March 27, 2011
Project Name Subproject Tower Crane
Subproject Name Tower Crane Installation
1, the site installation by the safety officer is responsible for the safety supervision of the work, the safety officer is required to conscientiously and responsibly exercise their authority.
2, all professionals participating in the installation, must be unified to receive safety education, each wearing a seat belt and helmet.
3, the installation of high-altitude workers with tools, appliances, all with a rope hanging string tied to the body, to prevent the installation of slip and fall hurt. Installation bolts and other important scattered parts, the use of special tools placed centrally.
4, set up one to two guards, specifically responsible for preventing unrelated personnel from entering the installation area.
5, the installation of all installation components in accordance with the original manufacturer's instructions, and detailed inspection after installation.
6, to ensure that the tower crane foundation to strengthen the level of section embedded, square, to ensure that the tower installation vertical.
7, the car crane operation must have a person in command.
8, found that the safety facilities have defects or hidden dangers, should be reported in time to deal with, to endanger personal safety, must stop construction, elimination of risk and then carry out work at height.
9, the car crane rotating radius shall not stand, before operation should be checked from the end of the very turn within 50cm without obstacles.
Tower crane installation, dismantling construction program
I, project overview
1, the project is located in the place. Conference center project for the underground three floors, seven floors above ground frame structure, the total height of 44.7m, the basement floor elevation is -14.1m. Plan this project using the Wuxi Great Wall Machine Manufacturing Co., Ltd. production of XC5013 type (QZT63) tower machine weight machine, the tower machine maximum lifting capacity of 6T, the maximum working range of 50M, the minimum working range of 1.9M, the maximum size of the lifting capacity of 1.3T, the lifting moment of 63 tons of rice, the maximum lifting moment of 82.5 tons of rice, independent free height of 40M, the maximum height of climbing 140M (when attached).
2, this program has considered the modeling of the units of engineering and external scaffolding with the removal of the tower after the impact. Specific location in the R axis to the south 4.1 meters cross 36 axis to 39 axis direction 4.2 meters. The place according to the main building of the conference center 5 meters, the tower crane set up and conference center parallel to the north elevation, and the east-west axis at an angle of 14 °, the foundation is located in the basement under the raft foundation, the bottom plate reinforcement through the tower crane foundation.
Second, the preparation of the basis
1, "the Chinese people's **** and the country safety production law"
2, "building construction work at height safety technical regulations"
3, "construction site safety management standards"
4, "construction drawings"
5, "construction organization design"
three, the installation of the Required machinery and tools: 45T car crane, a board hand, hand hammer, sling and so on.
Four, installation time Removal time
○1 Installation time: tentatively scheduled for April 2, 2011
○2 Removal time: the unit of construction of the main body of the project is completed after the completion of roofing construction is removed. Appropriate extension when conditions allow.
V, personnel organization list:
Demolition and installation of the commander-in-chief:
Site Commander:
Hoisting Commander:
Driver:
Electrical:
Machinery:
Hoisting Division cable:
Signal worker:
Sixth, the tower base load bearing capacity and the foundation of the selection
Tower crane foundation location of the Yellow Sea elevation of -13.000 meters, soil quality for the third layer of silt layer, check the geological exploration report learned that the foundation bearing capacity of the soil layer for fk = 150kpa. According to the Wuxi Great Wall Machine Manufacturing Co., Ltd. QTZ series of products XC5013 tower machine instruction manual requirements 125kpa endurance to choose the foundation, the tower using direct fixed foundation, foundation concrete Strength grade is C35; plane size is 5600×5600, foundation section height is 1350mm foundation are configured with Φ25HRB335@170 double-layer bidirectional reinforcing steel mesh, the upper and lower two layers of reinforcing steel mesh between the set of Φ16HRB335@510 reinforcement.
The reinforcement section buried in the concrete must be fixed to ensure:
(1) The depth of the reinforcement section buried in the concrete should not be less than 1.2M
(2) Ensure that the deviation of elevation of the top surface of the reinforcement section is not more than 1mm
(3) The standard section must be fixed firmly to ensure that it does not displace and affect the top surface smoothness during the pouring of the concrete
(4) Attention to (4) Pay attention to the correct lightning protection and grounding
(5) The concrete pressure-bearing capacity reaches more than 90% before entering the machine assembly
(6) The concrete strength grade is C35;
(7) The maximum independent height of this type of work is 40M.
