吊车安装方案.docx
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吊车安装方案.docx
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吊车安装方案
安装工艺规程Installationprocessprocedures
1轨道的安装Installationoftherail
1.1安装前的准备Preparationbeforeinstallation
1)熟悉规范、标准及图纸资料;Familiarspecifications,standardsanddrawings;
2)审查安装轨道所需材料的材质、规格、数量是否满足技术要求;Reviewwhetherthemounting-railmaterials’quality,specification,quantitymeetthetechnicalrequirements;
3)检查施工通道、清理现场,达到安全施工、文明施工要求;Checkthechannelsofconstruction,cleanupthesite,whichcanreachtherequirementsofsafeconstructionandcivilizedconstruction;
4)制定安全措施,设置安全生产区,有专人对高空作业及重物起升作业区进行监视,安全绳设置要有足够的强度及稳固性;Developsafetymeasures,setsafetyproductionarea,thereisspecialassignedpersonnelresponsibleformonitoringworkatheightandweightsliftingoperationareaandthesafetyropesetshouldhavesufficientstrengthandstability;
5)准备轨道安装所需用的机械、工具、量具;Preparerequiredmachinery,tools,measuringtoolsduringrailinstallation;
6)检查轨道的质量:
如发现有弯曲变形,应校正后才能安装;Checkthequalityoftherail:
iffoundbendinganddeformation,correctbeforeinstallation;
7)吊车梁放线检查及标高测量:
Thecranebeampayingoffcheckandelevationmeasurements:
a用经纬仪测量吊车梁中心线,并留下标记(2—3米设置一个点);Thetheodoliteisusedtomeasurethecranebeamcenterlineandleavemarks(setapointevery2-3m);
b用水准仪测量吊车梁的水平标高,并作记录;Usewaterleveltomeasurethecranebeamandmakerecords;
C吊车梁跨距用钢卷尺、弹簧称测量;注意弹簧称的示值应和检查大车轮距时一致;Cranebeamspanshouldbedwithmeasuresteeltape,springbalance;payattentiontothespringbalanceshowedvaluesconsistentwiththoseduringmeasurementofthethreadofthegantry.
1.2轨道安装Railinstallation
1.2.1重轨(38kg/m以上)压板式安装程序(带钢垫板)Heavyrail(38kg/mormore)pressureplateinstallationprocedure(withsteelshim)
1)基准板安装1)Thereferenceboardisinstalled:
在吊车梁上每隔2米左右固定一块垫板,要求标高(用水准仪测量)控制在±2m以内,纵横向水平度以2mm/m水平仪找平;Onthecranebeam,fixapadaboutevery2m,requiredelevation(measuredwithwaterlevel)shouldbecontrolledwithin±2m,verticalandhorizontallevelnessshouldbemadewith2mm/mspiritlevel;
2)轨道就位2)Railinplace:
把经检查符合安装要求并下料的轨道按预选排好的顺序吊装就位;Hoistcutrailswhichmeettheinstallationrequirementsandafterinspectioninplaceaccordingtopre-determinedorder;
3)轨道找正、定位、紧固3)Railalignment,positioning,fastening
安装所用的工具、材料(螺栓、垫圈、压板、螺母等)用小桶或工具袋吊到吊车梁上,注意放好,以防掉下伤人;必要时也可对位穿好,但不紧固,用鱼尾板把轨道联接成一体,注意轨道接头应有2mm间隙,以保证热膨胀要求;根据中心线找正轨道,先固定基准位置,并测量检查安装数据,符合要求后,垫其它位置,要求垫平、垫实并固定,检查后把螺栓全部紧固。
Installationtoolsandmaterials(bolts,washers,clips,nuts,etc.)shouldbehangedtothecranebeamswithakegortoolbag,andpayattentiontoputtingthemaway,topreventfall-againstinjuries;ifnecessary,counterpointassemblycanbemade,butdonotfastenthem,andmakecouplingconnectiontotherailwithfishplates,andpayattentiontotherailjointgapshouldbe2mm,toensuretherequirementsofthethermalexpansion;accordingtothecenterline,findalignmentfortherails,firstfixthereferencepositionandmeasureandchecktheinstallationdata,andpadotherpositionsaftermeetingtherequirements,andpadandfixsolid,fastenalloftheboltsafterchecking.
4)测量检查4)Measurementandcheck:
轨道安装找正后,用经纬仪、水准仪、钢卷尺、弹簧称等量具进行最后测量检查,质量符合安装技术要求和设计要求,并做记录,作为交工资料。
Aftertherailmountingalignment,finalmeasurementandcheckshouldbemadewiththeodolite,level,steeltape,springbalanceequalamount,andthequalityshouldmeettheinstallationrequirementsanddesignrequirementsandmakerecordmakerecordswellwhichshallbeusedasthehandoverinformation.
