12月1日 Team A 安装方案(终稿)

目录Contents

第一节编制依据Reference (4)

第二节工程概况General Information of the Project (5)

2．1概况 Condition (5)

2．2现场情况Site Condition (6)

2．3工程特点 Characteristic of Project (7)

第三节劳力及机具资源配置情况State of resource layout for labor and equipment (8)

3．1 劳动力资源配置表labor configuration table (8)

3．2机具配备动态计划表equipment configuration state schedule (9)

第四节钢结构安装工艺Steel Structure Installation Techeniques (10)

4．1安装思路 (10)

4．2钢结构安装工艺流程Installation Workflow in Steel Structure (10)

4．3 PART-A&C吊装顺序及工况分析Arrangement to PART-A&C Crane and Walking Way；

(29)

4．4吊机性能表 (30)

4．5吊机行走路线图 (33)

4．6 PART-A&C 钢柱吊装立面及平面图；The fa?ade and plan for lifting of column (35)

4．7 PART-A&C 最重的钢梁吊示意图；The schematic plan for lifting of the heaviest beam (35)

4．8 139.8米标高梁吊装立面图；The fa?ade for the beam which elevation is 139.8m (35)

第五节垫板及二次灌浆施工艺The shim plate and construction process for concrete and the second time grouting ..

(39)

5．1垫板工艺要求 the requirement for the shim plate process (39)

5．2二次灌浆施工艺 construction process the second time grouting (40)

5．3养护Maintains (41)

第六节高强螺栓施工工艺High Strengthen Bolt W orking

Process (41)

6．1 一般规定 General requirement (41)

6．2安装前的检查工作inspection working before installation (43)

6．3质量标准 Quality standard (51)

6．4应注意的质量问题 Quality issues with attention required (53)

6．5质量记录 Quality record (54)

第七节焊接施工工艺Welding Techniques (54)

7．1准备工作 Preparation Work (55)

7．2焊接工艺 Welding Techniques (55)

7．3焊接工作质量控制 Welding Quality Control (57)

第八节油漆涂装施工工艺Painting work construction job .57

8.1涂装工艺Painting Technique (57)

8．1．1工艺流程图Process Flow Diagram (PFD) (57)

8．1．2涂装工艺Painting Technique ......................错误！未定义书签。

8．1．3构件表面处理Member Surface Treatment ............错误！未定义书签。

8．1．4油漆修补涂装Repairing Paint .....................错误！未定义书签。

8．2质量控制和质量保证措施Quality Measures .............错误！未定义书签。

8．3安保措施 HSE Measures ..............................错误！未定义书签。

第九节测量方案 (66)

9.1准备工作Preparation Work (66)

axes setting-out (67)

9.2平面控制网的建立 Set-up of horizontal control network (69)

9．3高程控制网的建立 (71)

9．4钢柱控制测量 control measure of column (72)

9．5沉降观察测量Measurement to Settlement (74)

9．6测量精度保证措施Main Measurement to ensure the precision of the Measurement (76)

9．7工程测量记录The Record in the Construction Measurement (76)

第十节质量技术措施Quality Measures (77)

10．1工程施工质量目标Project Construction Quality Target (77)

10．2工程施工质量控制总体思路Guideline of project construction quality control (77)

第十一节安全技术措施Safety measures (80)

11.1安全操作平台 Safety Operation Platform (80)

11.2爬梯 ladders (81)

11.3生命绳 life line (84)

第十二节安全管理措施Safety Management Measures (87)

12.1作业人员的管理 Management of Operation Personnel (87)

12.2机具管理 Management of Machinery and Tools (87)

12.3临时用电的管理 Management of Temporary Electricity Supply (87)

12.4脚手架的管理 Management of Scaffold (88)

12.5进场道路的管理 Management of Entering Road (88)

12.6劳防用品的管理 Management of PPE (88)

12.7风险预知管理Risk Prediction Management (88)

第一节编制依据 Reference

1．1本工程招标文件；

The bid document for the project

1．2道康宁公司相关技术标准、规范及管理程序；

The Dow Corning’s relevant technical standard, the specification and

management program.

1．3东洋工程公司相关管理程序、技术标准；

Toyo Engineering Corporation’s relevant management program and technical

specification.