VII.TOWER INSTALLATION AND DISASSEMBLING
1.The tower uses a direct fixed foundation to directly fix the reinforcing section on the concrete foundation. fixed on the concrete foundation. When installing, check whether the 4 foot columns are horizontal or not, exceeding one thousandth, need to be trimmed.
2. Lift the tower base section and connect it with the lower part with bolts.
3. Sleeve the climbing frame into the tower body, and the opening direction of the climbing frame should be kept parallel to the building in order to dismantle it after construction.
4, on the ground, the upper and lower supports, as well as slewing bearings, slewing mechanism, etc., bolted together, then lifted to the tower body and the set frame, and locked with bolts.
5. Lifting the top of the tower, connect the first section of the balance arm tie rod with the tower cap with pin lock on the ground, then lift the tower cap to the upper support and connect it with four Φ60 pins.
6. Lifting the balance arm and balance tie rod. Put together the balance arm on the flat ground, and install the winch, distribution box, resistance box on the balance arm, connect the wires needed for each part, then lift the balance arm, install it on the connector of the upper support, and finish fixing it, then lift the balance arm into an angle to the installing position of the balance arm tie bar, after installing the balance arm tie bar, then lift a 2.4T counterweight block and press it on the front end (near end from the tower body), and then the crane unloading.
7, hoisting the lifting arm and tie rods.
7.1 Installation of lifting arm and tie rods
7.1.1 Configuration of arm and tie rod sections for lifting arm tie rods of different arm lengths.
7.1.2 Combine the crane lengths, assemble them together with the corresponding pins, connect the first arm section and the second arm section, install the trolley and crane blue, and fix the trolley and crane blue at the root of the crane arm, and dock the crane arm on the bracket at about 1M height, so that the trolley and crane blue leave the ground.
7.1.3 Combine the lengths of the tower crane, connect them with pins and fix them to the corresponding racks on the upper chord bar of the boom.
7.1.4 Check that the electrical circuits on the boom are perfect and thread and wind the trolley towing wire rope.
7.1.5 Lift the boom assembly smoothly with the truck crane, and keep the boom in a horizontal position during the lifting process, so that the boom can be installed smoothly on the boom hinge point of the upper support. (The center of gravity of 55M boom is about 22.5M from the root of the boom)
7.1.6 After the boom is connected to the upper support, continue to lift the boom so that the head of the boom is slightly lifted up and the wire rope of the lifting mechanism is used to pull up the tie rods through the top of the tower and a set of pulleys on the tie rods of the boom, so that the connecting plate of the short tie rods can be connected with the corresponding tie plates on the top of the tower by the pins. Then, the height position of the long tie-rod is adjusted so that the connecting plate of the long tie-rod can be connected to the corresponding pull plate at the top of the tower with a pin.
7.1.7 Slacken the wire rope of the hoisting mechanism. Lower the boom slowly so that the tie rods are under tension. And check whether the boom is up 1/100 according to the requirement, otherwise, replace the connecting plate of one set of tie rods until the requirement of up 1/100 is met. Finally, loosen the hoisting wire rope on the pulley block.
8, tower crane driver room. On the ground, after checking the electrical equipment of the driver's room, the driver's room will be lifted up to the plane of the upper support, and then, the driver's room will be connected with the upper support by the pin, and the driver's room will be suspended from the top of the tower with a steel wire rope at the outermost corner of the driver's room.
9, tower crane balance counterweight.
9.1 according to the length of the jib used, according to the provisions of the installation of different weight balance counterweight block.
9.2 wear winding lifting wire rope. The hoisting wire rope is led out through the rope arrangement device through the tower top guiding pulley, and then around the lifting capacity limiting pulley in the upper support, and then led to the trolley and the hook pulley to wear around. Finally, the rope end is fixed on the arm head anti-twisting mechanism.
10, check the mechanical part of the machine, the structure of the connecting part of the electrical and hydraulic part of the machine and so on after the start of the ascension work.
11.Installation and sequence of tower standard section.
11.1 Because the tower body standard section main chord bar specifications have two kinds, therefore, when installing the standard section should be according to the standard section main chord bar wall thickness size, in order from the bottom to the top of the standard section of the tower body according to the installation. The bottom three standard sections of the main chord wall thickness of 12mm, the remaining nine standard sections of the main chord wall thickness of 10mm. 12mm wall thickness of the standard section in the step on the drilling with markings.
