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Product Details (Chimney New Construction)

I. Project Overview:

This project is a reinforced concrete chimney structure (the foundation is selected from the national standard atlas).Base for 05G212, chimney wall selected from National Standard Collection 05G212), chimney foundation concreteC30; Base bedding, chimney heightMCylinder body concreteC35. Detailed construction content is specified in: Design Drawings and General Construction Instructions.

Section IICompilation Basis

1. China National Standard 05G212 Reinforced Concrete Chimney Catalog

2. Engineering Survey Specifications GB50026-93

3. Code for Acceptance of Construction Quality for Foundation and Substructure Engineering - GB50202-2002

4. Concrete Structure Construction Quality Acceptance Code GB50204-2002

5. Uniform Standard for Acceptance of Construction Quality of Civil Engineering Projects GB50300-2002

6. Safety, Fire Prevention, and Labor Protection Technical Regulations SH3505

7. Concrete Quality Control Standard GB50164-92

8. Concrete Admixture Application Technical Specification GB50119-2003

9. Masonry Construction Quality Acceptance Standard GB 50203-2002

10. Chimney Construction and Acceptance Standard GB50078-2008

11. Steel Structure Construction Quality Acceptance Code GB50205-2002

12. Relevant laws, regulations, standards, codes, and guidelines.

Section 3: Construction Plan

A. Basic Construction:

Construction sequence:Positioning stringing→Excavation →Foundation trench acceptance →Pouring C15 concrete base layer →Building brick outer formwork →Foundation reinforcement fabrication and installation →Foundation C30 concrete pouring →Second layer foundation brick inner formwork construction →Reinforcement fabrication and installation →Outer formwork installation →Foundation C35 concrete pouring →Demolish outer formwork →Install lightning protection grounding electrode →Backfill soil. 

B. Main Construction:

     1. The construction sequence is: steel reinforcement binding → outer formwork installation → inner formwork installation → pouring C30 concrete (with a height of 1.70 meters per formwork pour).

2. Inner mold: Made of 1650×200mm construction plywood, two sets are produced, with two layers of mold for flipping construction, with N pieces per layer. Each mold side is reinforced with two 35×50mm wooden planks as vertical ribs. A steel reinforcement protective layer is welded inside the chimney body wall at the radius size of the cylinder wall. Then, the molds are installed piece by piece, leaving a gap of 3-4mm between the lower edges of each mold. This ensures the proportion of the upper and lower sections of the inner mold. Reinforcement for the inner mold is done with two Φ25 curved steel bars, secured with tension bolts or wire.

3. Scaffold Template Manufacturing: The sliding formwork for chimneys is divided into external and internal templates.Outer template of the cylinder body2.0mm thick steel sheet templates, initially made based on the shrinkage ratio of the chimney cylinder. The outer templates are machined to be 1.72m high and 1.00m wide, with N holes punched along the edges. They are then connected with M5×15 bolts into four sections, with the total length measured to match the circumference of the cylinder. During construction, the outer templates are tightened according to the shrinkage ratio of the chimney cylinder to meet the requirements.

4、Chimney cylinder form installation: After assembling the four outer molds, apply oil and place them on the exterior side of the tied rebar of the cylinder wall for the installation of the outer formwork. Secure the lower opening of the formwork to the exterior side of the welded steel reinforcement protective layer (in future cylinder wall construction, the lower opening of each outer formwork can be directly fixed to the top of the cast concrete cylinder body, overlapping with the concrete cylinder wall).30-50mm, φ12 for the top of the moldRebar ends (length equal to the thickness of the chimney wall), one end of which is painted for corrosion prevention, are welded to a circumferential horizontal rebar at the top of the wall. This is used to control the protective layer of the inner and outer molds as well as the thickness of the concrete in the wall. Then, based on the actual outer diameter of the wall, the outer mold is reinforced (using a locking pliers to...).16Rootφ8The wire rope is tightened. When the outer molds overlap each other to0.80mWhen disassembling, promptly remove one outer template to avoid excessive overlap. See the mole grip in the illustration below:

5. Material Feeding Method: A gantry lifting frame is set up above the #-shaped scaffolding inside the chimney for material feeding. It moves upwards gradually as the chimney rises. Two 2-ton pulleys are installed on the gantry frame. Approximately 25 meters away from the chimney on the ground, a 2-ton winch is placed. Material feeding can be done using Ф12 steel wire rope. The winch's on/off is controlled by an AC contactor button switch. A button switch for controlling the up/down movement is installed on both the chimney operation platform and the ground level. A limit switch is fitted above the gantry frame to prevent accidents due to the failure of the button switch or operation errors.