1．4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.

1．5.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

1．6相关标准及规范，部分摘录如下：

The country’s relevant standard and the specification, as following: 《张家港油漆涂装标准》 09.061.000；

《Zhangjiagang standard for painting and protective coatings》09.061.000；

《建筑工程设计文件编深度规定》2003版；

《Construction engineering design document》-2003

《建筑结构可靠度设计统一标准》GB 50068-2001；

《Construction struction standard》-GB 50068-2001;

《建筑结构荷载规范》GB 50009-2001；

《Construction struction load specification》-GB 50009-2001;

《钢结构设计规范》GB50017-2003

《Steel Structure Designing Specification 》GB50017-2003

《建筑抗震设计规范》GB 50011-2001

《Impermeability of construction design specifications》GB 50011-2001

《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

《钢结构用高强度扭剪型大六角头螺栓》 GB 1228~1231-91

《High-strength steel structure with twisting hexagonal Shear big-head bolt》GB 1228~1231-91

《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 Specifications》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) 《工程测量规范》GB50026-2007

Construction Survey Specification, GB50026-2007

第二节工程概况General Information of the Project

2．1概况 Condition

工程名称：道康宁（张家港）有限公司19万吨/年有机硅聚硅氧烷项目（二期）工程

Project Name: Dow Corning 190kt/a Siloxane Project in Zhangjiagang

(Phase 2)

建设单位：道康宁（张家港）有限公司

Owner: Dow Corning (Zhangjiagang) Corp. Ltd.

管理单位：东洋管理公司

Management Company: AKER KVAERNER and TOYO ENGINEERING Corporation

设计单位：天津市化工设计院

Designer: China Tianjin Chemical Engineering Design Institute

监理单位：上海协同工程造价监理咨询有限公司

Supervising Company: Shanghai TJU Engineer Service Co., Ltd

施工单位：上海宝冶建设有限公司

Contractor: Shanghai Baoye Construction Corp. Ltd.

道康宁（张家港）有机硅有限公司为美国道康宁在中国境内的全资子公司，位于江苏省张家港保税区附属区扬子江国际化学工业园内。

Dow Corning (Zhang jia gang) organic silicon company is another sub-company which is invested by Dow Corning Corp. in China. The company stays in the Yangzi Chemical Industrial Park of Zhang jail gang free-duty area.

本工程是道康宁（张家港）有限公司19万吨/年有机硅聚硅氧烷项目二期工程的一部分，主要Team A 区 Part A&C钢结构设备支架的安装工作。

This project is part of Dow Corning 190kt/a Siloxane Project in Zhangjiagang (Phase 2), which mainly includes the installation of steel structure of part A&C in Team A area.

Team A部分钢结构主要分成Part A、Part B、Part C三部分。我公司承接的是Part A&C 部分钢结构的安装，约850吨。本工程钢材主要采用H型钢和少量的角钢、槽钢，连接上主要采用高强螺栓现场连接，支架上铺设钢格栅。柱底标高+106.500，钢框架最高点标高+139.800，结构最高达33.3米，10层。单重较大的构件集中在Part A区域。

There are four parts in Team A: Part A, Part B, Part C and A45. The elevation of the column in Team A is +106.500 and the elevation of the highest point of the steel frame is +139.800. The highest point is 33.3m to the ground and there are total 10 layers. The big single part is mainly in Part A area. There is about 800 ton for Part A&C.

2．2现场情况Site Condition

本工程张家港保税区附属区扬子江国际化学工业园内，现场一期工程已投入使用，二期

工程延一期继续建设，多家单位同时施工，施工期间现场协调工作量大。

The project locates in the Yangzijiang International Chemical Industrial Park of Zhangjiagang Free-duty Area and No.1 project has been put into use. The No.2 project will continue the construction. The land is vast and traffic condition is good. The management is strict and there are many zones in this project. Many corporations will cooperate with each other in the work.

