Installation of industrial building with mixed frame - Job Instruction

Contents

Paper

Table of contents

Introduction

Scope of application of task list

Regulatory References

1 Characteristics of used prefabricated railway elements and materials

2 Organization and procedure of works execution

2.1. Define Scope of Work

2.1.1. Development of Building Layout

2.1.2. Specification of precast reinforced concrete elements

2.1.3. Bill of Quantities

2.2. Preselection of Work Execution Option

2.3. Selection of installation cranes by technical parameters

2.3.1. List of grips and accessories

2.3.2. Define Required Crane Parameters

2.3.3. Required crane parameters for installation of precast reinforced concrete structures

2.3.4. Selection of installation crane

2.4. Development of layouts and installation of precast reinforced concrete elements

2.5. Determination of interchangeable operational capacity of the crane

2.6. Determining the composition of the bricklayer team and the size of dividers

2.7. Selection of vehicles

2.7.1. List of required vehicles

2.7.2. Determination of the required number of vehicles

2.8. Procedure of works execution

2.9. Operating card for installation of rafter beams

3 Compiling Labor and Machine Time Costing

4 Constructions installation hourly schedule

5 Construction of work execution cyclogram

5.1. Calculation list to cyclogram

6 Diagram of crane movement during installation of prefabricated railway elements

7 Construction delivery dispatch schedule

8 TEP of Job Instruction

9 Quality control and acceptance of works during installation of rafter trusses and beams

10 Development of occupational health and safety measures

10.1 Safety requirements during installation works

10.2 Masonry Safety

Conclusion

List of sources used

Paper

Process Sheet for Installation Works: Explanatory Note to the Course Project in the Discipline "Construction Production Technology": 70 02 01/BrGTU; Stankevich Zh.V. P218/Department of TSP. - Brest, 2020. - 45 p., 15 Table, 3 Fig., 16 est.

Keywords: nomenclature, structures, masonry, transport, crane, capacity, calculation, schedule, TEP, technology, quality, safety.

The explanatory note to the course project in its scope contains an abstract, introduction, maintenance, development of building layout, selection of cranes according to technical parameters, calculation of crane capacity during installation works performed from wheels, calculation of labor costs, calculation of a team of masons and the size of the plot, development of a work execution cyclogram, selection and calculation of the required number of vehicles for delivery of structures to the site, dispatch schedule of structures delivery, description of technology of basic construction processes execution, development of TB measures, standard set of required tools and equipment, accessories, development of measures for quality control of works, TEP, conclusion, list of used literature.

Introduction

Installation of building structures is a complex process of mechanized assembly of buildings and structures from finished elements of factory manufacture, and the processes performed at the same time are installation.

Erection of building structures is a leading process in construction. This is facilitated by developed networks of enterprises producing prefabricated structures, the use of effective integrated mechanization, in-line mechanization of installation, conveying and other organizational and technological methods that ensure the technical, economic and energy efficiency of installation work.

Installation of building structures - a process consisting of transport, preparatory and main (installation) processes. They are carried out in a certain technological sequence using vehicles, lifting machines, rigging equipment and various mounting devices.

Transportation processes consist in transportation of prefabricated structures from the manufacturer to the construction site, movement within its limits.

Preparatory processes include processes related to the preparation of structures for installation: checking the state of the structure using external inspection, equipping with mounting devices, pre-assembly, preparation of the foundation support surface.

Installation processes are processes that create completed structural elements: slinging, supply, installation of structures from the design position, their alignment along coordinate axes, treatment and termination of joints and joints. The leading machines are mounting cranes.

Increasing the efficiency of installation work can be achieved by:

- reduction of manual processes and implementation of effective mechanization methods;

- widespread use of variant design;

- Introduction of best practices;

- organization of in-line work execution.

Scope of application of task list

The process map was developed for the installation of prefabricated structures of a one-story frame panel industrial building and the production of stonework when laying walls 0.38 m thick of the ends of the building on lime cement sand mortar.

The span of the building is 18 m;

pitch of extreme columns - 6 m;

pitch of middle columns - 12 m;

the elevation of the bottom of the rafters is 10.8 m;

coating is made on steel rafter trusses;

crane building;

design delivery range - 9 km;

wall panels shall be mounted from vehicles;

working conditions - winter.

Installation of the structure is carried out with a longitudinal diagram of the crane movement, in a combined way according to the sequence of installation of elements.

Installation by car crane KS557135

The delivery of wall panels to the facility is carried out in accordance with the control schedule.

A schedule in the form of a cyclogram has been developed for the production of installation and stone works.

