspection items of quartz sand that pass test:a 重量检验（抽查）最低抽查率：2%重量检验的标准偏差：4%，也就是：50kg2kg当发现超出偏差范围时，重新选择4%的定量重新检验，如果选定了50%数量达不到标准，把这些材料退还给供应商。a. Weight inspection (selected) 1) MIN selected rate: 2% 2) Deviation standard of weight inspection is 4%, that is: 50 2kg 3) When find discrepancy. Reselect 4% for inspection, if there are 50% bags of selected quantity fall short of standard; return this lot material to supplieb 水分检验标准：水分2%检验方法将至少200g的石英砂放在干燥的金属托盘上（W金属），砂子和托盘的重量W1：然后把它放在烤炉上（100）至少烤1个小时，得到干砂和托盘的重量W2。 水分计算：=b. Inspection of water contentApproval standard: water content 2%Inspection method: Select M1N 200g quartz sand and put it on a dry metal salver (Wmetal) which is W1: sand and salverput it in oven ( 100) for baking at least I hour, which is W2: dry sand and salverc 在面层料所使用的砂子应在颜色相近。The sand should be in close color and luster for using as the surface slurry4.2.3 抗碱玻璃纤维 Alkali resistant glass fiber (AR Glass Fiber )1) 概要 GeneralGRC产品使用抗碱玻璃纤维，要提供厂家的技术说明书和检测报告。The specification and the testing report should be provided by the manufacturer.2) 进厂检验内容 Inspection itemsa. 表观检查：检验防湿层包装是否已经损坏，重量是否与标注重量吻合。 Appearance inspection ,check damp-proof packing whether it is damage, open carton to see whether it is disposed in sound order.b. 每批货中随机抽取5箱按上述要求进行检查，如果5箱货没问题，这批货就通过，否则，就打开所有的货，并把不合格的返还给供应商替换。Select 5 cartons fur above inspection items. If pass, this full lot is ok. If not, inspect all the cartons, return those disqualified to supplier for replacement.4.2.4 预埋件 Embedded parts and other hardware parts1)材料质量：Quality分成不锈钢（SS）和镀锌软钢（GMS） The quality is stainless steel ( SS ) , GMS:根据不同的工程要求，一般的SS被分成：等级202，等级304， 等级316L和等级316H等。Different projects have different requirements , the common SS fall into 304 class, 316L class arid 3161t class.简单方法鉴定：Discrimination method simple:不锈钢：对磁铁没有吸附力 SS; not attract to magnet镀锌软钢/不锈铁：对磁铁有吸附力GMS; attract to magnet材料的接收标准: Acceptance standard of material材料质量的接受标准：许可证（例如SGS报告）应符合工程要求Acceptance standard of material quality; the approval certificate * such as SGS report) should match engineering demand.2)接收的质量水平 AQL先在每批货中随机抽取5%或者选定20个样品，或者更多，检查，如果有3个以上被否定了，再随机抽取10%或者40件样品检验，如果这批货再有6个以上的被否定了，就不再检查，立即通知供应商收回整批货并替换。In 5% of each delivery lot quantity or randomly select 20 samples, if find 3 pcs disqualified, re-inspect in 10% of quantity or 40 samples, if find 6 pcs disqualified return whole lot to supplier for replacement.3) 表观检验：焊缝、焊点及表面平坦情况。 Inspection of appearance ,welding seam welding spot4) 尺寸检验 Inspection of dimension 偏差符合安装的尺寸要求 Deviations is up to the standard of installation.4.2.5 其他材料检验 Inspection of other material1) 减水剂 Water-reducing agent (SNN)a 表面：检查在包装桶上的名字和标签及有效期。 Appearance: exam name and label on the packing bucket, check its expiration date.b 数量：数一下桶数。Quantity: check the number of buckets2) 聚合物 Polymera 表面：检查在包装桶上的名字和标签及有效期。