沉井方案11(共15页)

1、上海迪士尼乐园项目GC-10主入口和花园总包工程 技术标 15/15一、声光(shn un)塔液压装置（HPU）概况(gikung)HPU summary 声光(shn un)塔位置：灯塔建筑219，用于在表演时升起照射舞台，平时则暗藏在灯塔建筑中。塔的建筑形式见于建筑图纸：1A-311Acoustooptic tower position: lantern tower of 219 is used to flash the stage when performing, and hided from the lantern tower at other times. The building

2、types of tower is shown on the construction drawing of 1A-311. 灯塔3# light tower 3# 灯塔4# lantern tower4#声光塔由不锈钢内胆和200毫米厚的钢筋混凝土外壳组成，地下层标高为从-3.240米，管底标高为：-17.04米。钢管材质为00Cr17Ni14Mo2(00Cr17Ni14Mo2(316L)不锈钢，内径为1240毫米，壁厚20毫米（以上信息详见于2S-502号图纸及建筑图纸）：Acoustooptic tower consist of stainless steel and 200mm ste

3、el concrete, and the EL of subsurface layer is -3.240m and the EL of tube bottom is -17.04m.The steel tube texture is stainless steel of 00Cr17Ni14Mo2(00Cr17Ni14Mo2(316L), and its internal diameter is 1240mm, the pipe thickness is 20mm.(See details in the drawing of 2s-502 and construction drawing).

4、二、技术方案分析 Analysis of technical solutions1、根据工程条件，采用明挖方法势必暴露出已经打好的工程桩，且开挖范围大，基坑很狭小，不宜采用；1. According to the construction conditions, ways of open excavation will make the pipe exposed. The range of excavation is big and foundation ditch is too narrow to use the way of open excavation.2、若采用泥浆护壁就地灌注空心(

5、kng xn)桩方法，则面临不锈钢管在混凝土和泥浆浮力下定位困难的问题(wnt)。现浇混凝土的问题(wnt)在于：旦比重较大混凝土浮力下移位，将无法纠正，而混凝土在不断地凝固，从而导致整个组件报废。Ifweusethemudto grouthollowpile on the site, stainlesssteelwillbedifficulttolocatebecauseofconcreteandmud buoyancy. The problem of concrete casting-in-place as below: once a larger proportion of concre

6、te buoyancy is shifting, it cannot be corrected, and the concrete is solidified in constantly, which leads to the entire discarding.3、经过讨论，岩土工程师提供的建议：场外预制，工地吊装，灌浆固定的技术路线，较为合理。3. Advice provided by geotechnical engineer is to prefabricate off the site and hoist on the site, and grout the technical ro

7、ute fixed, which is reasonable after discussion. 4、预制件吊装的技术路线应解决的问题有：4. Problems for solving by the technical route of preformed unit :大型不锈钢焊接件-转运-包覆混凝土-养护后转运Large stainless steel weldment - transhipment- concrete coating- transhipment after curing就地干成孔 (不能浸泡在泥浆里，也就没有浮力问题）To make hole on site(No soa

8、k in mud , no problems of buoyant force)吊装和校正垂直度（预制件不受到浮力干扰，重心在下方有利于垂直）Hoisting and correction perpendicularity ( Prefabticated member is not interferenced with buoyant force , center of gravity below is helpful to erect)灌浆固定（采用分层浇筑的自密实细骨料混凝土）To fix the grouting(fine aggregate concrete of delaminati

9、on grouting will be used)在髙水位下的干成孔，将采用旋挖钢套管工艺来实现，钢管旋挖到底后嵌入髙压旋喷加固体内，下口是封闭的，形成一个密闭的空腔。Holes under high water level will be completed with steel sleeve pipe digging helically, and casting concrete bottom by jetting helically with high pressure. The bottom is closed and shaping a closed cavity.三、施工流程Con

