21a-管廊钢结构施工方案(最终).doc

目 录 一 编制依据一 编制依据 REFERENCEREFERENCE 4 4 1 1 编制说明 INTRO 4 1 2 编制依据 REFERENCE 4 二 工程概况二 工程概况 GENERALGENERAL INFOINFO 6 6 三 人员 机具安排三 人员 机具安排 MOBILIZATIONMOBILIZATION OFOF EQUIPMENTSEQUIPMENTS ANDAND MANPOWERMANPOWER 7 7 3 1 项目组织机构图 SITE ORGANIZATION STRUCTURE CHART 7 3 2 作业人员配备情况一览表LABOR CONFIGURATION TABLE 8 3 3 机具配备情况一览表EQUIPMENT CONFIGURATION SCHEDULE 8 四 施工方案四 施工方案 CONSTRUCTIONCONSTRUCTION PLANPLAN 9 9 4 1 安装总体思路 GENERAL IDEA OF THE CONSTRUCTION JOB 9 4 2 工艺流程图 WORK FLOW 10 4 3 施工准备 11 4 4 钢结构拼装 S S ASSEMBLING 14 4 5 结构吊装ERECTION OF STRUCTURE 24 五 高强螺栓施工艺五 高强螺栓施工艺 HSBHSB TECHNIQUETECHNIQUE 4040 5 1 一般规定 GENERAL REQUIREMENT 40 5 2 安装前的检查工作INSPECTION WORK BEFORE INSTALLATION 42 5 3 质量标准 QUALITY STANDARD 51 5 4 应注意的质量问题 QUALITY ISSUES WITH ATTENTION REQUIRED 54 5 5 质量记录 QUALITY RECORD 55 六 测量施工工艺六 测量施工工艺 SURVEYINGSURVEYING TECHNIQUETECHNIQUE 5555 6 1 测量工作流程 FLOW CHART FOR SURVEY 56 6 2 测控网的建立ESTABLISHMENT OF MEASURE CONTROL NET 56 6 3 沉降观测SETTLEMENT OBSERVATION 60 6 4 测量精度保证措施 MEASURES TO ENSURE ACCURACY 61 七 垫板 二次灌浆工艺七 垫板 二次灌浆工艺 6161 7 1 垫板工艺要求 THE REQUIREMENT FOR THE SHIM PLATE PROCESS 62 7 2 二次灌浆施工艺 CONSTRUCTION PROCESS THE SECOND TIME GROUTING 63 7 3 养护 MAINTAINS 63 八 防腐涂装方案八 防腐涂装方案 ANTICRROSIONANTICRROSION PAINTINGPAINTING PLANPLAN 6464 8 1 涂装工艺 PAINTING PROCESS 64 8 1 2 4 构件表面处理 MEMBER SURFACE TREATMENT 67 8 1 2 5 油漆修补涂装 REPAIRING PAINT 68 8 2 质量控制和质量保证措施 QUALITY MEASURES 70 8 3 安保措施 SAFETY MEASURES 72 九 安全技术措施九 安全技术措施 SAFETYSAFETY MEASURESMEASURES 7373 9 1 钢管脚手架STEEL TUBE SCAFFOLD 73 9 2 生命绳 LIFE LINE 88 9 3 活动操作架台MOVABLE SCAFFOLD PLATFORM 90 9 4 笼梯CAGE LADDER 92 9 5 挂笼SAFETY CAGE 97 9 6 吊笼LIFTING CAGE 100 十 安全管理措施十 安全管理措施 SAFETYSAFETY MEASURESMEASURES 107107 10 1 作业人员的管理 MANAGEMENT OF OPERATION PERSONNEL 107 10 2 机具管理 MANAGEMENT OF MACHINERY AND TOOLS 108 10 3 临时用电的管理 MANAGEMENT OF TEMPORARY ELECTRICITY SUPPLY 108 10 4 脚手架的管理 MANAGEMENT OF SCAFFOLD 108 10 5 进场道路的管理 MANAGEMENT OF ENTERING ROAD 109 10 6 劳防用品的管理 MANAGEMENT OF PPE 109 10 7 风险预知管理 RISK PREDICTION MANAGEMENT 109 十一 工作风险分析表十一 工作风险分析表 JRA JRA 109109 一 编制依据一 编制依据 Reference 1 1 编制说明编制说明 Intro 本施工方案针对 Team D 管架钢结构工程编制 我司承担的 Team D 管架工程分为 24 段管架 总长近 1 3 公里 钢结构总量近 3800 吨 管架宽度分别为 2m 3m 3 5m 4m 6m 7m 和 8m 管架高度最高为 22 1 米 鉴于结构型式简单 施工 方法相近 仅是在吊机选型上有所不同 为此我们将其中最具代表性的 21a 管架作为典型 来编制此施工方案 其它管架 R20a R20b R20c R20d R20e 21a R22a R22b R22c R23 R24a R24b R25 a R25b R25c R26 R33a R33b R33c R34 R36 的施工参照此方案 This construction plan is compiled as per actual site situation of pipe rack in Team D and is only applicable for installation of steel structure pipe racks Since the project consists of 24 pipe racks which is 1 3 KM long and 3800 tons Width of pipe racks are 2m 3m 3 5m 4m 6m 7m and 8m highest part of pipe rack is 22 1 meter high Structure type is simple and the installation method is the same with other areas Here we will take the most difficult pipe rack 21a as an example to compile construction method Other pipe racks R20a R20b R20c R20d R20e 21a R22a R22b R22c R23 R24a R24b