Appearance: exam name and label on the packing bucket, cheek its expiration date.b 数量：数一下桶数Quantity: check the number3) 脱模油（脱模剂）Demoulding oil: (mould release agent)a 表面：检查在包装桶上的名字和标签Appearance: exam name and label on the packing bucket. b数量：数一下桶数Quantity: check the number of buckets4) 泡沫 pad检查是否有损坏的地方Check if there are any damage.4.3 模具的检验标准Acceptance standard of mould4.3.1 范围 Scope用于GRC生产的模具 Mould used for GRC product manufacture4.3.2 检验内容和许可的尺寸偏差 Content of inspection and allowed deviation of dimension1) 边长 Edge length2) 板高 Board height3) 预埋件位置Position of embedded parts4) 扭曲度 Surface warpage5) 表面平整度 Surface smoothness6) 边侧弯曲 Side bending7) 对角线偏差 Diagonal deviation4.3.2 在一定条件下，每个模具的检验方法和检测仪器，可以参考4.4部分的产品一般检测方法Inspection method and apparatus for each mould under certain circumstance please refer to 4.4 section for the normal inspection method.4.3.3 模具的误差范围 Allowed dimension tolerance of the mould内容 item偏差范围 Range of allowable tolerance1 边长 length 1mm/m，最大误差为max 3mm2 板高 height 2mm3 预埋件的位置 position of inserts3mm4 扭曲度 warpage1mm/m5 表面平整度 Flatness of surface误差1mm6 表面弯曲率Edge Straightness误差2mm7 对角线误差 Diagonal deviation1.5mm/m，最大误差max：5mm4.3.4 表观检验 Inspection of appearance1）钢模 Swage (Iron mould)检查表面平整度、锈迹、焊接位置以及铁板连接的情况。Exam surface smoothness, rustness, welding poison, iron sheet connection 2）木模 Wood mould检查表面平整度、光面、锈迹、焊接位置、裂缝、裂痕以及铁板连接情况。Exam surface smoothness, glaze, rustness, welding position, interstice, crack, and iron sheet connection3）FRP模 FRP mould 检查表面平整度、光滑面、加固，分块以及焊接情况。Exam surface smoothness, glaze, rustness, welding poison, interstice, crack, iron sheet connection.4.4 GRC生产过程的检验标准 Inspection standard on GRC manufacturing process4.4.1 范围 ScopeGRC产品生产过程的检验 Inspection of GRC product manufacture process4.4.2 塌落度实验 BSEN1170-1：19981） 标准， 4到7环2） 补充如果不符合标准要求，调整料浆比率并再次进行测试。4.4.2 Slump test BSENllTO-l: 19981) Standard4-7 rings2) AmendmentIf exceed standard requirement, adjust mixture ratio and test again.4.4.3 GRC混合物纤维含量测试，BSEN1170-2：1998（参考）Test for fiber content in GRC: (wash-out test: BSENl170-2:1998)1） 标准 Standard在喷射GRC的纤维含量在4.8%到5.3%。Fiber content in Spray-up GRC is: 4.8%-5.3%预制件的纤维含量至少要符合构件要求的90%Fiber content in precasted unit should at least meet the 90% requirements of the component.2） 许可的纤维含量误差 Allowable Fiber content tolerance 喷射GRC的纤维含量误差误差评估预制件纤维含量误差1%低的，可接受的0.5%1% 并 1.5%高的，比较能接受的0.5% 并 1% 1.5%不可接受的1%Fiber content tolerance in the Spraying methodEstimating toleranceFiber content tolerance in the pre-casting method1%Low, acceptable1.5%Unacceptable1%3） 修正 Amendment如果不符合要求，应重新检验生产过程并调整纤维的产量比例，再次进行测试If unacceptable, should re-inspect production process and readjust fiber output ration, test again.4.4.4 GRC BSEN1170-3：1997 喷射GRC纤维含量的测试方法Test method for Fiber content of sprayed GRC BSENllTO-3:19971） 标准 （以分钟为单位计算）Standard (calculate by minute)纤维产量范围在4.8%到5.3% Fiber output quantity range: 4.8%-5.3%2） 补充 Amendment如果不符合要求，应调整纤维或者水泥砂浆的比例，然后再进行测试。If failed, should adjust fiber or cement mortar output rating, then test again.4.4.5 纤维长度测试 Fiber length test用喷枪喷射2秒钟，随意选择3个切片，并测量其长度 Use spray gun to spurt for 2 seconds, select 3 fiber segmnents randomly, and measure its length.1） 标准 喷射：28-32mm预制件：12-25mm1) Standard: On Spraying: 28-32 mm On pre-casting: 12-15 mm2） 补充 Amendment当不符合要求时，根据以下方法调整纤维的长度 A 检查切割刀，如有裂痕或损坏应及时更换。B检查从外部纤维筒到喷枪之间是否有阻碍。C检查橡皮环的磨损率，如果橡皮环和刀片不能磨合要及时地更换，When exceed standard. Adjust fiber length according to below measures:a) Cheek cutting knife, should timely change if crack or damageb) Check if there is resistance from exterior to block fiber deliver in to spray gun.c) Cheek attrition rate of rubber ring, should timely change if rubber ring and blade are not driving fit4.4.6 厚度测试 Thickness test用辊子压实产品，然后用探测仪测试GRC喷射层厚度Use roller to consolidate the product, then use probe to test GRC spray layer thickness.1） 标准 Standard设计厚度：-0/+2mm Designed thickness: -0/+2 mm2） 补充 Amendment当不足设计厚度时，喷射GRC直到设计厚度，当超过设计厚度2mm时，除去多余的GRC，使用辊子压实然后再次测试。