中英文钢结构安全第一级检查规定.docx

此文档收集于网络，如有侵权，请联系网站删除This document is part of the Holcim Design Safety and Construction Quality Program (DSCQP). It is valid as long as the content of the reference document DSCQP-D-001 or any learning from the Program does not justify a revision of the present document.这份文件是豪瑞集团设计安全和工程质量制度的一部分。只要与之相关文件DSCQP-D-001或者任何从该制度延伸的内容没有作出合法的修改，该文档就是有效的。Holcim Group Services Ltd reserves its rights to modify, update or withdraw the present document at any time, and will in due time inform Principal and Associated Companies of the Holcim Group accordingly.豪瑞集团享有对这份文档修改、更新、撤销的权利，并且会根据改动结果及时通知豪瑞集团旗下的全资和合资公司。As the present document is a minimum standard, the parts in blue may be adapted, improved, translated and integrated in the maintenance management procedures of the facilities of the Principal and Associated Companies. By no mean shall this document be used as acceptance procedure of a new structure.由于当前文档时最低标准版本，所以下面蓝色部分需要各全资与合资公司维修管理制度方面经过调整、改进、转化、完善。1. Purpose of the Level I assessment第一级评估的目的To ensure that any structure, or part of a structure, which may pose a risk to safety, damage to property and environment is identified and categorized. Action shall be taken to prevent a failure from occurring.为了确保任何可能对安全构成威胁、对财产和环境造成毁坏的建筑或者建筑的一部分进行统计和分类，必须采取相关措施来避免事故的发生。2. Scope of the assessment评估的范围2.1. This procedure shall be used as reference for any Level I inspection of steel structures at the facilities of the Principal Companies of the Holcim Group and is recommended to be used by the Associated Companies.该制度应该作为豪瑞集团全资公司任何钢结构建筑检验第一级评估的参照标准，同时也推荐在合资公司中推行。2.2. This procedure shall be adapted to applicable local requirements, translated and integrated in the management system of the facility or of the Company as a “field procedure”. The field procedure shall be used for the first assessment of any steel structure as well as future preventive maintenance routines at the facility, every two years, or with a periodicity adapted to a potentially difficult operating environment or when structures are getting closer to the end of their defined service life.该制度要与当地的要求相适应，转化和整合后作为公司设施管理系统的现场程序。该标准适用于任何钢结构设施的初次验收评估，同样也适用于今后每两年例行的设备预防性维修，或者用于当钢结构设施频临退役淘汰的时候。2.3. The structures which:a) are newer than ten years can be more prone to design and construction defects, which if present will typically show up in the first years of operation (possible non-conformity or early damage),建造时间在十年以内的钢结构设施如果存在设计和建造方面的缺陷的话，一般会在使用的第一年暴露出来。（可能没有问题或者早期损坏）b) are older than 25 years may be susceptible to increased loads or reduced resistance due to corrosion, wear or impacts建造时间超过25年的钢结构设施由于长期受到腐蚀、磨损、挤压等原因，对在其上进行加装或者拆卸会很敏感。c) have been built without evidence of a proper quality control process 没有经过正式质量管理监管认证而建造的钢结构设施。d) have been modified from their original design conditions without evidence of a proper re-design and performed construction quality control shall be in the focus of Level I inspections, but this inspection shall not be limited to them only.原始的设计经过修改但是没有通过重新设计认证的，以上各种情况分类的钢结构设施的工程质量管理要按照第一等级检查执行，但是该标准不仅仅局限于以上情况。A definition of high load structures or components and a non-exhaustive list of priority one structures is provided in the reference document DSCQP-D-001, chapter .高负载的钢结构设施、部件和钢结构设施的简要优先列表的定义见相关文档DSCQP-D-001的第.章节。2.4. Compliance with this procedure: Where for any reason it is not possible to comply with any aspect or requirement of this procedure, the appointed inspector and its supervisor shall raise the matter through their site manager or line manager and an alternative means of compliance shall be sought. The alternative means shall offer an equivalent level of assessment.