10、struction procedure工况一:在加工厂内采用卷板焊接方法制作不锈钢组件 Working condition1: To product stainless steel modules by ways of roll bending in processing factory. 工况二：不锈钢组件转运到混凝土预制厂内，包覆混凝土Working condition2: Stainless steel modules will be transferred to the precasting concrete factory and cover concrete .工况三：旋挖机进场W

11、orking condition3: delivery of helical digger 1埋设(mi sh)护筒Protective sleeve installation 2 挖土 Earth excavation 3 Casting concrete Bottom 4 Stainless steel delivery of concrete precast module 5 吊装(diozhung) Hoisting 6 二次校正(jiozhng)Correct secondly 7 校正(jiozhng)工况下的剖面 Section for correction 8 灌浆固定Fix

12、with grouting9 灌浆材料可以选用高流动性、无收缩(shu su)、自密实细石混凝土Grouting materials can choose high liquidity, no-shrink and self-compaction coarse aggregate concrete.Crawler crane cooperating with helical diggerPosition of light towerHydraulic full rotation helical diggerDismantling stockpiling yard for steel sleev

13、eflat bed truckPosition of light tower10 作业区平面(pngmin)规划见上图： Operating area plan is shown as above首先(shuxin)完成西侧声光塔旋挖钻孔埋设套管，套管埋设完成后，西侧吊装作业开始。旋挖钻机转移到东侧进行钻孔和埋设钢套管作业。Digging helically the holes and filling the sleeve pipe for the west of acoustooptic tower firstly. The hoisting works begin after the fi

14、lling of sleeve pipe. Then the helical digger transfer to the east to continue the work of boring and filling of sleeve pipe. 附件(fjin) ：预制件制作(zhzu)方案 Solutions of making prefabricated member迪斯尼城堡(chngbo)预制不锈钢管-混凝土构件总长18640mm ,其中不锈钢管长18240mm、内径1240mm，壁厚20mm.外包200mm厚混凝土，混凝土部分长为13400mm.构件要求垂直度精准。The ov

15、erall length of stainless steel component part prefabricated of Disney Castle is 18640mm, the length of stainless steel pipe is 18240 mm , the internal diameter is 1240mm ,and the pipe thickness is 20mm. Outsourcing 200mm thick concrete, the length of concrete partly is 13400mm. Perpendicularity of

16、component should be precise.1、预制技术方案Technical solutions for prefabrication本构件加工主要难度为不锈钢管与底面垂直度精度的保证，13.4米长混凝土部分的浇筑方 案。我们经过讨论制定以下技术方案，确保该构件预制的质量：The difficulty for processing this component is not guarantee the perpendicularity precision between the stainless steel and its bottom. Solutions are devel

17、oped to ensure the quality of prefabrication components after discussion.不锈钢组件的焊接：由金属构件厂进行，采用卷板焊接的方法对20毫米不锈钢板 材进行号料、裁切、卷板、校正、焊接、二次校正。底板和加劲环采用30毫米平板制作并焊接到筒体上。施焊的方向和程序应注意避免焊接应力的累积导致不可逆的变形。根据吊装的要求和混凝土包覆的要求，在指定位置增加吊耳、栓钉等组件。焊接完毕后进行检测和验收。通过雇主驻厂代表验收后，发运到预制厂内，进行混凝土包覆工序。Welding of stainless steel components:

18、 to mark off, cut, bend rolls, correct, weld, and correct secondly 20mm stainless steel panel by ways of welding bending rolls at the mental construction factory. The bottom plate and stiffening rings use the 30mm panel to make and weld to the barrel. The direction and procedure of welding should av

19、oid the accumulation of welding stress which may lead to irreversible deformation .According to the requirement of hoisting and concrete coating, lifting lugs and male pins and other components should be added to the designated spot. Inspect and accept after welding. Dispatch them to the prefabricat