2．3工程特点 Characteristic of Project

2．3．1布局紧凑，空间狭小 compact layout, narrowness space

本工程东面及南面已有在建工程正在施工，西侧和北侧各有一条道路，但北侧的道路由于有下水井等构筑物暂无法通行。仅有西侧的道路（13号路）可以短期利用（当750吨吊机进场时必须让开）；构件运输、吊机进场都只能从西侧的道路进场；另外，大型构件构件吊装时，50吨履带吊施工作业主要依靠西侧（13号路）道路，同时道路的两旁还得留出一定的空间用于脚手架、构件堆放及临时工具房的摆放。

The east side and south side of the project is construction. There have the road on Westside and north side, but the north side road should not pass through, only west side road can use (when the 750 tons crane entry the site, it should leave),the members transportation and lifting machine entry can pass through the west side road to arrive on site; in addition, lifting for bigger members,50 tons caterpillar track only work in west side road(No.13 road),at the same time, it should be remain the space to use the scaffold ,lay-aside members and temporary tools room. 2．3．2高空作业量大，安全管理任务重

The height working is too large; the task for management is too heavy 本工程为设备支架的吊装工程，单根构件重量都较小（最小的水平支撑只有几十公斤），但但结构形式错纵复杂，无法拼装成片整体吊装，必须单根吊装，施工作业面多为高空作业（最低的一层平台只有3米多高），安全管理任务重。

The project is the lifting for instrument holder engineering, the single member’s weight is too light (the smallest HV is tens of kilogram).because the structure is complicated, it is impossible to consolidator the whole body to lifting,

it must lift for the single member, there are much height work (the lowest floor height has 3m), the task for management is too heavy.

2．3．3精度要求高，技术难度大

The high requirement for precision, the technical is difficulty

本工程所有构件的联结全部为高强螺栓，而且结构高度较大（最高部位达33米），层次

较多（平台多达10层），因此，构件安装的精度要求很高，结构安装技术难度较大。

The member should be connect with the HSB, the structure height is too high (the maximum height has 33m), and too many levels (it has 10 levels), so the high requirement for precision, the technical is difficulty

第三节劳力及机具资源配置情况State of resource layout for labor and equipment

3．1 劳动力资源配置表labor configuration table

3．2机具配备动态计划表equipment configuration state schedule

第四节钢结构安装工艺 Steel Structure

Installation Techeniques

4．1安装思路

将Part A和Part C作为一个施工区域，安装时共分为三个批次，第一个批次这第一节柱子及112.275m（含）标高以下的梁、支撑构件；吊机采用25吨汽车吊，安装的方向从北向（即从K轴向A轴方向），1~3轴同时吊装。第二批为D～K轴第二节柱及112.275m标高到127.275m标高的梁、支撑等构件，吊机采用50吨履带吊。剩余部分为第三批，吊机采用50吨履带吊。

Part A and Part C will be treated as one construction area and the installation will be divided into three batches. First batch: section one pillars and beams & support members with elevation fewer than 112.275m will be installed by 25-ton truck crane. Second batch: D～K axes section two pillars and beams & support members with elevation from 112.275m to 127.275m will be installed by 50-ton caterpillar crane. The rest part, which is the third batch, will be done by 50-ton caterpillar crane..

4．2钢结构安装工艺流程Installation Workflow in Steel Structure

结构安装艺总体上是先完成柱的安装，再进行梁、支撑的安装。为了安全起见，当天安装完成的结构件应当形成稳定的结构体系，否则需要采取适当的加固措施。

The installation procedure is: install columns first, and then install beams and bracing. For safety reasons, members installed should form as a steady structure system; otherwise, reinforcing measures should be done.

安装工艺流程图如下：

Process flowsheet as follows:

4．2．1准备工作 Preparation Work

钢结构吊装的准备工作主要是基础、构件、机具的验收及进场。

Preparation work for steel structure installation includes: the inspection and entering of foundation, members and machinery.

4．2．1．1基础验收：基础验收主要是验收基础的标高、轴线、地脚螺栓是否符合规范及设计要求；

Inspection of foundation: the inspection mainly includes: check whether the elevation, axis, and foot-bolts meet design requirement and specification. 4．2．1．2构件、机具的进场包括进场道路的规划、检查、验收、构件的堆放等工作。

The entering of members and machinery includes: the planned road for entering, inspection, accept and storage of members, etc.