R25a R25b R25c R26 R33a R33b R33c R34 R36 share the same method 1 2 编制依据编制依据Reference 1 2 1 本工程招标文件 The bid document for the project 1 2 2 道康宁公司相关技术标准 规范及管理程序 The Dow Corning s relevant technique standard the specification and management program 1 2 3 东洋工程公司相关管理程序 技术标准 Toyo Engineering Corporation s relevant management program and technique specification 1 2 4 江苏省及张家港地区现行的相关地方标准 规范 The relevant location standard and specification which belongs to Jiangsu province and Zhangjiagang area 1 2 5 宝冶建设有限公司相关管理程序及企业标准 Baoye Construction Corp Ltd s management program and standard 1 2 6 国家现行的相关标准及规范 部分摘录如下 Relevant GB codes and specifications as following 建筑工程设计文件编制深度规定 2003 版 Construction engineering design document 2003 建筑结构可靠度设计统一标准 GB 50068 2001 Construction structure standard GB 50068 2001 建筑结构荷载规范 GB 50009 2001 Construction structure load specification GB 50009 2001 钢结构设计规范 GB50017 2003 Steel Structure Designing Specification GB50017 2003 钢结构防火涂料应用技术规程 CECS 24 90 Steel structure fire retardant coating application technology point of order CECS 24 90 碳素结构钢 GB T 700 88 Carbon Structural Steel GB T 700 88 大六角头螺母 垫圈等技术条件 The large hexagonal nut washer and other technical conditions 钢结构工程施工质量验收规范 GB 50205 2001 Steel Structure Project Construction Acceptance Specification GB50205 2001 建筑钢结构焊接技术规程 JGJ81 2002 Architectural Steel Structure Welding Technology Specification JGJ81 2002 钢结构高强度螺栓连接的设计 施工及验收规范 JGJ 82 91 Steel Structure High Strength Bolt Designing Construction and Acceptance Specification JGJ82 1991 石油化工企业设计防火规范 GB 50160 92 1999 年版 Petrochemical companies code for fire protection design GB 50160 92 1999 建筑施工扣件式钢管脚安全技术规程 GBJ130 2001 Technical code for safety of steel tubular scaffold with couplers in construction GBJ130 2001 二 工程概况二 工程概况 General Info 21a 全长 94 8 米 轴线到轴线 宽度 7 米 轴线到轴线 高度 20 米 最大跨距 15 米 最小跨距 3 8 米 共 11 条轴线 总重量约 600 吨 东侧与一期老管架相连 西侧与中核二 三承建的管架相连 北侧为中建二局在建项目 南侧为张家港路 道路条件良好 但施工 区域内拼装作业面狭小 且紧挨 21a 管架南侧有水沟在施工中 对拼装吊装 吊机站位带 来了诸多的不便 21a is 94 8 meters long axis to axis 7 meters wide 20 meters high and with 11 axes and about 600 tons steel structure The span ranges from 3 8 meters to 15 meters The east part of 21a connects with Phase 1 pipe racks and west part connects with pipe racks which are under consideration North side of 21a has other projects and south side is Zhangjiagang Road This road is in good condition but there is a trench under construction near it All these factors caused lots of inconvenience for installation and the setting of cranes 三 人员 机具安排三 人员 机具安排 Mobilization of Equipments and Manpower 3 1 项目组织机构图项目组织机构图 Site Organization Structure Chart TJU Site manager wang Quan 3 2 作业人员配备情况一览表作业人员配备情况一览表 labor configuration table 序号 No 工种 Position数量 Num 备注 Remark 1 起重指挥 Erection singleman 4 人 2安装工 erector40 人 3 吊机操作工 crane operator 4 人 4油漆工 painter4 人 5电工 electrician1 人 6电焊工 arc welder2 人 7测量工 surveyor2 人 8架子工 scaffolder20 人 3 3 机具配备情况一览表机具配备情况一览表 equipment configuration schedule 序号 No 名称 Title 规格 specification 数量 Qty 备注 Remark 1汽车吊 truck