钢箱梁制作方案

-1-凤凰山高架桥和凤凰山路、双沙路、双瑞二路工程（ZX99#～ZX102#桥墩）中的钢箱梁工程钢箱梁制作方案编制人：审核人：审批人：四川建筑机械化工程公司2015年4月-2-目录1、工程综述··························································11.1编制依据···························································11.2工程概述···························································22、钢箱梁的总体施工方案············································32.1总体施工方案·······················································32.2总体工期安排·······················································42.3施工组织设计·······················································43、工程材料及其管理··················································63.1工程主材料·························································63.2工程焊接材料·······················································63.3涂装材料···························································63.4材料管理···························································64、箱梁构件制作要求及工艺流程·····································74.1加工材料及技术准备·················································74.2放样号料···························································84.3钢箱梁分节参数····················································114.4钢箱梁单元的组合拼装··············································114.5厂内分段拼装······················································124.6焊缝探伤检测······················································124.7焊接工艺··························································134.8焊缝质量要求······················································144.9钢箱梁涂装························································164.10临时吊点布置·····················································195、钢箱梁运输及成品保护··············································205.1待运······························································205.2散件运输··························································205.3成品防护··························································20-3-6、钢箱梁施工质量保证措施···········································216.1工程质量管理保证措施··············································216.2焊接变形控制措施··················································216.3钢箱梁线型控制措施················································246.4钢箱梁焊接质量控制措施············································257、钢箱梁制作安全措施················································287.1钢箱梁涂装施工安全文明施工措施···································287.2钢箱梁吊装施工安全措施············································287.3钢箱梁加工安全措施················································29-4-钢箱梁制作施工方案1．工程综述1.1编制依据1.1.1根据现场实际地形、地貌和施工图纸；1.1.2现场地形、交通条件、施工环境等的现场调查情况；1.1.3我单位的施工经验及其他施工要求。