Wall masonry is carried out by a team of masons, consisting of four links "two." The walls are laid from the inventory scaffolding. Work on the masonry of walls is carried out using the operationally divided principle of labor organization.

Quality control and safety measures have been developed for the work.

Description of the method of works execution is also given.

Regulatory References

The following regulatory sources are used in the development of the task list:

TKP 451.01-159-2009

Process Documentation for Construction and Installation Works Composition, Procedure for Development, Approval of Job Instructions.

TKP 451.03-161-2009

Organization of Construction Production, "Ministry of Architecture and Construction of the Republic of Belarus, Minsk, 2010

Regulation No. 24/33

Labor Safety Rules for Construction Works

SN 1.03.01-2019

MN 1.03.012019 Erection of building structures, buildings and structures.

TKP 451.03-63-2007

Installation of the building. Mechanization rules.

NZT, Collection No. 1

Internal transport works/Ministry of Architecture and Construction of the Republic of Belarus, Minsk, 2009

NZT, Collection No. 3

Stone works/Ministry of Architecture and Construction of the Republic of Belarus, Minsk, 2009

NZT, Collection No. 4

Installation of prefabricated and monolithic reinforced concrete structures/Ministry of Architecture and Construction of the Republic of Belarus, Minsk, 2009

NZT, Collection No. 5

Installation of metal structures/Ministry of Architecture and Construction of the Republic of Belarus, Minsk, 2009

NZT, Collection No. 6

Carpentry and carpentry works in buildings and structures/Ministry of Architecture and Construction of the Republic of Belarus, Minsk, 2009

NZT, Collection No. 22

Welding works. Issue 1. Constructions of buildings and industrial structures/Ministry of Architecture and Construction of the Republic of Belarus, Minsk, 2009

GOST 25573-82

Slings freight ropes for construction. Specification

GOST 2.10595 ESKD

General requirements for text documents

GOST 3.110990 ESTD

Terms and definitions of basic concepts

GOST 1650481

System of state tests of products. Product testing and quality control. Basic terms and definitions.

GOST 9467-75

Electrodes coated with metal for manual arc welding of structural and heat-resistant steels. Types.

GOST 24259-80

Installation tooling for temporary fixation and reconciliation of building structures.

GOST 823989

Hot-rolled steel I-trays. Sortament.

STB 2089-2010

Construction and installation works. Welding works. Nomenclature of controlled quality indicators. Quality control of works

STB 19592009

Construction. Installation of precast concrete and reinforced concrete structures. Quality control of works

STB 1958-2009

Construction. Erection of cast-in-situ concrete and reinforced concrete structures. Nomenclature of controlled quality indicators. Quality control of works

STB 1035-96

Concrete mixtures. Specification

STB 1160-99

Brick and ceramic stones. Specification

STB 1178-99

Reinforced concrete columns for buildings and structures.

STB 1185-99

Wall panels external concrete and reinforced concrete for buildings and structures.

STB ISO 7050-2001

Self-cutting screws with a secret head and a cross-shaped spline. Specifications.

STB 1382-2003

Profiles of metal cold-bent for roofs and components for them. Specification

STB 1749-2007

Construction. The structures are steel. Quality control of works.

STB 1959-2009

Construction. Installation of precast concrete and reinforced concrete structures. Quality control of works.

STB 1396-2003

Rafter trusses for production buildings. Specifications.

STB 1307-2012

Mortar and mortar mixtures. Specifications.

Characteristics of the main materials and products used

The following materials and products are used in the routing:

Reinforced concrete columns - STB 117899.

Metal rafters and adjustment trusses - STB 13962003.

Reinforced concrete crane beams - STB 13182002.

Roofing sandwichpanels STB 18082007.

Wall sandwichpanels - STB 18082007.

Ceramic bricks and stones - STB 116099.

Concrete construction C16/20-STB 15442005, SNB 5.03.01.

Construction solutions M50, F50 - STB 13072002.

Reinforced concrete slabs and floors for buildings and structures - STB 13832003.

Materials and products subject to mandatory certification must have a certificate of conformity, and imported construction materials and products for which there is no experience in use and regulatory and technical documents in force on the territory of the Republic of Belarus must have a Technical Certificate of the Ministry of Construction and Architecture.

Organization and Technology of Works

Crane installation method is used for building erection. Structures shall be mounted by longitudinal installation method:

Installation of columns and vertical links, temporary attachment of columns, sealing of column joints in foundations. The columns are installed by a caterpillar crane MGK25 with a main boom length of 17.5 m;

Pre-assembly of crane track systems, installation of crane beams. Installation of crane beams is carried out by KS3561A car crane with a long boom of 22m.