制度的服从：无论由于任何原因造成不能完全遵从该制度的地方，指定的巡查员及其监督员要向对应场所的经理或生产线经理反映该问题，并采取一个最优的折中方案。该折中方案应该具备同等的评估等级。3. Responsibilities职责The responsibilities directly related to this procedure are defined in the following Table I.与该制度相关的责任认定细则见下面表1.Company CEO公司执行总裁 Ensures that the latest version of the DSCQP is transmitted to the relevant functions of the Company 确保最新的安全质量制度传达到相关部门 Is informed of the structures presenting a High Risk and shall act accordingly 知晓存在高危的钢结构设施并制定相应行动方案Director/Functional Head主管领导 Ensures that the latest version of the DSCQP requirements is integrated into field procedures 确保最新的安全质量制度要求整合到实际执行标准中 Is informed on the structures presenting a Medium or High Risk and shall take action accordingly 知晓存在中度或者高度危险钢结构设施，并制定对应的方案 Agrees on the appointment of the inspector, upon proposal of the site manager or of an expert body. 检查员任命、 项目经理提议的审核批准Site Manager or by delegation Head of Maintenance or of Project Department.项目经理 Ensures that previous reports and surveys of the structures are available for the inspection to be done 根据钢结构设施之前的报告、调查，确保检查的可行性 Appoints the inspector or agrees on his appointment 指定检查员，及其任命的审核批注 Validates the risk level according to the applicable risk matrix model 核实危险等级 Reports without delay the structures presenting a Medium or High Risk and shall take action accordingly. 第一时间向上级报告存在中度或高度危险的设施，并采取相应措施Supervisor of the inspector检查员的直接上级 Validates the Level I report and evaluates the risk level according to the applicable risk matrix model. 审核第一级检查报告，并根据适当的风险矩阵模型评价风险等级Appointed inspector指定检查员 Carries out the Level I inspection and prepares the Level I report, including DOD, DNC and LFF. 实施第一级检查评估检查并出具第一级检查报告，包括：DOD（损坏程度）、 DNC（不一致性）、 LFF（故障可能性）Table I: Management and inspector responsibility表一：管理团队及检查员的职责定义4. Requirements要求4.1. Precautions to be taken prior to the inspection and preparation of the inspection.预防措施优先于巡检以及巡检前准备工作Prior to undertake the inspection the appointed inspector and/or his/her hierarchy shall have informed the facility of the scope and date of the inspection and all safety precautions shall be taken to perform the inspection (Refer to local applicable OH&S standards and Holcim Fatality Prevention Elements).在执行巡检之前，指定的检查员及其上级要明确需要检查的设施、检查时间，开展检查工作的安全防护措施。4.2. Methods to carry out the inspection开展检查的方法The method of inspection is based on visual observations, which will detect most of the wear, cracks, deflections and deformation of steel members affecting their integrity.检查方法基于视觉的观察，视觉的观察能够发现影响钢结构设施完整性的大部分磨损、断裂、倾斜、变形现象。For critical structural elements, i.e. members which are essential for the stability of a structure, welding seams, plates and connections, it is recommended a) to carry out a “soft” hammer test to find loose fastenings, loose plates or connections, cracks or to evaluate corrosion condition, b) to use non-destructive techniques (NDT) such as flaw detection penetrant dye by trained technicians for not clearly visible cracks and c) to make measurements (plate thickness, member deformation) where possible or needed, in addition of or to confirm visual observations. 对于存在危险的钢结构设施必不可少的关键支撑部位，对于焊接裂缝、护板、连接检查建议按照以下方法操作a)用橡胶锤敲击实验来找出焊接松动部位、松动的护板或连接，断裂或者评估腐蚀状况。b)用非破坏性技术，比如经过培训的技术人员用染料剂渗透探伤检测手段来检测不明显可见的断裂。