crane25 T3 台 2汽车吊 truck crane50 T1 台 3汽车吊 truck crane120 T1 台 4拖车 trailer1 台 5 水准仪 water level gauge 1 台 6经纬仪 theodolite2 台 7 电焊机 electric welding machine 2 台 8手拉葫芦 chain block5 T10 9手拉葫芦2 T30 10扭力扳手 torque wrench60 300N m2 把 11扭力扳手 torque wrench 200 1000N m 2 把 12千斤顶 jack5 T10 四 施工方案四 施工方案 Construction Plan 4 1 安装总体思路安装总体思路 General Idea of the Construction Job 根据该工程管架的特点 单件重量较轻 散架较多 结构形式相似 工作面分散 单 件吊装对整个工程进度影响较大 为提高工效 保证进度 我们确定以下安装总体思路 1 地面散件拼装 整体吊装 2 多点作业 流水施工 3 主结构先行 次结构随后 Since there are lots of single structures which are light in weight so it would be inefficient to install them at height Also the safety measures required for work at height would be unfavorable to the schedule So these PR will be assembled on ground and then erected as a group structure This can decrease the workload at height Scaffold platform and access with lifeline can ensure the safety of construction General idea is 1 assembling on ground erect as group structure 2 work at multi spot 3 first main structure then auxiliary structure 21a 管架效果图 4 2 工艺流程图工艺流程图 Work Flow 4 3 施工准备施工准备 准备工作包括基础的验收与检查 拼装胎架的制作检验 构件材料 吊装机械 运输 机械 小型工机具的进场检验等工作 Preparation work includes inspection and check of base set up of site assembling platform entering and inspection of members lifting appliance transportation machinery and small equipments and machinery Explained as below 基础验收 检查复核上道工序提交的相关资料 复核基础的轴线 标高 地脚螺栓的 偏移量是否合格 合格后方可交接进行钢结构的安装 对于不合格的依业主及管理公司 NCR 程序上报 并全力配合研究处理方案 直至合格 Inspection of base check the relevant documents of preceding process recheck the offset of axis elevation and anchor bolt Only these items are accepted can the installation be commenced for unqualified items process NCR as per requirement of DC and TOYO Coordinate with them to bring out treatment 基础表面处理要求 清除基础表层浮浆并凿毛 设置好柱脚垫板 此部分在垫板及二 次灌浆施工艺中加以详述 Requirement of base surface treatment remove laitance and set anchor bolt correctly 胎架的制作 胎架主要是用于门形钢架及桁架结构拼装工作 由于现场场地条件较好 用枕木根据拼装结构的尺寸 重量 施工的需要等要求摆放在地面上 抄平 找正即可 Making of assembly jig assembly jig will be used up assembling of portal frame and truss Choice on sleeper will be decided by size weight of members and the need of construction Sleeper will be set on ground and evened and aligned 机械 机具 设备进场 本项目主要使用的机具有 25 吨汽车吊 三台 50 120 吨汽 车吊 各 1 台 根据现现场进度情况穿插安排 及各种测量仪器 进场前向业主及管理公 司提交有效的合格证及检测鉴定报告等资料 经确认后 方可使用 Entering of Machinery Equipment 25T truck crane 3 a 50T truck crane and a 120T truck crane and all kinds of measuring apparatus Report to Client and TOYO with QC Certificate and inspection report Only use them when accepted 构件 材料进场 所有构件在领用前 必须进行构件质量检查 构件外观 质量证明 文件等 并对所有进场构件做好记录 Entering of member and materials all members appearance QC certificates etc should get inspected before putting into use Record for all members should be kept 构件进场检查项目包括外观质量 构件外形尺寸等 构件表面不应有疤痕 泥沙等污垢 中线线 标高线 构件编号标志齐全 明确 The surface of members should not have the scale and dirt It should be marked the centerline elevation and the number of marker 外形尺寸检查允许偏差 Inspection for the permissible deviation of shape size 