Reinforced Concrete Beam Manufacturing Plant

General Section

1.4 Structural solutions of the building

Structural diagram of the frame building. Spatial rigidity of the frame in the transverse direction is ensured by the operation of transverse frames, which are formed by columns jammed in foundations and rope structures hingedly resting on the columns. In longitudinal direction, frames are connected by crane beams, substructures, rigid coating disk, steel links and wall panels.

1.4.10 Roof

The roof on the roof of the designed building is mastic. Consists of the following layers:

Ogruntovka "Autocrine";

Vapor insulation layer of isoplast on mastic;

Insulation from polystyrene foam plates PSBS35 - 100mm;

Cement-sand bracing M100 - 20 mm;

Reinforcing material "Fiberglass" 1 layer;

Mastic "Autocrine" 1 layer;

Reinforcing material "Fiberglass" 1 layer;

Mastic "Autocrine" 1 layer;

To remove atmospheric precipitation from the roof, water intake funnels with a diameter of 100 mm are provided. Each funnel serves no more than 80 m2 of roof area. The entire roof is divided into separate sections served by one funnel. Roof slope to water intake funnel i = 0.03 is provided in these sections. Binding of water intake funnels to longitudinal axes is 500 mm, to transverse 450 mm.

1.10 Exterior Finishes

Wall panels are painted with facade colors. External brick walls are plastered with sophisticated plaster and painted with facade paints.

1.11 Engineering Equipment

This building is equipped with: water supply - economically protective network. Water head H = 38m. In case of internal fire extinguishing, water head H = 24m.

Water reuse system H = 10m.

Domestic sewerage system.

Hot water supply from gas heater.

Heating from a gas-fuelled boiler.

Domestic sewerage system in the external network.

The ventilation is natural.

Power supply from external network, 220 V.

Gas supply from the yard network of the low-pressure gas pipeline.

Low-current networks - radio, telephony, fire alarm.

Organizational and Technological Section

3.1 Job Instruction for Installation of Building Frame

3.1.1. Scope of Application

The process sheet was developed for the installation of the frame of the plant for the production of reinforced concrete beams in Svetlogorsk.

The works considered in the map include:

- installation of columns of rectangular cross-section in shells of foundations;

- installation of crane beams;

- installation of trusses and rafters;

- laying of ribbed slabs;

Termination of joints between structures, welding of elements are not included in the Job Instruction, because they are taken into account in the main processes.

3.1.2. Regulatory References

- GOST 2021389 Reinforced concrete trusses. Specifications.

- GOST 2282785 General purpose boom cranes. Specifications.

- GOST 13015.484 Concrete and reinforced concrete structures and articles. Transportation and storage rules.

- PCN 8.03.1072007 Collection 7, Concrete and reinforced concrete prefabricated structures;

- SNB 1.03.0296 Composition, procedure for development and agreement of design documentation in construction.

- STB 117899 Reinforced concrete columns for buildings and structures. General specifications.

- STB 118699 Rafters and rigging beams, girders and reinforced concrete runs for buildings and structures. General specifications.

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

- STB 19682009 Construction. Installation of prefabricated structures. Item of monitored key figures.

- STB 19592009 Construction. Installation of precast concrete and reinforced concrete structures. Quality control of works.

- TKP 451.01-159-2009 (02250) Construction. Process documentation during construction and installation works. Composition, procedure for development, approval and approval of Job Instructions;

- TKP 451.03-40-2006 Occupational safety in construction. General requirements.

- TKP 451.03-44-2006 Occupational safety in construction. Construction production.

- TKP 451.03-63-2007 (02250) Installation of buildings. Mechanization rules.

- TKP 455.03-130-2009 (02250) Prefabricated concrete and reinforced concrete structures. Installation rules.

3.1.4.3 Description of the organization and technology of construction production

General Information

The following processes shall be performed prior to the construction of the building framework:

fall asleep the sinuses of the foundations;

apply hairlines of installation axes on four faces at the level of upper plane of foundations;

close the foundation sleeves with shields to prevent contamination;

prepare sites for storage of columns at the place of their installation ;

deliver the necessary installation facilities, accessories and tools to the installation area;

check the position of all embedded parts of columns ;

apply hairlines of mounting axes on side faces of columns;

obtain written permission to perform work from organizations operating air networks in the area;

Obtain written permission to perform the work.

Installation of columns

Installation is carried out by caterpillar crane MKG16 with preliminary laying of columns at the place of installation.

Before installation, each column must be inspected so that it does not have deformations, damages, cracks, shells, chips, exposed reinforcement, concrete strains. It is necessary to check the geometric dimensions of the column, the presence of a mounting hole, the correct installation of steel embedded parts.