20、ing factory, and do concrete coating after the acceptance by resident represent of owner.为了保证不锈钢管的垂直度，我们拟采用直立模具浇筑混凝土方案,模具直立放置， 从上而下浇筑混凝土，考虑到混凝土浇筑部分长8米，不易振捣，同时混凝土的浇筑会造成 不锈钢管的上浮，从而造成构件的偏差。我们将模具分成6节，上下模具髙为1m，中间四节为每节1.5米，每节圆环模具采用两片相同的半圆环模具拼装组成，在每节混凝土绕筑完 成，混凝土初凝之前，进行上一节模具的拼装并浇筑该节混凝土，以此类推，浇筑至整个混凝土完成。最下面一节

21、设置成1m主要是考虑将因混凝土浇筑而造成的不锈钢管上浮的浮力 降到最小，保证构件的精度，分节如图1所示。To ensure the perpendicularity of the stainless steel pipe, we take the solution of pouring concrete with vertical mould. The mould is laid vertically and pouring concrete from top to bottom. Considering the length of a part of concrete poured is 8

22、m, it is difficult to vibrate, meanwhile, the pouring of concrete will lead to the rise of stainless steel pipe which lead to the error of component part .The mould will be divided into 6 sections, the height of mould between top and bottom is 1m, the intermediate sections height is 1.5m per section

23、. Each circular ring mould is consolidated by two same semicircle ring mould. Continue the consolidation of mould and pour the concrete before the initial set of concrete, and the like, pouring concrete until all the concretes are poured. The final section is set 1m, because it can make the buoyant

24、force of pouring concrete minimum to guarantee the precision of component part. See details in drawing 1.Pre-embedment for located steel platePlatform of steel mouldPrefabricated concrete baseLocating device for the bottomLocating device for the topSteel mouldHookStainless steel pipeSteel rack图1 不锈钢

25、管混凝土构件整体(zhngt)预制方案Prefabrication solution of stainless steel pipe and concrete component(3)为了保证(bozhng)不锈钢管的垂直度和消除因混凝土浇筑造成的不锈钢管的上浮问题，我们拟预先预制(y zh)加工如附件：混凝土和钢结构加工深化图中所示的预制底座构件。通过加劲肋和锚固钢筋将预制件和不锈钢管的底座牢固连接 To ensure the perpendicularity of stainless steel pipe and avoid the rise of stainless steel pipe

26、 due to concrete pouring, we make a plan for prefabrication as attachment. Connect the prefabricated member with the bottom of stainless steel pipe solidly by the stiffening rib and anchorage steel.(4) 混凝土采用C35P6抗渗混凝土。Water-tight concrete of C35p6 will be used(5)预制件顶部预留插筋，伸入后续施工的基础底板并浇成整体。The top of

27、 prefabricated member should reserve the dowel bar, enter into the foundation slab of subsequent construction and pouring them to be integral.(6) 混凝土上部浇筑上安置对称的两只吊环，吊环下部锚筋焊接在不锈钢管上，以保证吊环的承载力。Two lifting lug will be installed symmetrically at the top of concrete. The anchor bar of lifting lug bottom sh

28、ould weld on the stainless steel pipe to guarantee the bearing capacity of lifting lug.(7)混凝土浇筑成型完毕后,设置同条件养护混凝土试块，强度达到设计值就可以出厂。 Set up the concrete samples in the same caring condition after the pouring concrete is molding. It can be delivered when the strength is up to the design value(8) 我们(w men)

29、在迪斯尼园区5Km内有预制(y zh)预制构件厂，可用于该预制构件的加工，可以确保 运输的快捷和便利。We have prefabricated unit factory in distance of 5km in Disney Park. It can be used to process the prefabricated units to guarantee the convenient transport.2、构件加工(ji gng)工艺流程 Draft procedure for component processing 预制底座构件的加工预 制底座构件的安装 不锈钢管垂直度调整及固

30、定 钢筋笼骨的绑扎与安装就位 钢模安装（第一节） 混凝土饶筑与振捣 钢模安装（第二节） 混凝土浇筑与振捣 钢模安装(第六节) 混凝土浇筑与振捣 养护 脱模 起吊 堆放 出厂 安装Processing of prefabricated base units Installation for base units Adjustment and fixture of the perpendicularity of stainless steel pipe Fasten and installation for steel keel Installation for steel mould( Sect