柱外形尺寸允许偏差表 Permissible deviation of column shape size 项目 item 允许偏差 permissible deviation 检查方法或工具 Inspection method or equipment 备注 remark 柱高 the height of column 3 0 钢尺检查 the inspected by steel rule 柱脚螺栓孔中心对柱子 轴线的距离 the distance for axis 2 0 钢尺检查 Inspected by steel rule 柱截面尺寸 the column section size 4 0 钢尺检查 inspected by steel rule 柱身扭曲 the warping for column s body 5 0 钢尺检查 inspected by steel rule 翼缘板对腹板的垂直度 The perpendicular for flange plate to web plate b 100 且不应大于 5 0 b 100 it is not more than5 0 钢尺检查 inspected by for steel rule b 为翼缘板宽 度 b means the width of flange plate 柱身弯曲矢高 The column s bending vector height H 1500 且不应大于 5 0 H 1500 it is not more than 5 0 钢尺和拉线检查 Inspected by steel rule and pull line H 为柱高 H means the height of column 钢梁外形尺寸允许偏差表 the permissible deviation of beam shape size 项目 item 允许偏差 permissible deviation 检查方法或工具 Inspected by method or equipment 备注 remark 梁长度 height of beam l 2500 10 0 钢尺检查 inspected by for steel rule l 为梁长度 l means the height of beam 侧弯矢高 side bend the vector height l 2000 且不应大于 10 l 2000 it is not more than 10mm 钢尺 拉线检查 Steel rule and pull line l 为梁长度 l means the height of beam 扭曲 warping h 250 且不应大于 10 h 250 it is not more than 10mm 钢尺检查 inspected by steel rule 腹板局部平面度 the flatness for the part of web plate 5 0 1m 直尺及塞尺检查 Inspected by 1m straight scale and feeler 翼缘板对腹板的垂直度 The perpendicular for the flange plate to web plate b 100 且不应大于 3 0 b 100 it is not more than 3 0 钢尺检查 成品保护 finished product protection 大量的施工物资 构件进场后 由材料经理负责管理 并做好详细出入库登记 构件 卸车 倒运过程中 必须做好相应的保护措施 构件与构件 构件与车厢不得直接接触 必须用枕木分隔开来 同时在吊运时 对吊点部位必须用胶皮包扎 以免破坏油漆涂层 在堆场堆放时必须在构件下方均匀设置枕木 构件的堆放层数不得超过三层 枕木的摆放 位置必须每层相同 以免构件受力不均而变形 When construction materials components entered the site special materials manager should be designated and entering records should be recorded For components that cannot be lifted at the time move them into the stacking yard Unload component appropriately with protective measures so that components and component elements would not contact directly with the carriage During the process of lifting connecting parts should be protected with rubber dressing to avoid damage of paint coating Effective measures should be taken to prevent deformation of components in the stack yard Under normal circumstances choose smooth venue for stacking to avoid deformation Set sleepers under the bottom of the components Components should not be stored for more than three layers Sleepers should be positioned at the same on each floor to avoid deformation 4 4 钢结构拼装钢结构拼装 S S assembling 4 4 1 门形钢架的组装 assembling of portal frame 门形钢架拼装主要是将钢柱与纵向主梁在地面胎架组装成一个整体单元 在地面胎架 上完成节点螺栓的紧固后整体吊装 我们拟采用 25 吨汽车吊进行门形钢架的组装 Steel columns and longitudinal girders will be assembled into a group unit on ground Tightening of bolts will be done on ground Then the group unit will be erected 25T truck crane will be used for assembling 门形钢架拼装如图所示 assembling of portal frame shown as below 门型钢架组装工艺流程 assembling work flow of portal frame 门形钢架拼装步骤assembling procedure of portal frame 钢柱组装 