5)质量检查符合要求后,将方垫圈与压板点焊,并每隔五组对焊一组。
Afterqualitycheckandmeetingthequalityrequirements,makespotweldingforsquarewashersandthepressureplate,andonegroupofbuttweldingwillbemadeeveryfivegroups.
1.2.2轻轨(24kg/m以下)、方钢轨道安装Installationoflightrail(24kg/morless)andsquaresteelrail
1)基准板安装1)Installationofthereferenceboard:
在吊车梁上每隔1.5米左右固定一块垫板,要求标高(用水准仪测量)控制在±2mm以内。
纵、横向水平度以2mm/m水平仪找平。
Fixapadaboutevery1.5monthecranebeamandtheelevation(measuredwithwaterlevel)shouldbecontrolledwithin±2mm.Verticalandhorizontallevelnessof2mm/mandfindlevelingwithspiritlevel.
2)轨道就位2)Railinplace:
把经检查符合安装要求并下料的轨道按预选排好的顺序吊装就位;Hoistcutrailswhichmeettheinstallationrequirementsandafterinspectioninplaceaccordingtopre-determinedorder;
3)轨道找正、定位、紧固、焊接:
3)Railalignment,positioning,fastening,welding:
a栓压板式安装找正、定位、紧固方法和重轨安装方法相同。
Boltpressureplatemountingalignment,positioning,fasteningmethodsarethesameastheheavyrailinstallationmethods.
b焊接式安装:
在基准板位置进行找正,并点焊,待两条轨道所有基准板处都点焊完后,进行测量检查,符合要求后,进行复垫固定并点焊,最后进行全面焊接。
Weldedinstallation:
alignmentatthepositionofthereferenceplateandmakespotwelding,andafterallthereferenceplatesoftworailsaremadespotwelding,andmeettherequirementsaftermakingmeasurementandinspection,re-pad,fixandmakespotwelding,andatlastmakefullwelding.
4)方钢轨道接头的宜在螺栓处,如不在螺栓处,应在接头下面放钢垫板。
Squaresteelrailjointshouldbeattheplaceofthebolt,ifnotattheplaceofthebolt,steelpadplateshouldbeputunderthejoint.
5)测量检查Measurementandcheck:
轨道安装找正后,应进行最后测量检查,安装质量应符合要求并作好记录,作为交工资料Aftertherailmountingalignment,finalmeasurementandcheckshouldbemade,andtheinstallationqualityofshallcomplywiththerequirementsandmakerecordswellwhichshallbeusedasthehandoverinformation.
1.2.3车挡制作与安装Carbumperproductionandinstallation
1)车挡按施工图或标准制作。
Carbumpersshouldbemadeaccordingtoconstructiondrawingsorstandards
2)车挡焊缝要饱满,不得有裂纹及咬边现象。
Carbumpers’weldinggapbefull,nocracksandundercuts.
3)车挡与吊车梁联接孔必须按吊车梁的实际孔间尺寸而定。
Thesizeofcarbumpersandthecranebeamcouplingholeshouldbesubjecttotheactualsizebetweentheholes.
4)缓冲器紧固螺栓必须用双螺母和斜垫圈。
Bufferdevicefasteningboltsmustbedoublenutsandtaperwashers.
5)同一跨内两条平行轨道上,车挡与起重机缓冲器的接触面要在同一平面并和轨道纵向中心线垂直。
使两者到定位线的距离≤4mm。
Ontwoparallelrailsofthesamespan,thecontactsurfacebetweenthecarbumperandthecranebufferdeviceshouldbeofthesamesurfaceandverticaltothelongitudinalcenterline,andletthepositioningdistanceawayfromthecarbumperandthecranebufferdevice≤4mm
6)车挡制安装完后,应刷防锈漆两遍。
Afterthecarbumpersystemisinstalled,paintantirustpainttwice.
1.3轨道安装技术要求Railmountingtechnicalrequirements
1.3.1轨道安装的偏差要求Railmountingdeviationrequirements:
1)轨道实际中心线对安装基准线的位置偏差不应超过3mm。
Thepositionaldeviationbetweentheactualrailcenterlineandthemountingbaselineshouldbenomorethan3mm.
2)轨道实际中心线对吊车梁实际中心的位置偏差不应超过10mm。
Thepositionaldeviationbetweentheactualrailcenterlineandthecranebeamactualcentershouldbenomorethan10mm.
3)两条轨道中心线间跨距偏差不应超过±5mm。
Thespandeviationbetweentworailscenterlineshouldnotexceed±5mm.