Before slinging, columns with a height of more than 12 m are equipped with stairs, mounted cradles, bracing.

Strapping of columns is performed behind column cantilever. Self-balancing crossbeams are used to lower the column on the foundation vertically. Columns are lowered into foundation cup on leveling layer of concrete mixture by means of mounting crane.

Alignment and temporary fixation of columns installed in foundations is carried out using a set of installation equipment. The design position of the bottom of the column on the bottom of the foundation shell, temporary attachment and vertical alignment of the columns are carried out using wedge inserts. Stability of columns after installation is provided by wedge inserts. Reconciliation and correction of the column vertically is carried out using jacks. Columns up to 12 m high are fixed in foundation cups only with the help of wedge inserts, conductors and braces are additionally used for higher columns. Disassembly of the installed columns should be performed after their reliable fixation in the foundation cups with wedge inserts, and, if necessary, bracing.

After the columns are reconciled, they are fixed in the design position by concreting joints with a concrete mixture on fast-hardening non-shrinking cement using a pneumatic charger. Wedge inserts are removed only after concrete acquires the joint strength specified in the work design or when concrete reaches 50% of design strength.

During installation of columns, it is necessary to check the elevation of the bottom of the foundation shell, the alignment of the hairline on the face in the lower part of the column with the layout risk on the upper face of the foundation, the verticality of the columns, the elevation of the crane console and the column tip. Alignment of column axes and layout axes shall be controlled by two axes, column verticality shall be ensured by means of one or two theodolites on two layout axes. Elevations of support platforms for crane beams and trusses are controlled by geometric leveling.

Installation of crane beams

Installation of beams is carried out only after installation with concrete in the frozen joint of the column with the foundation of the given strength. The following preparatory works shall be performed before installation:

-Planning of laying areas of crane beams before lifting;

- travel device for movement of mounting crane and car

transport;

-Finding and securing all columns and vertical columns as per design

links on them;

-geodetic check of elevations of support platforms of columns consoles with determination and provision of installation horizon.

Installation of crane beams is carried out in complex together with other coating structures. Laying of beams and other frame elements in the installation area must be performed on wooden liners, laying prefabricated elements at a small angle to the row of columns (that makes it possible to inspect the ends and prepare the connected parts for installation), and at a distance from them of about 50 cm. Laying of crane beams is carried out taking into account their installation, when the crane from the installation parking performs their lifting and laying without changing the boom departure. Before lifting the crane beam, install installation ladders on the columns, clean the installation units from dirt and debris, attach the drawers on the beam and build it up.

During installation of crane beams within the grip the beams are mounted and temporarily fixed. Tool levelling of beams is performed at support points. All other support points of beams are raised under the level of the highest elevation using steel gaskets. Unverified installation of beams is possible with increased accuracy of production and installation of columns that provide the necessary horizon of cantilevers of these columns.

Crane beams up to 6 m long are lifted to design position by slings with hooks. The beam is raised above the design elevation by 30... 50 cm and with the help of braces it is brought to a position close to the design one. During installation of crane beams, hairlines on the lower end faces of the beams must coincide with hairlines on the column consoles.

Elevation of upper shelf and position of longitudinal axis are checked with geodetic tools. The beams are fixed by welding embedded plates in the ends of the beams and in two levels near the column at the upper face of the crane cantilever and on the side face above the beam shelf. Space between crane beam and column is filled with concrete mixture in inventory formwork, and joints of beams are filled with cement mortar.

Installation of rafters and trusses

Unloading of trusses and beams on the site, laying and installation of elements is carried out usually by an automobile crane in the area of ​ ​ the crane. To ensure stability of mounted elements on the ground, they are stored in special cassettes. When delivering structures to the object in significant quantities to the acquired warehouse, temporary storage is carried out in group cassettes without laying out in the installation area. If Before installation of the structure it is necessary to equip: - with safety rope, mounted cradle with safety rope.

For slinging of trusses and beams, crossarms equipped with grips with remote automatic or semi-automatic disassembly shall be used.

When lifting the truss, its position in space is adjusted by means of braces. At a height of about 0.6 m above the resting points, the truss is accepted by installers (located on mounting platforms attached to the columns), guided by axial risks and set to the design position. Then embedded parts are welded, after which the truss is disassembled.

Trusses and roof beams should be installed in the design position, combining axial hairlines at their ends with hairlines on the support surfaces of the underlying column structures. Elements are secured by conductors pre-installed on column heads. Disassembly is performed after installation of spacers and welding of bonds to upper belts.