6. Each concrete pour is 1.70 meters high. Before pouring, check the rebar binding and embedment positions to ensure accuracy before proceeding. Pour and vibrate in layers, approximately every 500mm in height, with three pours per mold to prevent template displacement and central deviation errors.

7. After each concrete pour, proceed with the next pour's rebar tying within 5 to 6 hours. Raise the outer formwork by using 16 hand-tensioning winches fixed above the chimney rebar grid. By turning the winch handles, the outer form can be lifted as a whole. Once raised, align the formwork center and then securely fasten the bottom of the outer form to the already poured chimney body (repeating the concrete by about 50mm). Weld a protective layer around the top opening of the form using rebar ends according to the radius size. Secure the form to the rebar grid of the cylinder body. After verifying the correct dimensions of the inner and outer forms, inspect the rebar and embedded parts before pouring concrete. Repeat this process until the chimney is completed.

8. The chimney of this project has two flues, with the bottom of the flues rounded at a center point of 3.00 meters. Reinforcement bars are pre-buried at the edges of the beams (additional reinforcing bars as per the drawings), followed by the construction of temporary scaffolding on both sides of the chimney for the second phase of work.

9. Method for workers' ascent and descent: As the chimney is gradually raised with each mold, the pre-fabricated, painted and anti-corrosive ladders are installed step by step. Workers can then ascend and descend using the ladders. (Temporary ladders for heights under 10 meters are installed similarly, but are removed once the 10-meter steel rotating ladder is set up.)

Four: Safety Measures:

1. Construction personnel must undergo three levels of safety education, special trade workers must hold valid certifications before starting work, smoking is strictly prohibited in the factory area, and unauthorized use of all machinery and equipment within the facility is not allowed.

2. Workers entering the construction site must wear a hard hat, work clothes, and rubber shoes. A safety belt must be fastened when working at heights above two meters.

3. Construction personnel must be knowledgeable and familiar with the main operational procedures for chimney construction and must not issue illegal instructions or perform illegal operations.

4. Individuals with heart conditions, high blood pressure, or other health issues are strictly prohibited from working at heights. Alcohol consumption or those feeling unwell are also prohibited from performing high-altitude work (all workers must undergo a medical examination before the construction of this project, and only those who meet the requirements may participate in the construction work).

5. All machinery and equipment must have a dedicated switch for each unit, equipped with a leakage protection switch (circuit breaker), and must be grounded to prevent electric shock accidents.

6. A hazardous area of 25 meters around the chimney must be enclosed with a fence and equipped with prominent warning signs. A designated person must supervise the construction site at all times, and non-employees are strictly prohibited from entering.

7. When working at heights, all tools must not be thrown up or down to prevent injury from falling.

8. Safety Shelter: Establish a safety passage at the personnel entrance and exit of the chimney flue. Construct a temporary safety shelter with boards 4.5 meters inside the chimney. A safety shelter must be erected above the winch and mixer.

9. All machinery, wire ropes, pulleys, and safety belts must be checked meticulously and strictly every day. Any issues found should be addressed immediately, and items that cannot be used should be replaced on the spot to prevent accidents.

10. For the # type scaffolding, additional diagonal bracing and upright columns are installed at the cantilevered joints every 10 meters in height to reduce the load-bearing capacity of the 100-meter-high scaffolding and ensure construction safety. The scaffolding boards are made of 50mm thick pine boards, and when laying them, the boards must be securely tied to prevent any loose or overhanging boards.

11. Workers must wear safety belts when performing exterior wall repairs or installing platforms on ladders or hanging ladders to prevent accidents.

12. Strong winds, thunderstorms, heavy fog, and other severe weather conditions prohibit forced construction. We are currently in the thunderstorm season, so high-altitude work must constantly monitor weather conditions and take timely measures to ensure the personal safety of construction personnel.

Five、Staff Organization and Arrangement:

   Winches, mixers, welders, electricians, bricklayers, carpenters, reinforcing steel workers, and laborers, all included:12 people.

Six: Quality Assurance Measures:

1. Strict adherence to the construction drawings is required during construction. The contractor is not permitted to alter the drawings for construction without the approval of the factory or the design department.