4)同跨两平等轨道的标高相对差在柱子处应不大于10mm,其它处应不大于15mm。
Therelativedifferencebetweenelevationsoftwoparallelrailsofthesamespanatthepillarsshouldnotbegreaterthan10mm,othersshouldnotbemorethan15mm.
5)轨道的纵向下水平度不应超过1/1500;轻轨重轨,起重机轨和方钢轨应在每根柱子处测量。
全行程上最高点与最低点之差不应大于10mm。
Therail’slongitudinallowerlevelingdegreeshouldnotexceed1/1500;Lightrail,heavyrail,cranerailandsiderailshouldbemeasuredateachpillar.Thedifferencebetweenthehighestandlowestpointsinthefullstrokeshouldnotbegreaterthan10mm.
1.3.2两条平行轨道的接头位置应错开。
其错开距离不应等于起重机前后车轮的轮距。
Jointpositionoftwoparallelrailsshouldbestaggered.Thestaggereddistanceshouldnotbeequaltothetreadbetweenthefrontandrearwheelsofthecrane.
1.3.3轨道接头应符合下列要求Railjointsshallmeetthefollowingrequirements:
1)接头用鱼尾板或与鱼尾板规格相同的联接板联接时,接头左、右、上在面的偏移均不应大于1mm,接头间隙不应大于2mm。
Duringjointsusefishplatesorcouplingplateswiththesamespecifications,deviationsontheleftandright,aboveandbelowshouldnotbegreaterthan1mmthejointgapofnomorethan2mm.
2)接头用对接焊时,焊条和焊缝应符合钢轨的材质和焊接质量的要求,焊好后接头平整光滑。
Duringjointsusebuttwelding,electrodeandtheweldgapshouldmeettherail’smaterialandweldingqualityrequirementsandshouldbesmoothafterwelding.
3)伸缩缝处的间隙应符合设计规定,其偏差不应超过±1mm。
Expansionjoints’gapsshouldbeconsistentwiththedesignrequirementsandthedeviationshouldnotexceed±1mm.
4)用垫板支承的方钢轨道,接头的垫板宽度应比其它处增加一位。
Squaresteelrailsupportedwithsheetpad,thewidthofthesheetpadatthejointshouldbeincreaseanorder.
1.3.4在钢吊车梁上铺钢轨时,钢轨底面应与钢梁顶面贴紧。
如有间隙,其长度超过200m时,应加垫铁垫实,垫铁长度不应小于100mm,宽度应大于轨道底面10~20mm,每处垫铁不应超过三层,垫好后与钢梁焊接固定。
Whenpavingthesteelrailsonthecranebeam,steelrailundersideshouldcloselyalignwiththesteelbeamtopsurface.Ifanygapanditslengthofmorethan200m,addsizingblockstopadit,andthelengthofsizingblockshouldnotbelessthan100mm,thewidthshouldbe10~20mmgreaterthantherailbottomsurface,andatnoplacewillthesizingblocksexceedthreelayers,weldedandfixedwiththesteelbeamafterpaddedwell.
1.3.5轨道上所有螺栓必须拧紧,拧紧后螺纹最短应露出螺母1.5扣,最长应低于清道板10mm以下。
Allboltsontherailmustbetightened,andaftertightened,theshortestthreadednutshouldexpose1.5bucklesandthemaximumoflessthan10mmbelowtheway-cleaningboard.
1.3.6露天跨的起重机轨道所用的紧固螺栓。
在露出螺纹部分刷钙基脂黄油。
Theexposedthreadedportionoffasteningboltsusedtheopen-air-spancrane’srailshouldbepaintedcalciumgreasebutter.
1.3.7同一跨端的两车挡与起重机缓冲器均应接触,否则应调整。
Twocarbumpersonthesamespan-endshouldcontactthecrane’sbufferdevice,otherwiseitshouldbeadjusted.
1.4测量检查Measurementandchecks
1.4.1轨道安装好以后,应按规范要求进行轨道中心线相对位置偏差、轨道标高、轨道标高相对差、轨道跨距的偏的测量检查。
并在记录,以便整理交工资料。
Aftertherailisinstalled,measurementcheckshouldbemadeforrailcenterlinerelativepositiondeviation,railelevation,relativelyrailelevationdeviation,railspandeviationaccordingtorequirementsandmakerecords,tofinishhandingoverthedeliveryrecords.
1.4.2测量检查方法Measurementinspectionmethods:
1)轨道中心线相对位置偏差:
用经纬仪、钢直尺测量,也可依据所放基准线用钢直尺测量。
Therelativepositiondeviationofthecenterlineoftherail:
measuredwiththeodoliteandsteelruler,andmeasurementcanb
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