11.2 Rotate the lifting arm in the direction of the standard section of the tower.
11.3 Adjust the clearance between the climbing frame and the tower, generally 2 to 5mm is appropriate.
11.4 Fix the four introduction rollers on the four corners of the tower standard section on the ground first, then lift the standard section and install it on the outer frame. Adjust the position of the trolley so that the upper center of gravity of the tower crane is in the position of jacking cylinder sorghum (if 55M jib, the trolley is driven to the position of the amplitude of about 40M or lifting a standard section at the position of 20M, if 50M jib, the trolley is driven to the position of the amplitude of about 42.5M or lifting a standard section at the position of amplitude 25M, if 45M jib, the trolley is driven to the position of the amplitude of about 45M or lifting a standard section at the position of amplitude 25M), then lift a standard section at the outer frame. (25M position), then connect the climbing frame with the lower support with 16 M24 high-strength bolts, and finally remove the 8 M36 bolts connecting the tower body with the lower support.
11.5 Put the jacking sorghum on the step of the tower body, turn on the hydraulic system and jacking cylinder. The use of jacking cylinder and climbing claw rotation support to realize the climbing work. After two times of jacking cylinder, climbing to be able to install a standard section of the space until. Using the introduction of the roller rolling in the outreach frame, the standard section of the bolt connection holes, retract the cylinder to put down the jacking part, with 8 M36 high-strength bolts will be the upper and lower tower standard section of the connection (tighten the bolts are generally used in the wind plate hand BE42 or torque plate hand, preload 23T, preload torque of 150KGm) unloading the introduction of the roller, adjusting the cylinder's retracting length, will be the lower support and the tower connected to the firm, that is the completion of a standard section of the addition of connection, the use of jacking cylinder and climbing claw rotation support. That is to complete a standard section of the work of adding sections. If you add a few standard sections in a row, you can follow the above steps several times in a row.
(1) in the jacking process, the driver's room is equipped with a knob 2QA, when the boom to the desired position, rotate the 2QA knob, control the tower crane slewing mechanism brake will be the boom lock, forbidding the boom slewing. Ensure that the direction of the lifting arm is the same as that of the standard section introduced into the tower.
(2) After adding a tower standard section, before lifting the next tower section, it is necessary to make each chord of the tower and the lower support have a M36 bolt connection.
11.6 After all jacking work is completed, the climbing frame can be lowered to the bottom of the tower and fixed and removed to lower the center of gravity of the whole tower and reduce the windward area.
11.7After lowering the climbing frame, on the highest section of the tower, the tower platform and movable platform are installed to increase the access between the tower and the lower support platform.
12.Tower machine disassembly. Tower disassembly method and installation method is basically the same, just work procedures and installation of the opposite, that is, the first installed first disassembled, however, in the disassembly process can not be sloppy, otherwise personal and equipment safety accidents will occur.
13, the use of cranes.
13.1 General Instructions:
13.1.1 Cranes must work on a fixed foundation in accordance with the design drawings.
13.1.2 Crane operators must be trained to understand the construction and use of machinery, must be familiar with the maintenance of machinery and safe operation procedures, non-installation and maintenance personnel are not allowed to climb the tower machine without permission.
13.1.3 crane normal working temperature of +40 ℃ ∽ -20 ℃, the wind speed is less than 20m / s.
13.1.4 cranes move once a day after the site re-arrangement, it must be unloaded, static load, dynamic load test before lifting operations, its static load test lifting weight for the 125% of the rated load, dynamic load test The static load test weight is 125% of the rated load, and the dynamic load test weight is 110% of the rated load.
13.1.5 When working at night, in addition to the lighting of the tower crane itself, the construction site must be provided with sufficient lighting equipment.
13.1.6 It is prohibited to store lubricating oil, oil cotton yarn and other flammable and explosive items in the driver's room, and fire prevention should be paid more attention to in winter when the electric stove is used for heating.
13.1.7 Cranes must have good electrical grounding measures to prevent lightning strikes, in the event of thunderstorms, it is strictly prohibited to walk around the chassis.
13.1.8 tower crane should be fixed machine and person, special machine and person in charge of the system. Non-crew members are not allowed to enter the driver's room and unauthorized operation, in dealing with electrical accidents, there must be more than two full-time maintenance personnel.
13.2 crane jacking operations
13.2.1 in the process of jacking operations, there must be a person to command, a person to take care of the power supply, a person to operate the hydraulic system and a person to tighten the bolts. Non-operators, may not board the climbing frame operating platform, not to mention unauthorized starting pump valve switch or other electrical equipment.