After lifting, installation and alignment, the first truss is braced with braces, which are fixed to rearranged inventory anchors or pre-installed and frozen columns, the following are connected to each other by special struts having a rigid size in axes. After the installation of the first pair of trusses, they are laid and fixed 3... 4 coating plates to create an initial rigid system. Then all temporary fasteners are removed, i.e. all inventory spacers and braces are removed as the coating plates are laid and welded. At the same time, all permanent connections provided for by the project should be established with the farms.

Installation of coating plates

Slinging of slabs is carried out by a four-branch sling of the spider type. Installation of slabs is carried out in the same flow as trusses (coating beams), therefore, immediately after installation of the next truss, another row of slabs is laid.

The coating plates are laid from one end of the truss to the other. Slabs are laid by marking on upper belts of trusses (beams) in order to ensure their design position in plan on rafter structure.

The first slab installed on rafters is welded in four support units. Embedded parts of each subsequent plate in at least three support units must be welded to embedded parts of the upper girder belt (the fourth corner of the plate is not available for welding).

When laying in each cell of the first plate, one installer is on a plate laid in an adjacent cell, the second - on a ladder platform hung on a column. In the future, both installers switch to the newly laid plate for receiving and laying the next one.

The outermost paving plates shall be equipped with an inventory fence structure. Seams between slabs are sealed with fine-grained concrete mixture.

The coating plates are stored in the working area of the installation crane together with other elements entering the installation flow. Plates are stacked up to 8... 9 pcs. Spacer between trusses is removed after laying and welding of embedded parts of plate laid at spacer to truss. Installation of reinforced concrete slabs on rafters is carried out in the same sequence and in the same methods as on trusses.

3.2 Construction Network Schedule

3.2.1 General instructions

The network is one of the versions of the schedule model and also the basis of the design, process and production-process documentation. When developing networks, technological processes (works) are linked in time and space, the system of supply and consumption of resources is determined, that is, variants of competitive methods of organization of work are developed and the most suitable competitive conditions are selected.

The network is the main document of the work execution project. It covers the entire complex of work on the construction of the facility, ranging from preparatory work to commissioning, testing and testing of hot and cold water supply systems, sewage, heating, improvement of the territory adjacent to the facility.

According to the network schedule, the total duration of the construction of the facility is established, the need for labor and material resources, the delivery time of structures and equipment is determined, operational planning is carried out and annual, quarterly, monthly and daily work plans are drawn up .

Main regulatory document for network development

are:

TKP 45-1.03442006 Labor safety in construction. General requirements.

TKP 45-1.03442006 Labor safety in construction. Construction

production.

TKP 45-1.031612009 Construction organization.

3.2.2 Selection of work methods

On-site preparatory works

On-site work begins with the removal of groundwater and surface water. Before performing construction and installation works, the territory must be cleared, its fencing, geodetic breakdown of the axes of buildings and structures, and the construction of access roads. It is necessary to erect temporary buildings (household, warehouse), equip sites for material storage, pre-assembly. If there are any buildings on the construction site, then it is necessary to disassemble them, as well as carry out the removal of all existing underground and above-ground communications. The Technical Inspectorate supervising the construction area shall issue in writing a work permit.

Earthworks

The complex of earthworks includes:

- cutting of vegetal soil layer;

- planning of the construction site;

- development of soil by excavator with ground grinding to design elevation;

- loading of vegetal soil with excavator into dump trucks;

- transportation of developed soil by dump trucks outside the construction site;

- soil compaction.

Mechanized development of the pit is carried out by the Dragline excavator EO4321, equipped with a reverse shovel with a ladle capacity of 0.65 m3. Excavator parking level is higher than the level of developed soil.

At the bottom of the trenches and pits, manual rework of the soil with shovels to a depth of 0.2 m is carried out.

To fill the trenches of the pit, bulldozer DZ19 is used. As pit is filled, layer-by-layer soil ramming is performed.

Foundation arrangement

Construction of monolithic columnar foundations is carried out after compaction of the base soil and transfer of the foundation axes to the bottom of the catlane and trench.

Prefabricated formwork is used to erect the foundation.

Reinforcement grids are supplied by self-propelled crane MKG16.

Concrete mixture is supplied to the formwork by the method of crane-badya.

Foundation arrangement is performed in layers with compaction of each

layer with vibration racks.

Waterproofing of foundations

Before the waterproofing device, all insulated surfaces are dried, all protruding parts and strands are cut off, the ends of reinforcement and wire are cut off. Adhesive waterproofing is made of several layers of roll material along a cut base using special water-resistant mastic.

Installation works

Installation operations are performed by goose cranes of MKG16 and KS8161 grade. Selection of cranes is made in Job Instruction for installation of building frame.

Installation of the frame of a single-storey industrial building is carried out by a combined method of work, which involves sequential installation of columns and installation of other frame structures by cells. The stability and strength of the mounted elements is ensured by the use of temporary fasteners. After the joints are frozen, technological breaks are provided to ensure concrete strength. Installation of wall panels begins after the final fixation of all elements of the building frame.