胎架组装完成之后 进行上下两节钢柱的组装工作 如下图所示 After complete assembly jib to assembling high and low two steel column as follows 在钢柱组装时 必须保证总体尺寸的偏差在规范要求之内 待组装完成后 检查组装 尺寸 合格后方可进行梁 撑的组装 When assembling steel column to make sure the overall size in the deviation of specification In order to assembling beam and bracing After complete assembly steel column check the assembly size assembling beam and bracing when it is qualified 梁 支撑组装 梁的安装按先两端后中间的组装程序进行 组装完成后 检查总体尺 寸 然后进行中间梁的组装 最后进行支撑的组装 如下图所示 Assembling beam and bracing before assembling beam and bracing plinth After complete assembly check the total size to make sure the total size according with specification and then assembling intermediate beam Finally assembling bracing 梁 两端 组装图 梁 中间 组装图 支撑组装图 螺栓紧固 油漆修补 螺栓的紧固在结构组装 校正完成且尺寸检查符合规范要求后 进行 具体工艺要求详见高强螺栓施工工艺 油漆修补工作在整个拼装过程中穿插进行 油补工艺详见油漆涂装方案 Fastening bolts paint repair the fastening bolts after the structure assembly correction and according with specification specific technical requirements detailed in the construction technology of high strength bolts paint repair work with the fastening bolt at the same time the specific oil premium paint coating process as detailed in the method statement 拼装用吊机选型及工况分析 Assembled by crane Selection and analysis of working conditions 门型钢架单件最重构件为 3 98 吨 钢架拼装时 选用 25 吨汽车吊 工作半径为 10 米 起重量 5 8 吨 工况图如下 The Structure of portal frame portal frame heaviest component is only 3 98 tons the steel frame assembly the selection of 25 tons of car to hoist working radius of 10 meters from the weight of 5 8 tons the status of plans as follows QY25 张 家 港 路 A B 25 吨汽车吊性能表 performance chart of 25T crane 21a 管架共计 11 榀 高度 20 米 为了节省场地 在钢架拼装时 采用两层拼装 即 第一榀钢架拼装完成后 现在其上面错开摆放拼装第二榀钢架 需要注意的时 先行吊装 的桁架必须摆在上方 即后进行拼装 以免二次倒运 21a pipe rack has 11 sets which are up to 20 meters high Assembling will be performed into two layers When first layer is assembled second layer will be put onto first layer so as to save space Truss that would be lifted first should be on the top layer so as to avoid repeated transportation 4 4 2 桁架拼装 assembling of truss 根据管架结构形式桁架主要分为以下几种拼装形式 井型桁架 多层桁架 散件组装 According to type of pipe racks truss is divided into several types well shape truss multilayer truss and assembling of spare members 4 4 2 1 井型桁架拼装 assembling of well shape truss 井型桁架拼装主要是将桁架梁与纵向主梁在地面胎架组装成井型结构 高强螺丝紧固 后整体吊装 桁架分布于 2 3 轴 4 5 轴 8 9 轴 10 11 轴 123 5 126 米标高部位 组装 完成后如下图所示 Well shape truss assembling is to assembly truss beam and longitudinal beam into well shape structure on assembling jig The structure will be erected when HSB is tightened and accepted These structures are disturbed at 2 3 axis 4 5 axis 8 9 axis 10 11 axis with elevation of 123 5 126 Assembled structure is shownas below 4 4 2 1 1 井架拼装工艺流程图 well shape truss assembling procedure 4 4 2 1 2 拼装工艺图示 assembling technique 井型桁架组装方法步骤如下 assembling procedure 底层主梁组装图 Bottom layer main beam installation and assembled picture 底层次梁组装图 Bottom layer sub beam installation and assembled picture 小立柱 立面撑组装图 Small column and brace assembled