When under designed thickness, spray GRC till reach designed thickness. When designed thickness for +2 mm exceed, remove the rested GRC, use roller to consolidate it, then test again.标注：产品在每个厚度测试之后要再次压实Remark:The product should be consolidated again after each thickness test.4.4.7 浸水法吸水率和干燥密度 Ratio of water absorption & immersion and dry density测试方法按 BSEN1170-6：1998执行，客户没有要求可不做。SENl170-6:1998, not nessary if not required by the clients.1） 标准吸水率不能超过18%1) StandardWater absorption should not exceed 18%2） 干燥的容积密度不应超过以下：GRC喷射不超过1800kg/m3预制方法不超过1800kg/m32) Dry bulk density should not under:1800 Kg/m3 for GRC spraying method1800 Kg/m3 for GRC pre-casting method3） 潮湿的容积密度不应超过以下：GRC喷射不超过2000kg/m3用预制方法不超过2000kg/m33) Wet bulk density should not trader2000 Kg/m3 for GRC spraying method2000 Kg/m3 for GRC pre-casting method如果不符合标准（在标准之下），从成品上切割一块试条并再次实验，如果再次失败，在那天所生产的所有产品都不能发运。If under standard, cut a test bar from finished product and test it again, if failed again in the second test, all product produced in that day should not deliver.4.5 GRC抗折强度检验标准Inspection standard on GRC flexural strength4.5.1 简单的抗折强度测试（7天）BSEN1170-4：1998Simple bending resistance test (7daystestbar) BSENl170-4:19981） 标准（特性值）Standard (characteristic value)a 预制7天LOP：4.2Mpa7天MOR：7.0Mpaa. Pre-cast: 7 days LOP: 4,2 MPa 7 days MOR: 7.0 MPab 喷射7天LOP：4.9 Mpa7天MOR：12.6 Mpab. Spray cast7 days LOP: 4.9 MPa 7 days MOR: 12.6 MPa4.5.2 完整的抗折强度测试（7天或者28天测试记录）BESN1170-5：1998 Complete bending resistant test: (7days or 28 days test bar)BSENl170-5:1998a 预制28天LOP：6.0 Mpa28天MOR：10Mpaa. Pre-cast: 28 days LOP: 6.0 MPa 28 days MOP: 10MPa b 喷射 28天LOP：7.0 Mpa 28天MOR：18.0 Mpab. Spray cast: 28 days LOP: 7.0 MPpa 28 days MOP: 18.0 MPa4.5.3 MOR值关系式（喷射和预制是同样的）The relationship expression of MOR value (same in pre casting and spraying):比率= 4.5.4强度值标准 Statistical value standard项目预制喷射LOP4次连续平均值7.25Mpa8.00Mpa单个值不能低于5.00Mpa6.00MpaMOR4次连续平均值12.00Mpa21.00Mpa单个值不能低于8.50Mpa15.00MpaPS如果结果低于标准，从成品上切割一试块并再次测试，如果第二次测试再次失败，所有当天生产的产品都不能发运。Pre-castingSprayingLOP4 classes consecutive mean7.25Mpa8.00MpaSingle class value should not under5.00Mpa6.00MpaMOR4 class consecutive mean12.00Mpa21.00MpaSingle class value should not under8.50Mpa15.00MpaP.S If the result under standard ,cut a test bar from finished product and test it again, if failed again in the second test ,all product produced in that day should not deliver.4.6 GRC产品的检验标准Acceptance and inspection standard for GRC products4.6.1 GRC产品的分类Classification of GR C producta 非建筑构件类型（标准类型） Non building construction type (standard type)b 建筑形（标准类型）Building construction type (standard type)c其他类型（非标准形） Other types (non - standard type)4.6.2 检验项目和内容 Inspection content and approval standard如果客户要求的话，首先要做个样品取得客户的认可，然后把许可的样品放入车间作为大批生产的标准。If customers requires, make samples first for customers approval, then put the approved sample in workshop as standard of mass production.1） 非建筑类型产品（标准形）没有特殊规定，通过以下内容对每件产品检验a 表面效果b 形状和外观c 主要尺寸1）Product of non building construction type (standard type)Without special regulation, inspect each product by below contents: a. Surface effectb. Figur