Where possible, internal inspections shall be carried out on hollow structures such as bins, particularly where abrasive or corrosive material is involved, and structures like platforms, bridges and conveyors be inspected from underneath. In hollow structures, especially suspended ones, welds which cannot be inspected from inside shall be subject to ultrasonic testing by a qualified person.在一些内部空洞特别是材料在受到磨蚀和腐蚀的情况的钢结构譬如金属容器，内部需要检查，和一些平台、桥、传送带之类的钢结构底部需要进行检查的时候。内部空洞的特别是处于悬空状态的钢结构，在其焊接点不能通过内部进行检查的时候，需要专业人员用超声波探伤技术来测试。Appropriate inspection conditions (Access, cleaning, uncovering, lighting) are necessary. Binoculars or similar device are required to inspect areas of difficult access and a digital camera is necessary for the documentation of findings. Where substantial high load structures are involved, drawings and documents should be used in support of the review.适当的检查条件（可进入的、干净的、未封闭的、有光亮的）是必要的。在对那些检查难以到达的地方，双筒望远镜以及类似的设备是必备的。数码相机需要用来为将来报告提供隐患图片证明。对于确切高负荷的钢结构，需要用图表、文档数据来进行分析评估。4.3. The inspection shall typically cover (but is not limited to):常规检查部位包括以下几条（但是不限于以下） Significant foundation or structure settlement, deflection, movement or vibration 重要钢结构基础部位的沉降，倾斜，移动，震动 Parts of structures or members incorrectly erected, welded, riveted or bolted 钢结构的组成部件没有正确地竖立安装，焊接，铆接，拴紧 Absence of rivets, bolts, nuts, washers or similar locking mechanisms 铆钉，螺栓，螺帽，垫圈或者类似的紧固零件的缺失 Loose connections between members, or displaced connections 钢结构部件之间连接松动，连接单元缺失 Damage caused by impacts or notches in structural members 钢结构由于撞击和划痕而造成的的损伤 Any notable structural weakness resulting from missing or damaged parts or advanced corrosion 任何由于零件缺失、损坏、腐蚀而造成的明显结构不稳固的部位。 Absence of, missing or removed structural members 钢结构部件的丢失、移动 Wear caused by abrasion 摩擦造成的耗损 Loss of cross section due to wear, abrasion or corrosion and paintwork condition 由于磨损、锈蚀、油漆状况不良造成的横截面损伤。 Welding quality, cracks on plates, members, in welds and bolts 焊接质量，由于焊接和螺栓状况不良造成的钢结构、护板的裂缝。 Excessive vibration, impact loading, duty cycle or movement during equipment operation 设备操作时周期运动造成的过度摆动、撞击。Note: Defects on new structures may substantially differ from observations on old structures and the inspectors a) may be too confident that a new structure is exempt of defects or b) may have more difficulty to identify them. Faulty design or construction is typically characterized by settlement, deflection or distress, hinged or displaced connections, which are less easy to identify than impacts, corrosion, and wear and tear. Inspectors shall take that these factors into consideration.注意：新建钢结构的缺陷和旧的钢结构从外表观察来看本质上是不一样的。所以检查员可能过分相信新建的钢结构设施没有任何缺陷或者有更大的难度鉴别出缺陷。不正确的设计和施工通常会带来钢结构沉降、倾斜、连接部位移动。这些现象比撞击、腐蚀、磨损难发现。检查员在进行巡检的时候要把这些因数考虑进去。4.4. Categorization of observations with DOD or DNC and LFFDOD、LFF分类标准The following table shall be used for the categorization of the Degree of Damage (DOD) or Degree of Non Conformity (DNC) and Likelihood for Failure (LFF) of a structure.以下表格用于分类判定钢结构的损坏程度（DOD）或不一致性（DNC）和故障可能性（LFF）。损害度（DOD）或不一致度（DNC）事故可能性（LFF）等级类型等级类型5极端A必然4严重B很可能3中度C可能2轻微D不一定1无E几乎不可能One difficulty is to categorize observations made on structures and translate them in equivalent DOD or DNC and LFF.难点在于把钢结构检查报告分类并转化成为对应的损坏程度和故障可能性等级。Note that an observation generally refers to one member of a structure or one part of the structure (ex. a connection beam-column), therefore the categorization shall be made for that member or that part of the structure, not for the entire structure. It is in the Level I report that the consequence of the DOD, DNC and LFF shall be documented for the entire structure, and that a progressive collapse scenario has to be assessed. A general categorization for an entire structure could however be done in the case of generally advanced corrosion, where almost all the structural members would present the same DOD and LFF.