2. Materials used for chimneys must have a factory certificate of conformity and a warranty, and substandard materials such as不合格的cements, sands, stones, and refractory bricks are prohibited.

3. Construction is strictly carried out according to the concrete mix ratio. Cement is measured by 50 kg per bag, sand and stone materials are weighed and marked on the material truck for measurement. Two concrete test blocks are made every 10 meters for chimney height to facilitate testing.

4. When casting concrete in molds, layer-by-layer pouring and compaction are required. Compaction should be done every 500mm in height to prevent displacement of forms and misalignment. Pay close attention to compaction to avoid the occurrence of honeycomb and rough surface phenomena.

5. After the exterior model is installed, it is crucial to check according to the radius and height of the chimney to prevent errors. Ensure that the radius and wall thickness deviations are within the construction specifications.

6. The chimney center is suspended with a 40 kg heavy line weight. To prevent wind interference, the chimney smoke inlet can be sealed. During construction, the deviation of the chimney center is kept within the minimum range.

7. Construction personnel must maintain detailed construction records, keep a daily construction diary, promptly address any issues, and require relevant parties to make timely corrections.

8. Key Quality Control Points: Chimney verticality, radius, wall thickness, steel bar spacing, protective layer thickness, inner lining joint thickness, fullness, down wire welding, settlement records.

Section 7: Quality Acceptance Standards for Construction Work

1. Allowable deviation for basic location and dimensions

2. Allowable tolerance for the dimensions of reinforced concrete chimney筒wall

Emergency Response Plan

10.1 Emergency Event Management:

The objects of emergency management should focus on accidents (events) that are likely to occur, but accidents (events) that are less likely to happen yet could have severe consequences should also be considered. The main objects for implementing emergency management include:

Landslide incident

Major machinery accidents and injuries.

Operation accidents and personal injuries involving construction equipment.

Lightning and electric shock;

High-altitude fall

10.2 Responsibilities

Team LeaderResponsible for the command, coordination, and organization of emergency incidents, implementing the policies and guidelines for emergency incident management, and ensuring the effective operation of required materials and human resources from all parties.

    Deputy Team Leader:Oversees on-site command and dispatching for emergency operations, directly responsible for the implementation of the overall plan for emergency incidents (events) and the fulfillment of disaster relief tasks. Organizes the formulation of emergency plans, promptly communicates relevant information from higher authorities, and ensures the normal operation of the system.

MemberEstablish preventive measures within your designated responsibilities, ensure high-level coordination during emergencies, follow command and dispatch, implement emergency management plans, inspect the implementation of your unit's preventive measures, promptly report the execution of daily management work to your superior leaders, and assist the commander in coordinating subordinate departments and units.

10.3 Emergency Event Handling Procedure:

1) Emergency Event Report

When an emergency event occurs, the person discovering the emergency should immediately report to the highest-ranking official at the scene of the incident. The highest-ranking official at the scene is responsible for reporting to the Project Department's main emergency control center.

Upon receiving an emergency report, the main emergency control center of the project department should immediately report to the relevant leaders and be responsible for contacting the rescue department.

2) On-site Handling of Emergency Incidents

Upon occurrence of an emergency, immediate emergency measures should be taken to prevent the emergency situation from escalating, and corresponding measures should be adopted to protect the site where the emergency occurred.

Following an emergency, personnel should immediately evacuate along the routes designated by emergency management measures, and a designated person (typically the first-line management supervisor) should verify individuals present at the scene by unit and report to the emergency coordinator promptly, who in turn reports to the emergency control center; direct reporting is allowed in urgent situations. For incidents involving injuries or fatalities, immediate medical assistance to the injured should also be organized.

After personnel evacuation from the emergency accident site and control of the emergency matters, the emergency command center will organize post-emergency response measures in accordance with the emergency management procedures.

3) Emergency Drills

The Emergency Control Center of the Project Department is located in the Construction Management Department, responsible for conducting emergency response drills and ensuring that all personnel are familiar with and understand the emergency response plan.

A drill of the emergency response plan must be conducted prior to construction.

After each drill, confirm whether the emergency plan has been tested, and identify any shortcomings and deficiencies.

③ Make necessary modifications to the emergency response plan to meet emergency management requirements.

④ Resources required for emergency response plan

⑤ Emergency Management Network Contact Information