Arrangement of built-in rooms in two levels with flooring of reinforced concrete elements and covering of sandwich panels. Installation of designs of overlapping, covering panels and also supply of solution and pallets with a brick is made by the KC4561A crane ;

Prefabrication of trusses, installation of coating structures and their temporary fixation, laying of "sandwich" type coating plates. Installation of coating structures and panels by KS4561A crane;

Installation of cards of a wall protection and installation of wall panels to be made by the automobile KC3561A crane from a long arrow of 22 m.

Installation technology of prefabricated structures

The following works shall be performed prior to installation of the frame structures:

- the foundations for the columns were erected, and the correctness of their location in plan and height was checked;

- sinuses of foundations are filled;

- delivered to the installation area of the structure and installation equipment;

- hairlines of laying axes are applied along the top of foundation sleeves;

- walls of foundations are closed with shields for protection against contamination;

- axes of motion of boom cranes are indicated;

- bypass routes are arranged.

Installation of structures is carried out in the following sequence:

- installation of columns and termination of joints with foundations;

- installation of coating structures;

- installation of wall fencing.

In parallel with the installation of structures, electrical welding of mounting joints and their anticorrosion coating is carried out.

Installation of columns.

Installation is carried out by the MGK25 crane which moves along a number of columns in the middle of flight.

Installation of columns is performed by one column from one crane parking lot. Strapping of columns is performed by traverse of unified TsNIIOMTP, RF-455-69. Temporary attachment and alignment of columns is carried out using wooden wedges. The correct position of the columns in the plan is achieved by combining axial hairlines on the column with axial hairlines on the foundation. Column verticality is checked by theodolite and reference surface elevations by leveling. The joints of the columns with the foundation are sealed with C16/20 concrete followed by watering with water until the concrete reaches 70% strength.

The installation process is organized as follows:

- the column is inspected, cleaned of dirt, concrete strains;

- geometric dimensions of columns are checked and axial hairlines are applied;

- foundation glass is prepared: the glass is cleaned from dirt, axial hairlines and glass bottom marks are checked;

- column slinging is performed;

- the column is moved to the vertical position;

- the column is supplied to the installation site, at that the column is kept from rocking by installers;

- the column is lowered into the foundation sleeve, then temporarily attached with steel wedges and braces, after which the crane hook is released;

- alignment of the columns along the plumb and centering in the plan along two mutually intersecting axes, combining the installation axial hairlines on the column faces with the hairlines on the foundation.

- joints of installed columns are ground, maintaining temporary fixation, until concrete strength in joints reaches 70% of strength.

Installation of rafters.

To ensure stiffness of the work frame, we divide within one span. Installation starts with end coupling cell. Temporary attachment of trusses (first two) by means of braces to fixed supports on ground. Stiffness of the first cell is ensured after final installation of links and coating runs. The stiffness of subsequent cells is ensured after the final installation of the coating runs. Temporary attachment of the truss is made to previously installed trusses. After the construction of the coating structures, we lay the coating panels (sandwich panels) (see Installation of roofing sandwiches)

Before lifting the truss, holes of support platforms are cleaned from rust and dirt and planks are attached to support the coating plates. On the upper belt of the truss, installers install a temporary spacer and mounted cradles. Two hemp rope braces are attached at the ends of the truss to keep the truss from swinging during lifting. Steel safety rope is pulled between side struts of truss, to which installers attach carbines of safety belts.

Before lifting the truss, the installers check the reliability of the load gripping devices, the correctness of the sling and the uniformity of the tension of the slings. When lifting and installing the farm, a link of five people participates. Two installers by means of hemp braces keep the truss from swinging.

Assemblers located in cradles near its support units are directed to the truss installation site. Two installers at this time, having risen to a previously installed truss, lift the strut with the help of a rope and fix it. The installers perform the work at the height by attaching the installation belt to the safety rope with a carbine.

The overlapping joints, especially the seams on the backing ring, are welded into at least two layers, which provides the necessary melting of the edges of the welded elements. The assembly and welding of both halves of the rafter truss can be carried out both vertically and horizontally. The procedure for welding the characteristic joint of a rafter truss shall be as follows. Welding is started with seams connecting truss belts with horizontal straps. Then horizontal straps are welded with truss shapes.

Then vertical straps are welded with truss shapes and horizontal straps. To ensure stability of truss prior to its disassembly, upper belt of truss is fixed with braces or struts to previously mounted structures. Trusses are lifted and installed with fixed braces and braces.