picture 上层主梁组装图 Upper layer main beam assembled picture 上层次梁组装图 Upper layer sub beam assembled picture 4 4 2 1 3 吊机选型及工况分析 choice on crane 桁架单件最重构件为 1 33 吨 拼装主要选用 25 吨汽车吊 工作半径最大为 10 米 起 重量 5 8 吨 如下图所示 Heaviest beam in 21a area is 1 33 ton 25T truck crane will be used for assembly of truss Maximum working radius is 10 meters Lifting capacity is 5 8 ton see illustration bellow A B QY25 张家港路 25 吨汽车吊性能表 performance chart of 25T crane 4 4 2 2 多层桁架拼装 assembling of multilayer truss 多层桁架以下分为两种结构形式 形式一 井型桁架与 H 型立柱组合成整体结构进行吊装 主要分布于 2 3 轴 4 5 轴 8 9 轴 10 11 轴 113 119 米标高 不包括 119 米标高的梁 组装完成后如下图所示 There are two types of multilayer truss First kind of multilayer truss multilayer truss one is formed by well shape truss and H shape column This kind of structures are disturbed 2 3 axis 4 5 axis 8 9 axis 10 11 axis with elevation of 113 119 meters beam of 119 meters excluded Assembled structure is shown as below 形式二 单层平面桁架与 H 型立柱组合成整体结构进行吊装 主要分布于 2 3 轴 4 5 轴 8 9 轴 10 11 轴 119 123 5 米标高 不包括 123 5 米标高的梁 组合完成后结构 如下图所示 Second kind of multilayer truss multilayer truss two is formed by sing layer truss and H shape column This kind of structures are disturbed 2 3 axis 4 5 axis 8 9 axis 10 11 axis with elevation of 119 123 5 meters beam of 123 5 meters excluded Assembled structure is shown as below 组合桁架拼装工艺 同井型桁架拼装工艺 Assembling procedure is the same as well shape truss assembling 组合桁架的拼装也选用 25 吨汽车吊进行 工况同井型桁架拼装时工况条件 25T truck crane will be used during multilayer truss assembling 4 5 结构吊装结构吊装 erection of structure 4 5 1 门形钢架的吊装 erection of portal frame 4 5 1 1 门形钢架吊装工况分析 work analysis 该区域门形钢架共计 11 片 钢架几何尺寸为 7m 20m 最重钢架单件为 21 447 吨 最轻钢架单件为 15 020 吨 根据钢架特点吊装方法主要双机递送抬吊法进行钢架的吊装 主吊机选用 120 吨 一台 汽车吊 副吊机选用 50 吨 一台 汽车吊 以下我们选取 21a 8 轴钢架 钢架 21 447 吨 为例进行吊装工况分析 This area has 11 portal frames wit dimension of 7m 20m The heaviest member is 21 447 ton while the lightest one is 15 020 ton 120T truck crane and 50T truck crane will be used 21a axis 8 portal frame 21 447 ton will be exmplified as below 1 吊机站位 作业半径 详见下图 setting of crane and working radius QY50 张 家 港 路 LTM1120 8 轴门形钢架吊装工况图 2 吊机工况表 performance chart of crane 120 吨汽车吊 120T truck crane 作业半径 working radius 臂长 jib length 额定起重量 rated lifting capacity 起重高度 lifting height 80 起重量 80 of rated lifting capacity 11m27 8m27 2 吨24m21 76 吨 50 吨汽车吊 50T truck crane 作业半径 working radius 臂长 jib length 额定起重量 rated lifting capacity 起重高度 lifting height 80 起重量 80 of rated lifting capacity 10m15 4m12 2 吨9m9 76 吨 3 双机抬吊计算 double cranes erection calculation 吊点设置 setting of lifting point 50 吨吊机吊点设置在两柱脚部位 120 吨吊机吊点设置在高柱高方向 15 米部位 具体 如下图所示 lifting point of 50T crane will be set at two bottoms of column while for 150T crane about 15 meter high position of column See illustration below 吨吊机吊点 吨吊机吊点 吊机起重力分配计算 calculation of crane lifting capacity P1P2 G 双机抬吊负荷计算图 主要吊机荷载分配 main crane load distribution 已知钢架重力 G 214 47kN 主吊机此种工况条件下最大起重力为 272kN 按允许荷载 为吊机起重力 80 计算 P 272 80 217 6kN 大于钢架重力 即主吊机满足钢架吊装的 要求 Gravity of portal frame G 214 47kN maximum load capacity of main crane