13.2.2 jacking operation should be carried out during the day, in case of special circumstances, need to work at night, must be equipped with adequate lighting equipment.
13.2.3 The jacking operation can be carried out only when the wind speed is lower than 13m/s. If the wind speed increases suddenly during the operation, the operation must be stopped and the connecting bolts must be tightened to make the upper and lower towers become one.
13.2.4The cable must be relaxed before jacking up, so that the cable relaxation length is greater than the total length of the climbing height, and make a good cable reel fastening work.
13.2.5 In the process of jacking up, the rotary part of the tight brake, strictly prohibit slewing and other operations.
13.2.6 In the process of jacking, if faults are found, it must be stopped immediately for checking, and the climbing work shall not be continued unless the truth is found out and the faults are removed.
13.2.7 After each jacking before and after, must be carefully made preparations and first and last work especially after the jacking. Each connecting bolt should be tightened according to the specified pre-tensioning force, not loose, climbing sleeve roller and tower standard section should be adjusted, the operating lever should be returned to the center position, the power supply of the hydraulic system should be cut off, and so on.
13.3 crane operation
13.3.1 The driver must work strictly in accordance with the amplitude and lifting capacity specified in the performance table of the crane, no overloading.
13.3.3 The crane is not allowed to pull and lift items diagonally, and is prohibited to be used for the crane is not allowed to pull and lift items diagonally, and is prohibited to be used for pulling piles and other similar operations.
13.3.4 work on the tower ladder is strictly prohibited, and is not allowed to adjust or repair machinery and other operations.
13.3.5 It is strictly prohibited for an idle person to walk into the range of activity of the boom during work.
13.3.6 The value of the safety valve of the hydraulic system, the adjusting value of the protection device of the electrical system and the adjusting value of other mechanical and structural parts (brake, limit switch, etc.) are not allowed to be changed at will.
13.3.7 When there are more than two tower crane work, according to the characteristics of the project, pay attention to the position of each other, and the use of different elevations, so as to avoid the tower crane's lifting arm, balancing arm collision with each other.
13.3.8 crane operation is completed, drive to the middle of the track position to park and clamp the rail clamp tightly pressed on the track, the slewing mechanism to release the hook lift, the trolley stops at 45M from the center of the tower crane.
14, crane maintenance:
Crane should be frequently inspected, maintenance and repair, transmission part should have enough lubricant, the wearing parts must be frequently checked, repair or replacement, the mechanical bolts, especially often vibration of the parts, such as the tower body should be checked whether the connecting bolts are loose, such as loosening, it must be tightened or replaced.
14.1 mechanical equipment maintenance and maintenance:
14.1.1 each structure of the brake should be frequently checked and adjusted brake tile and brake wheel time gap, to ensure that flexible and reliable, and its gap to ensure that between 0.5-0.1mm, in the friction surface, there should not be the presence of dirt, in case of dirt must be washed off with gasoline or thin material.
14.1.2 The lubrication of each part of the reduction gearbox, gearbox, external gears, etc. as well as the hydraulic oil are carried out according to the requirements in the lubrication table.
14.1.4 Where the open gear drive must be oil shield, walking open gear lower part of the exposed part, so often check the cleanliness of the track. So that sand and dirt do not enter the gear, and damage to the gear.
14.1.5 often check the connection of each part, if loose, should be tightened in time, the tower connecting bolts should be checked when the tower is under pressure to check the tightness (can be used to rotate the arm to cause the pressure state) all connecting pins must have cotter pins and need to be open.
14.1.6 often check whether the operation of the mechanism is normal, there is no noise.
14.1.7 mounting, dismounting and adjusting the slewing mechanism, pay attention to ensure that the center of the slewing mechanism planetary gear reducer and gears parallel to the center of the mesh surface is not less than 70%, and the gap should be moderate.
14.2 Hydraulic climbing system maintenance:
14.2.1 Use of hydraulic oil in strict accordance with the provisions of the lubrication table for refueling more oil and clean the inside of the tank.
14.2.2 relief valve pressure adjustment, shall not be arbitrary change, each time before climbing, the oil pressure gauge should be used to check whether the pressure is normal.
14.2.3 should always check whether the pipe joints are fastened tightly, no oil leakage phenomenon.
14.2.4 oil filter should always have no blockage, check the safety valve in the use of the adjusted value of change.
14.2.5 oil pumps, cylinders and control valves, such as leakage should be promptly serviced.