After temporary fixation of the first two trusses vertical links shall be installed on trusses. A pair of end trusses with established connections provide a connecting unit, stability of subsequent trusses in the longitudinal direction is ensured after installation of lattice runs. The installation of runs in the communication unit is carried out only after the links are finally fixed. The installation procedure of the coupling trusses and grid beams is similar to that of the trusses.

Installation of roofing sandwiches.

Before works start, clean the locking parts of panels from protruding glue and insulation. Remove excess with wooden scraper. On the load-bearing structures of the roof it is necessary to arrange working flooring from the board.

Roofing panel slinging shall be performed in the purchased warehouse with strubcins. When slinging and lifting the panel, make sure that there is no damage to the panel.

Movement on mounted panels is allowed only using flooring, in order to maintain the integrity of the panel coating.

Process sequence of works:

1. Check the installation of panels according to the wiring diagram. To reconcile the location of the first panel, it is recommended that you make the necessary markups on the structural structure;

2. Glue sealing tape on roofing runs;

3. Install the first (end) roof panel.

Mount the first panel with an open wave towards the end of the building. The tubing should be attached to the panel at a distance of 1/41/5 L from both ends, the center of the pressure plate should be located in the interval between the first and second or second and third corrugations. Snap capron cables to panel edges to stabilize the panel during transfer to the mounting point. Hold the panel to lift the panel with a crane to the installation place. Align the edge of the panel with the end of the building, with the outer edge of the wall sandwiches. Set the panel overhang to the distance specified in the project. Check the parallel end edge of the panel with the building axis by pulling the cord along the skate, and if there is no panel joint, then along the building elevation.

Clearance in locking connection between panels is 11.5 mm. It is forbidden to exert excessive pressure when connecting the panels, there must be a guaranteed gap between the panels to avoid bulging of the lock connection;

4. Tilt the drilling area. Attach the panel with clamping screws with sealing washers. The number of fastening self-cuts on the sides of the roof shall be selected at the rate of 3 self-cuts per run panel. Tightening of self-cuts is performed until metal washer bending is eliminated. Screws are installed along the tops of the top skin waves of the panel.

5. Trim the upper skin lock along the longitudinal edge into a plane with the panel core, as it will interfere with the installation of the end face.

6. Install the following panel. Panel is laid with protruding corrugation on the same corrugation of adjacent panel and is placed in design position in circular motion.

7. Previously, a vapor-insulating rubber seal is laid in the lock of the lower sheet of the mounted panel, and a silicone sealant with a roller diameter of 5 mm is applied in the chute of the lock corrugation.

8. The panel is attached in the same way as the first panel. After that, panels are connected to each other by means of self-cutting roofing screws with sealing rubber washer. Screws are installed on corrugation ridge with spacing of 300 mm.

9. After installation of the panels, install the necessary headers, snow retainers and drainage systems according to the design documentation.

Installation of wall sandwiches.

Runs from rolled steel beams shall be arranged. Runs are fed by crane to place of installation by crane, where it is fixed to embedded parts of columns by means of welding.

The panels shall be attached to the runs by special self-cuts with sealing gasket to protect the paint coating. The location of the self-cuts is determined by the position of the beams or by a number of panels already installed. Before installing the subsequent panel into a "lock," a panel seam sealing device is required. Scraps and scratches of the paint coating produced during the installation of the panel must be additionally painted in the color of the facade with the type of paint according to the manufacturer's plant .

Before installation of sandwiches, make sure that there are no deviations from design dimensions and straightforward structural structures. If necessary, wall fasteners (girders, beams and other frame elements) are straightened with the help of additional protrusions and elements. The quality of the anticorrosive coating of the frame is checked and, if necessary, its restoration is carried out. Before starting the installation, check the accuracy of the dimensions and the flatness of the base surface. It is also necessary to clean the surface of the panels from possible contaminants just before the start of work. Panel ends shall not be wetted during installation, and panel joints shall have a reliable sealing.

The following measures shall be performed immediately before the installation works are started:

- check the quality of panels and their dimensions;

- perform accurate breakdown of panel installation places in longitudinal, transverse directions and by height;

- apply hairlines, which determine position of vertical seams and planes of panels, with a pencil or marker;

- prepare places for crane operation;

- deliver the necessary installation facilities, accessories and tools to the installation areas.

Technology of joints and joints sealing

Termination of joints of columns with foundations provides for supply and laying of concrete mixture into the joint cavity.