4．2．1．2．1构件机具进场道路规划：A区Part A&C位于13号路东侧，根据现场勘察情

况来看，构件进场只能从西2号路、张家港路、15号路、到13号路。如下构件进场路线图：Plan for transportation of members: Part A & C locates at the east side of Road 13. According to the conditions at site, members can use West 2rd Road, Zhangjiagang Road and 15th Road to reach Road 13. See the roadmap bellow.

Page 14 of 88

构件、机具进场路线图

4．2．1．2．2大量的构件存放于东洋公司仓库，现场需要安装的构件提前三天左右的时间从东洋仓库倒运到安装现场。因此，构件到现场有一定的存放期，在此期间，需要对构件的中心、标高标记在构件上，同时还需要对构件进行质量检查。因此，构件的堆放一定要考虑到构件检查工作及标记工作的空间，同时还得考虑到卸货车辆的进出道路和卸车吊机的行走路线。构件在堆放时必须用枕木垫起，堆放的顺序及层次必须与吊装的先后顺序相符合。

Lots of members will be stored in the warehouse of TOYO. Members needed for installation should be removed from warehouse to site 3 days in advance. During the period of storage at site, mark the center and elevation on the members and inspect the quality. So the space for marking and inspection should be considered beforehand. Also the road for trucks and cranes should be considered. Sleepers should be put under the members when stacking. The sequence of stacking should meet the sequence of installing.

4．2．1．2．3构件进场质量的检查主要是检查质量证明文件是否齐全，构件尺寸（详见如下构件外形尺寸偏差表）是否符合规范及图纸要求；主要检查构件外形尺寸,螺孔大小和间距等,并做好检查记录。制作超过规范误差和运输中变形的构件必须在安装前在地面修复完毕，减少高空作业。机具的进场验收主要是检查合格证、鉴定证书是否在有效期限内，同时检查机具本身是在性能及安全方面是否满足吊装工作的正常使用。

The inspection of members when entering the site mainly includes: whether the documents are complete, whether the size meets the drawing and the specifications. The inspection of members mainly includes: whether the quality certificates are still valid, and whether the performance and safety capacity are competent for the installation.

柱外形尺寸允许偏差表

the permissible deviation of column shape size

钢梁外形尺寸允许偏差表

the permissible deviation of beam shape size

4．2．2柱的吊装Lifting of column

4．2．2．1 准备工作preparation work

4．2．2．1．1 基础上弹出建筑物的纵、横定位轴线（一般在基础侧面用红油漆作好标记）和钢架的吊装准线，作为钢柱对位、校正的依据。

By the longitude and altitude axis which is projected by the building and the lifting axis of the steel frame, the steel column will be adjusted. 4．2．2．1．2检查基础螺栓位置、标高、剪力槽尺寸及位置。

Inspect the position, elevation and the size of shear slot

The position, elevation and length of the hold down bolt will be adjusted and checked.

基础螺栓位置偏差为2㎜，螺栓露出长度偏差为

030

+

㎜。

The position deviation of foundation bolt is 2mm.the length deviation of revealed

bolt is

030

+

㎜

依设计要求，剪力槽尺寸比柱子剪力榫尺寸大20㎜，底标高比剪力榫低20㎜，一般情况下，尺寸只能大不能小，底标高不能高只能低。

According to the design specification, the size of shear slot should be 20mm bigger than that of shear tenon. The bottom elevation of shear slot should be 20mm lower than that of shear tenon. Under most circumstances, the size and elevation of shear slot can only be bigger or lower than that of shear tenon. 4．2．2．1．3 调整、清洗地脚锚栓。

The anchor bolt will be adjusted and washed.

清除螺栓上的污染物，所有螺栓螺母重新扭动一遍，检查螺栓是否全部合格，镀锌层是否完好等。

Removed the contaminator in bolt, inspect tighten the bolt and nut, inspect whether bolts are qualified and the zinc coat are in good condition. 4．2．2．1．4 基础凿毛，清除表面浮层。

The ground will be made to be flat.

4．2．2．1．5基础面中心标记鲜明（一般用经油漆对标高、轴线做鲜明标记）。

The remark on the foundation center will be clear. (using paint to mark the elevation and axis)

4．2．2．1．6垫板准备充足。

Enough washers will be prepared.