一份检查报告通常是针对于钢结构的构件之一或者钢结构的一部分，（例如梁柱的连接），因此分类等级是针对于钢结构的一部分而不是整个钢结构。在最终等级报告中整个钢结构的损害程度、不一致程度、故障程度结果需要有充足的证明材料，并且对损害发展趋势要进行评估。The following paragraphs provide practical means to evaluate the DOD, DNC and LFF. This evaluation shall consider the combination of other factors (loads, steel fatigue, and overall structural conditions) in complement of the criteria set below.以下段落为损害度和故障率等级评估提供了具体的标准，评估要考虑到其他因素（负荷、金属疲劳、整体刚机构状况）并作为以下细则的补充。4.4.1. Practical categorization of DOD, DNC and LFF for worn or corroded structural members磨损或腐蚀钢结构等级评判标准In absence of detailed information about the structures design safety factor, which is a common case, a practical approximation that can be made regardless of the design code is that the safety factor of the maximum permissible stress in the steel may be in the range of 25% to 35%, say 25%.不考虑钢结构设计安全因素的情况下，钢铁的最大应力承受安全系数应该在25%到35%之间。If the structure has not been modified and operates without extra load, a simple rule of thumb is that the DOD of a member of the structure would be Extreme and its LFF Almost Certain if the reduction of the cross section of any of the members part, i.e. plate, flange or web would be close to or greater than 25%. That rule may be applied for corroded structural members too (consider that cross section refers to the thickness of non-corroded steel and excludes the rusted part) or for a partially worn-out section or for a member which does not have the same cross section than other similar members having the same function (ex. bracing members).如果钢结构没有被改动过并且使用时候没有额外的负载，如果有任何部件的横截面有磨损，通过经验判断 钢结构构件的损害程度DOD等级会是极高的，故障率LFF等级几乎是必然的。这条经验判断方法也适用于存在腐蚀情况的钢结构，或者存在局部磨损的部位或者适用于与其他有相同的结构但是横截面却不一样的部件。（ 如支撑部件）If a structural member would have lost respectively 0-5%, 5-10%, 10-15%, 15-25% of its cross section its DOD/LFF should respectively be categorized as 1/E, 2/D, 3/C and 4/B.如果一个钢结构部件磨损程度分别达到自身横截面积的0-5%, 5-10%, 10-15%, 15-25%，那么这个部件的磨损度/故障度分别被归纳为1/E, 2/D, 3/C and 4/B.Paintwork condition: As such the lack of paint on surfaces, connections, welds or fastenings does not pose a short term problem in terms of LFF, but will accelerate corrosion over the time. Deterioration of paint work should be categorized as DOD/LFF 2/D and actions considered to remedy to it.喷漆状况：对于那些表面、连接处、焊接处、扣紧部位缺少油漆的钢构部位根据故障度等级来看可能短期不会造成问题，但是随着时间流逝这些部位将会锈蚀程度会不断加速。油漆状况恶化的部件磨损度/故障度应该被归纳为2/D，并且要考虑制定对应的修复方案。4.4.2. Categorization of DOD, DNC and LFF for deflected elements倾斜部件的评判标准A visual inspection revealing a structural element which is deflected as a result of load or impact is symptomatic of a deformation beyond the elastic limit of the steel. Attention should immediately be paid to all the connections of this element to evaluate their condition (See 4.4.3 below). Deflected or deformed elements shall be categorized at least as DOD/LFF 3/C.由于负荷或者挤压而导致倾斜的钢结构在肉眼检查时会发现有形变，但是还在其最大弹性限度内。注意力马上要集中到这类构件的所有连接部位并对它们的状况进行评估。（见下面第4.4.3章节）倾斜变形的构件的磨损度/故障度等级应该被归纳为3/C.4.4.3. Categorization of DOD, DNC and LFF for connections连接部件的等级评判标准One basic principle is that a connection is designed to carry the full strength of the connected members; therefore a connection shall always be stronger than the biggest connected member, in order to prevent plastic hinges in the connection.一个基本原则是，设计连接部件是用来承受被连接件的全部力量。因此连接部件要比最大的连接件更坚固从而防止连接部位的断裂Another principle is that the stresses and implied deformation of each individual fastener (bolt, rivet or weld) shall be within the permissible design limits.