14.2.6 general assembly and overhaul after the first start of the oil pump, should first check whether the inlet and outlet reversed, the direction of rotation is correct, the suction pipeline is leakage, and then hand-tested, and finally in the specified speed start and test run.
14.2.7 When starting in winter, it should be started and stopped, repeated several times, until the oil temperature rises and the control valve rotates flexibly before formal use.
14.3 Maintenance and care of metal structure:
14.3.1 In transportation, try to prevent deformation of components and collision damage.
14.3.2 During use, regular overhaul and maintenance must be carried out to prevent rust and corrosion.
14.3.3 Frequently check the structural connection bolts, welds and components for damage, deformation and loosening.
14.3.4 Spray paint every 1-2 years.
14.4 Maintenance and upkeep of the electrical system:
14.4.1 Frequently check all wires and cables for damage, and bandage and replace damaged parts in time.
14.4.2 Encounter motor has overheating phenomenon to stop in time, troubleshooting before continuing to run, motor bearings well lubricated.
14.4.3 collector ring and other parts of the brush, its contact surface should be kept clean, adjust the brush pressure, so that the contact area of the Department of less than 50%.
14.4.4 each control box, distribution box should always keep clean, sweep the dust on the electrical equipment in time.
14.4.5 the operation of the safety device switch touch open and close must be reliable, touch arc pit should be polished in time.
14.4.6 Shake the protective earth resistance twice a year (spring and fall) to ensure that it is not greater than 4 Ω.
14.5 Tower maintenance time regulations:
14.5.1 Daily maintenance (carried out on every shift)
14.5.2 After 1000 hours of tower machine work, the mechanical and electrical systems for minor repairs.
14.5.3 After 4,000 hours of tower crane work, carry out intermediate repairs to mechanical and electrical systems.
14.5.4 After 8000 hours of tower crane work, the mechanical, electrical system, etc. for major repair.
15 When the tower working height exceeds the free independent height, install the attachment in time according to the requirements of the manual.
16 Multi-tower operation precautions
16.1 In order to avoid the front end of the tower crane boom touching, should control the tower crane height difference between each other beyond 5m.
16.2 two tower boom in the staggered direction of operation, the hook should be controlled in each other's safe turning radius, to prevent collision.
16.3 two tower crane driver in the operation of the boom slewing, before arriving at the same direction should sound the horn to remind each other attention.
16.4 stop operation, the two tower crane hook should be raised to the height limit distance of 2m, in order to prevent jib rotation with the wind when the hook collision jib.
Eight, tower crane installation acceptance, record
Tower crane installation is completed, the site project safety officer to organize the project technology department, project machinery department, electrician on the verticality of the tower crane, bolts, electromechanical for a comprehensive inspection, after passing the inspection, reported to the supervisory unit for acceptance.
Supervisory unit acceptance by the project mechanical responsible person to apply for government full-time department for inspection, by the government full-time department after acceptance for the record use.
Nine, safety precautions
1, the site installation by the safety officer is responsible for safety supervision, requires the safety officer to conscientiously and responsibly exercise their authority.
2, all the professionals participating in the installation, must be unified to receive safety education and safety technology briefing, each person is equipped with seat belts and helmets.
3, the installation of high-altitude workers with tools, appliances, all with a rope hanging string tied to the body, to prevent the installation of slip and fall hurt. Installation bolts and other important scattered parts, the use of special tools placed centrally.
4, set up one or two guards, specifically responsible for preventing unrelated personnel from entering the installation area.
5, the installation of all installation components in accordance with the original manufacturer's instructions, and detailed inspection after installation.
6, to ensure that the tower crane foundation to strengthen the level of section embedded, square, to ensure that the tower installation vertical.
Ten, emergency rescue measures
1, when the site of the tower crane installation accidents, to report the situation to the higher leadership in a timely manner, and organizing personnel on the first aid work of the personnel present in a timely manner to call the "120" Emergency Medical Service Center, will be sent to the hospital immediately to save the injured.
2, the fall of personnel working at height, according to the severity of the situation of the person for treatment, light injuries, can be sent to the hospital, for serious injuries, to be treated by the personnel with medical knowledge or call the "120" Emergency Center, can not be handled on their own.
3, the site of the material in the event of a fire, required to call "119" fire alarm, the timely evacuation of the staff present, and the organization of personnel with fire extinguishers to fight the work.
4 Emergency Rescue Leadership Team
Leader:
Deputy Leader:
Members:
The team is composed of the following members