1.1.4施工和检验标准与规范；《城市道路设计规范》(CJJ137-2012)《城市桥梁设计规范》(CJJ11-2014)《公路工程技术标准》(JTGB01-2011)《公路桥涵设计通用规范》(JTGD60-2004)《城市桥梁抗震设计规范》(CJJ166-2011)《公路桥涵钢结构及木结构设计规范》(JTJ025-86)《铁路桥梁钢结构设计规范》(TBl0002.2-2005)《公路桥涵施工技术规范》(JTG/TF50-2011)《钢结构设计规范》(GB50017-2003)《钢结构工程施工规范》(GB5755-2012)《铁路钢桥制造规范》(TBl0212-2009)《钢结构工程施工质量及验收规范》(GB50205-2011)1.1.5原材料与检验标准；《低合金高强度结构钢》(GB／T1591-2008)《厚钢板超声波检验方法》(GB/T2970-2004）《碳素结构钢》(GB/T700-2006）1.1.6焊接材料验收及标准；《气焊、焊条电弧焊、气体保护焊和高能束焊的推荐坡口》GB/T985.1-2008《埋弧焊的推荐坡口》GB/T985.2-2008《碳钢焊条》(GB/T5117-1995)《埋弧焊用低合金钢焊丝和焊剂》(GB/T12470-2003)-5-《气体保护电弧焊用碳钢、低合金钢焊丝》（GB8110-2008）1.1.7焊缝及焊接相关检验与规范《金属熔化焊焊接接头射线照相》(GB/T3323-2005)《钢焊缝手工超声波探伤方法和探伤结果的分级》(GBll345-89)《无损检测焊缝磁粉检测》（JB/T6061-2007）1.18箱梁涂装及相关检验与标准、规范：《铁路钢桥保护涂装》（TB/T1527-2004）《涂装前钢材表面锈蚀等级和除锈等级》(GB8923-98)《公路桥梁钢结构防腐涂装技术条件》（JT/T722-2008）《建筑用钢结构防腐涂料》（JT/T224-2007）1.2工程概述本工程桥梁分为左右两幅修建，左幅桥为变宽桥梁，桥宽由0.15m+12.45m+0.15m变到16.84m；右幅桥为等宽桥梁，桥宽为0.15m+12.75m+0.15m。跨径布置为30+37+25m，左幅桥上部结构为变截面连续钢箱梁，右幅桥上部结构为等截面连续钢箱梁，梁高1.82m梁体采用预制拼装施工。钢箱梁采用纵横向划分，节段钢梁间连接方式主要采用工厂焊接与工地现场焊接相结合的方式。左右幅桥顶底板均采用1.5%的单向横坡，顶、底板平行，腹板铅垂。具体跨度、重量、长度等主要参数见表见钢箱梁一览表1.1。表1.1钢箱梁参数一览表序号联号跨径材料工程量（t）梁高（m）宽度（m）一左幅左侧钢箱梁30+37+25mQ345C1.82二左幅中部钢箱梁30+37+25mQ345C1.82三左幅右侧钢箱梁30+37+25mQ345C1.82四右幅左侧钢箱梁30+37+25mQ345C1.82五右幅中部钢箱梁30+37+25mQ345C1.82-6-六右幅右侧钢箱梁30+37+25mQ345C1.82合计-7-2、钢箱梁的总体施工方案2.1总体施工方案钢箱梁在四川省建筑机械化工程公司指定的下属金属结构有限公司厂内整体拼装，按图纸制作段加工，再运至现场拼装、安装及吊装。根据考察运输公路的路面条件和交通法规要求，货物运输宽度限制在4.5米内，长度限制在30米内，重量限制在100t内。根据实际情况及钢箱梁结构特点，我们确定的钢箱梁总体施工方案是：根据施工质量要求、结构特性、运输宽度的限制等因素，钢箱梁根据图纸尺寸不在分割，满足运输和安装要求。金属喷涂、底漆、面漆涂装均在厂内涂装，采用长车从公路运输，现场采用大型起重设备对钢箱梁分段吊装到临时支架上，采用榪板连接。形成纯钢断面的连续梁后，在支架上进行箱间纵、横梁联结焊接，然后拆除该施工分段的临时支架。钢箱梁具体施工方案为：（1）加工制作钢箱梁构件的制作主要分为翼板、桥底板、桥内侧腹板、桥中腹板、桥外侧腹板、I型肋及其肋板等零部件的制作。钢箱梁在拼装地面胎架流水线上进行组装、焊接。钢箱梁通过胎架进行组立、焊接以及矫正。零部件加工通过在数控及机械设备进行。钢箱梁结构加工制作，以最大限度的使用机械操作并利用工装夹具，以减少手工操作的随机性和不稳定性，提高构件的准确率及生产效率。焊接完成后按照设计要求进行涂装，并经验收合格后方可运输至工地。（2）构件运输组织构件在工厂加工完成后，可采用长车进行运输，对于超宽车辆应报请交通运输部门批准后方可起运。长车应设置必要标志。钢箱梁应采取牢固的包装，以防构件受损。行驶路线为：运至工地。（3）现场拼装箱梁组拼件在工厂加工后，运输到工地。钢箱梁现场组装焊接要求达到与工厂加工水平一致的质量标准。（4）钢箱梁安装钢箱梁安装支架在节段钢箱梁下部设置临时支架，临时支架应有足够的刚度、强度和稳定性，以防支架变形.箱梁节段采用履带吊或轮胎式汽车吊配合吊装，应对其吊装半径、吊装能力进行检算，确保安全。钢箱梁拼接后应调整位置、标高至设计要求，再进行焊接。在支架处设置操作平台及检测平台，便于操作，焊接质量应进行探伤检测。-8-2.2工期安排计划制作工期2个月，根据土建施工计划确定制作每联钢箱梁的制作先后顺序，制作结束开始现场安装，计划安装工期2个月，计划总工期4个月。2.3施工组织设计2.3.1劳动力计划表2.1制作劳动力投入计划表序号工种人数备注1管理人员52起重工53起重指挥员24钳工65电焊工205铆工106防腐工127电工28测量工29质检员210探伤员411辅助工5合计75-9-2.3.2主要机械设备序号设备名称规格型号数量权属1门式切割机F.P.9000D1自有2门式埋弧焊机ZR10001自有3数控等离子切割机OMNIMATP6502自有4端铣机dx1500*20001自有5液压剪板机10*30002自有6液压折弯机10*40001自有7铣边机B81120A1自有8数控平面钻床PD161自有9车床CW6163C2自有10钻床Z30802自有11CO2焊机60～500A40自有12交流电焊机Bx1(2)-50010自