Masonry works

The process of masonry consists of the following operations: setting orders and pulling the berth; bed preparation, supply and leveling of solution; laying stones on the bed to form stitches; verifying that masonry is correct.

When performing work, the building is divided into grabs, on which a team of masons works during the shift.

The brick is supplied to the workplace with bags on pallets. The masonry solution is supplied by crane in boxes with a reserve of 2-3 hours.

Brick and mortar are supplied by goose crane KS8161.

Performance of works at height is provided by means of scavenging.

Filling of window and door openings

Filling of window and door openings is performed after installation of wall panels and other enclosing structures.

Supply of window panels to the installation site is performed by KS8161 crane.

Window panels are installed in openings formed by wall panels

The boxes are initially reinforced with wedges and only after checking their verticality and horizontality, as well as coinciding their vertical and horizontal axes with filling of other openings are finally fixed. Clearances between boxes and walls are carefully penetrated with antiseptic heat insulation materials, and in internal rooms - with sound insulation materials.

The filling of the openings is carried out in parallel with the installation of the roof, in this regard additional measures are provided for to ensure safety and safe work.

Plaster works

Elements of buildings and structures before plastering are accepted by the act of the commission with the participation of representatives of organizations that performed previous works of plastering, and the performer.

Plaster is made on an improved site. Plaster solution is applied on surface layer-by-layer.

Plaster solution is supplied by plaster unit

SO-57A.

Surfaces to be plastered shall be checked by vertical and horizontal planing with installation of inventory demountable grades.

Plaster works are performed using scaffolding and hinged cradles.

Painting works

Painting works are carried out after plaster works and parallel to external finishing, which makes it possible to use one complex team of finishers.

To reduce the duration of work and reduce labor costs when painting surfaces, SO61 paint consoles are used.

To ensure safe operation at altitude, scavenging devices and hinged cradles are used.

Floor arrangement

Filling floor arrangement is performed after installation of underlying layers

and their necessary strength during the technological break, and

consists of the following processes:

- arrangement of underlying crushed stone layers sealed by ramming;

- arrangement of underlying layers of concrete;

- arrangement of cement braces;

- base bending;

- polyvinyl acetate coating device;

- plinth device.

Preparation from cast-in-situ concrete is laid with separate maps by measures

3x3, 4x4 using a set of concrete laying machines.

Plinths shall be installed after completion of works on the device

of the sexes.

Roof arrangement

Installation of the roof is carried out after installation of wall panels with "Autocrine" mastic on a low-slope base .

In places of adjoining walls mastic carpet is turned on parapet.

Water intake funnels are installed in the holes of the coating plates until the mastic carpet is installed.

Light-aeration lights are installed by separate panels and are supplied to the roof by KS8161 crane.

Paving device

Around the building along the outer walls there is a pavement made of dense waterproof material - asphalt concrete. The width of the pavement is 1000 mm with a slope of 1.5% from the building. Before the asphalt concrete mixture is arranged, the base under the pavement is compacted with crushed stone with grain size of 1215mm. Compacted by hand ramming. Asphalt concrete is laid in a layer with a thickness of 10 mm. The pavement serves to divert atmospheric precipitation from the walls and foundation of the building.

Special Cycle Works

The work of the special cycle is carried out throughout the construction period and is divided into two stages. The first stage of the work of the special cycle is carried out after earthworks and before the installation of wall panels, the second stage after the installation of the roof and before the end of construction. Other unaccounted works are carried out in three stages. The improvement of the territory is carried out after the completion of all main construction processes.

3.3. Construction Master Plan

3.3.1 General Instructions

Construction Master Plan (SGP) is a construction site plan that shows the location of buildings and structures under construction, designed and existing, construction machines, as well as construction facilities intended for maintenance of the work. The construction master plan is part of the work execution project and is developed on the basis of the construction schedule, as well as decisions taken in the process of its design.

Construction facilities required for the construction period include: production plants (concrete and mortar units); warehouses of building materials, structures and parts; temporary buildings and structures for administrative, hygienic and cultural purposes; roads and railways; power supply, water supply, sewerage, communications, etc.

The purpose of construction plans is to develop and implement the most effective model of the construction site organization, which provides: the best conditions for high-performance labor of workers; maximum mechanization of construction and installation works; efficient use of construction machines and vehicles; compliance with occupational safety requirements.

The basic regulatory documents for the development of construction plans are:

TKP 45-1.03442006 Labor safety in construction. General requirements.

TKP 45-1.03442006 Labor safety in construction. Construction

production.

TKP 45-1.031612009 Construction organization.