The process of grouting joints with concrete mixture includes the following operations:

preparation of joint cavity;

filling of joints with concrete mixture ;

providing care for the concrete mixture in the process of its strength gain.

Remove debris and dirt from the joints cavities immediately before soaking, blow with a jet of water or compressed air. Remove water after washing.

The concrete mixture shall be used within an hour of preparation.

When laying the concrete mixture manually, its mobility should be 68cm according to the draft of a standard cone.

Concrete mixture shall be prepared mechanically at the plant in accordance with the order of the installation organization.

Grouting of joints is carried out with fast-hardening concrete on high-quality cement (the period of collection of 70% strength is 2-3 days), the aggregate in which is crushed stone with size of fractions up to 20 mm. Close joints manually. The duration of the dewatering process should be minimal.

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Erection (arrangement) of embedded rooms

Masonry of walls on gripping is performed after installation of columns.

Scaffolds are installed after masonry of the 1st tier in parallel with masonry.

For the production of stone work, we use the flow-capture principle of labor organization, using a horizontal flow development scheme. Walls are laid by single-row dressing system. Openings in the walls are shifted along the masonry by jumpers (prefabricated railway beams). The solution is supplied to the workplace in boxes with a capacity of 0.25 m3, g/s units are supplied to the workplace with pallets with a volume of 1.75 m3.

Masonry of external walls from ceramic stones is composed of the following operations:

- setting of order and tightening of the cord;

- bed is prepared, solution is supplied and leveled;

- g/s blocks are laid on the bed with formation of seams;

- as soon as masonry is done, its correctness is checked;

- as soon as masonry is done, stitching is performed;

Wall masonry is performed using the operationally divided principle of labor organization in the link:

- installation of formations, installation of blocks in rows, check of correct masonry and stitching of joints is performed by a mason of high qualification;

- supply and distribution of solution, cutting of blocks is performed by low-discharge bricklayer.

Masonry is performed by six links "two."

Installation of floor slabs is carried out after all elements of wristwalls and internal walls within the installation area are erected. Prior to installation check masonry level in support areas. When laying slabs, it is necessary to ensure the horizontality of the ceiling formed by the slabs and the same coupling of joints.

Prior to mounting, a 1015 mm thick solution layer is applied to the cleaned support surfaces. Laying begins from the wall with inventory scaffolding, and subsequent slabs, with previously mounted. Installation is carried out by the "four" link. One installer picks up the slabs, slings them with a four-branch sling and sends a signal for lifting. Two installers, being on the floor, accept the panel, turn to the design position and are installed when lowered. The fourth installer is located on the floor of the underlying floor and controls the level of installation of the plates. After final alignment, the slabs are anchored to each other and to the walls according to the design. Immediately after installation, the joints of the floor slabs are sealed between each other and between the walls with M100 cement mortar.

Installation of bridges is carried out in the process of masonry. The rigger slings the necessary jumper, while the bricklayer prepares a solution pastel. Then bridge is lowered and laid, value of support on walls is controlled. The next step is to check the horizontal level and shade the welds. Ordinary jumpers with a small weight can be laid manually.

Stairways and platforms are mounted as the walls of the building are erected. The first (intermediate) platform and the first march are installed in the course of masonry. The second (storey) platform and the second march - at the end of the masonry of the floor.

Before the installation of staircases, the places of their installation are marked and the elevations of the platforms are transferred to the walls, it is checked whether the levels of the nests in the walls coincide with the design levels, where the supporting parts of the mounted platforms need to be laid.

After checking, a layer of solution is applied to the resting places and a platform is installed. Methods for installing staircases do not differ from techniques for laying slabs. However, check the stairway position not only vertically but also in plan. To check the position of the platform in the plan, a wooden template is used that copies the profile of the stairwell. Check by template is performed in two points of support of march.

Immediately after the alignment of the position of the platform, a flight of stairs is mounted. This allows you to adjust the relative position of the flight of stairs and the upper platform before the solution is fixed. Staircase marches are delivered by crane using four-branch slings, which, when lifted, give the elements a slope that is slightly larger than the design one. When setting a flight of stairs, it is first rested on the lower platform, and then on the upper platform.

Conclusion

During the course project, a process plan for installation work was developed during the construction of a one-story industrial building. In the course of execution, the scope of work was determined and installation cranes were selected according to technical parameters, the TEP of production was calculated, a cyclogram of work performance, hour and dispatcher schedules were built, labor costs were calculated, all necessary operations were taken into account when arranging masonry, transporting structures. The total duration of installation of the building framework was 43 working days, the duration of masonry - 3 working days. The total duration of the building installation was 43 working days.

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