另外一个原则是每个单独的紧固件所受的压力及产生的形变应该在它所允许的设计极限内。The categorization of DOD, DNC and LFF shall consider if the connection elements are still within the permissible design limits or to which extent. As an example, if a connection would have only three bolts installed instead of four originally foreseen, the remaining safety factor would be less than 25% and that particular connection would have to be categorized as Extreme DOD with an Almost Certain LFF. The same would apply if one out of four fasteners would be loose.连接部件的损坏等级，故障等级的判定要它是在所允许的设计极限之类还是超过其设计极限。例如，如果一个连接部位原始应该有四个螺栓但是现在仅仅剩下三个螺栓，那么这个连接构件的安全系数就低于25%，这种状况的连接构件的必须归纳为损坏度5级和故障度A级。如果四个螺栓其中的一个松动，评判等级也是和以上一样5/A。The remedial action shall be to restore the original connection type and capacity, if possible.在允许的情况下，应该要采取修复措施来恢复连接部位原有的结构和强度。4.4.3. Categorization of cracks in members or welds, welding quality焊接点、焊接质量拼盘标准. Cracks裂纹The DOD and LFF of members showing cracks or of members welded together and showing crack in the weld or next to it are more difficult to categorize, as cracks may show very different patterns (thickness, depth and length of crack, direction and speed of crack propagation, etc.). In general, a simple rule is that the DOD is Extreme as soon as the crack length equals or exceeds 25% of the welding seam length or the member thickness or member width.对于有裂纹、焊接在一起、焊点有裂纹、或焊点旁边有裂纹的部件的损坏等级判断更加难以归纳，这是因为裂纹会呈现出许多不同的样式（裂纹的厚度、深度、长度，裂纹扩展趋势及方向等等）。总体来说，简单原则是如果裂纹的长度大于或等于焊缝长度或者部件厚度或部件者宽度的25%时损坏等级应该定为5级。. Welding quality焊接质量Unless otherwise specified in the structures documentation, a basic reference that can be made is that welding quality for all the structures shall be at least of ISO 5817-Class C (medium) and at least of ISO 5817-Class D (moderate) for minor elements such as cover plates for example. (For any equipment other than structures, do not use that basic reference and refer to the equipment documentation).除非钢构件说明文件有特别的说明，否则所有的小型钢构件（类似于盖板）的焊接质量的基本参考标准应该至少符合ISO 5817-Class C和ISO 5817-Class D。（钢构件之外的任何设备不要使用这条参考标准，而应该参考设备自身的说明书）Under this Level I procedure, the categorization of the quality level of a welding can be done as follows: 钢构件焊接质量等级判断可以按照下面所述来确定：For Class C welds, and especially for critical structural members and connections, imperfections such as internal and external cracks, incomplete or lack of fusion, lack of or incomplete root penetration, metal overlap, burn through, any root porosity also called “spongy” or “bubbling” formation, poor restart, stray arc, shrinkage cavity, crater pipes and inclusions are not permitted or are limited and shall be categorized at least with a Major DNC 4.对于C型焊接，特别是对于有风险的钢构组成部件和连接部位，内部和外部的瑕疵（例如内部和外部开裂、未完全融合焊牢、根部未完全焊透、金属重叠、焊穿、焊接后产生气孔或气泡、缩孔、内部有杂质等等）是不允许的或者受限制的，这种状况的损害等级至少应该定为4级。For Class D welds, imperfections such as internal and external cracks, incomplete or lack of fusion, lack of or incomplete root penetration, metal overlap, burn through, extensive root porosity also called “spongy” or “bubbling” formation and inclusions are not permitted or are limited and shall be categorized at least with a Major DNC 4.对于D型焊接，内部和外部的瑕疵（例如内部和外部开裂、根部未完全焊透、金属重叠、焊穿、焊接后产生气孔或气泡、内部有杂质等等）是不允许的或者受限制的，这种状况的损害等级至少应该定为4级。“Short imperfections” are defined as one or more imperfections of total length not greater than 25mm in any 100mm length of the weld or with a maximum of 25% of the weld length for a weld shorter than 100mm. Short imperfections such as undercut, shrinkage groove, incompletely filled groove, root conca