根据现场实际情况，我们每支柱子设置4组钢垫板。规格全为120*100，厚度分为20、16、10、5、2多种，具体数量根据现场安装情况边安装边加工。

It based on the actual state, it should set four groups shim plate per column. The specification is 120*100,the thickness is 20、16、10、5、2 and kinds. It should accord with the erection situation to ensure the quantity.

4．2．2．1．7钢柱四面中心及标高标记鲜明（亦用红油漆作标记）。

Center and elevation on each side of the column will be clearly marked. (Using the red paint to mark)

4．2．2．2钢柱的吊装Lifing of steel column

4．2．2．2．1吊点、吊索的选择choose on lifting lug and lif appliance 根据钢柱的形状、长度、质量、起吊方法及吊机性能等因素，设置、确定钢柱吊点，采用安全吊带或钢丝绳绑扎，同时采用相应措施（橡皮、软布等）对绑扎点油漆进行保护。

The lifting point will be set according to the column’s shape, length, quality, method of lifting, performance of the crane. Workers will use safety harness or steel rope to band the steel column. Meanwhile, other material such as rubber or cloth will be used to protect the painting system.

为确保柱子的正确就位（必须保正柱子吊装时接近垂直状态），必须合理选择正确的吊点或采取合理的铺助措施。根据本工程实际情况，对本项目柱吊装是吊点的设置及摘钩方法分以下几种情况作详细说明。

4．2．2．2．1．1对于对接部位没有牛腿的柱子，吊装时宜采用两吊耳夹住柱子的腹板，并用螺栓与柱子腹板连接牢固，以吊耳为吊点，吊耳示意图如下：

To ensure that the correct place to facilitate post (ensure to be close to the vertical post when hoisting the state) must be reasonable to choose the right hanging points, or shop to help take reasonable measures to ensure the normal post in place.

The docking site has not corbel-piece, should be Hoisting am hanging ear caught a two pillars of the web and web columns and bolts used to connect firmly to ear suspended for hanging, hanging ear node diagram is as follows:

吊

4

吊耳的

to column

one

calculation

in Lifting

3.4.1-1，

㎜2

=2280㎜2；

吨，两个吊

耳承载力总计为:49.02*2=98.04吨。

As showed above, the narrowest part of lifting lug is 190mm and cross section is :190㎜*12㎜=2280㎜2；bearing capacity of single lifting lug is ：215 N/㎜2*190㎜*12㎜=490200N, which is 49.02 ton. The bearing capacity of two lifting lugs amounts to: 49.02*2=98.04 ton.

4．2．2．2．1．1．2螺栓承载力计算：Bearing capacity of bolt

螺栓选用6颗4.8级M20普通螺栓，长度根据每根柱的腹板厚度灵活选用；

查钢结构设计规范GB50017-2003中表 3.4.1-4，得 4.8级普通螺栓抗剪强度设计值140N/㎜2；

故6颗4.8级M20的普通螺栓承载力为:

140 N/㎜2*3.14*(10㎜)2*0.5*6=131880N，相当于13.188吨。

This project use six class 4.8 M20 plain bolt according to the web plate thickness of each pillar;

According table 3.4.1-4 in Steel Structure Design Specifications GB50017-2003, shear strength of class 4.8 plain bolt is 140N/㎜2；

Bearing capacity of six-class 4.8 M20 plain bolt is:

140 N/㎜2*3.14*(10㎜)2*0.5*6=131880N，amounts to 13.188 ton. 4．2．2．2．1．1．3验算结果Test results

吊耳和螺栓两者中承载力应当取小者，故此吊耳最大承载力为13.188吨。

Team A区最重的柱子不超过5吨，以5吨计算，取1.4动载系数，即5*1.4=9吨，远小于13.188吨，满足吊装需要。

Minor bearing capacity of lifting lug and bolt decides the test result, so the maximum bearing capacity of this lifting lug is 13.188 ton.

The heaviest pillar should not exceed 5 ton. The dynamic load factor is 1.4, so the result is 5*1.4=9 ton which is smaller than 13.188 ton. The bearing capacity meets the requirement well.

4．2．2．2．1．2对于对节部位有牛腿的柱子，可以对称绑扎在相对的牛腿上作为吊点，经保证吊装时正确就位，如下示意图：

The section on the site of a pillar of the bracket, you can bundle up in the