31、ion 1) Pouring and vibration for concrete Installation for steel mould( Section 2) Pouring and vibration for concrete Installation for steel mould ( Section 6) Curing of pouring and vibration for concrete Demoulding Hoisting Stockpiling Delivery Installation如果建筑师有要求，预制件可以很方便地刷上一层黑色聚氨酯涂料提高防水能力，这是就地灌注

32、混凝土所无法比拟的优势。Fabricated units can be brushed a paints of black Polyurethane to improve the waterproofing capacity if required by the architect . Its an incomparable advantages for pouring concrete on site.附件(fjin)：旋挖成孔埋设(mi sh)套筒方案 Solutions for digging holes helically and filling bush1 设备(shbi) Equi

33、pment拟选用如图中的拔桩设备：RT-200全回转钻机，设备照片及参数见下图1及表格。We plan to choose the pile withdrawal equipment as the picture show. Its full slewing drill of RT-200.See the equipment photos and parameters as below:图1 RT-200型号：Model全回转钻机RT-200 Full slewing drill of RT-200描述：Description挖掘口径：2000mm（钢管外径为1980mm）Excavation

34、 diameter:2000mm(The external diameter of steel pipe is 1980mm)套管拉拔力：2600（265）瞬时2990（305）KN(tf)Pulling capacity of sleeve:2600(265), instantaneously,2990(305)KN(tf)套管压入力：最大470（48）+自重220（22）KN(tf)Press-in enforcement of sleeve:MAX470(48)+ Self weight 220(22)KN(tf)压入行程：750mmPress-in stroke:750mm2 套管回转

35、 Sleeve rotationRT-200型采用楔型夹紧机构将回转钻机的回转支承环与套筒固定，楔型夹紧机构的原理图见图2、图3。RT-200 uses the wedge-type fastening device to fix the rotating retaining ring of rotation drill and sleeve. See the principle of the wedge-type fastening device in the drawing 2&3.夹紧油缸位于钻机的固定部分，由于不与套管一起回转，从而液压管可以始终处于接续状态，回转时无需将夹紧装置液压管

36、分离，可以大为提高钻进的效率。SleeveTight the fixed portion of fuel tank which is standing on the drill. Because it dont rotate with the sleeve, the hydraulic tube can be in persistent state all the time. There is no need to separate the hydraulic tube of fastening device so that it can improve the efficiency of d

37、rill.Clamping fuel tankWedge blockRotation supportFluid motorOffpatternWedge blockClamping fuel tankSleeveRotation supportFluid motorOnpattern图2 楔形夹紧机构及回转装置(zhungzh)原理 图3 楔形夹紧机构(jgu)及回转装置原理图 Wedge fastening device and theory of rotation device Wedge fastening device and theory of rotation device3 套管

38、(to un)压入 Jacking sleeveA、套管插入初期（自重压入）Primary stage of jacking sleeve在套管插入初期会对以后套管的垂直精度有很大影响，所以须慎重压入。（采用经纬仪双向控制）。套管在插入初期,应利用套管自重压入，禁止强行压入套管。Primary stage of jacking sleeve will have a good effect on the perpendicularity precision of the later sleeve, so the sleeve must be jacked carefully.(Theodolit

39、e is used to control bilaterally).Self weight jacking should be used at the primary stage of jacking sleeve. Forced jacking is not allowed. 只有当自重进行压入速度变慢时，方可逐步增加压入力。It can gain the pressure gradually when the speed of self-weight jacking become slow.采用采用自重压入时，压入力计算公式为：When using ways of self-weight

40、jacking, the computational formula of the pressure is as below:压入力（自重）F=钻机的一部分自重（W1）+套管自重（W2）周边摩阻力(R)+前端阻力（D）钻机的一部分自重RTP-200E-2型为25t。Pressure (self-weight) F=Self weight of a part of drill (w1)+Self weight of sleeve(w2) Frictional resistance around (R) +The frictional resistance of front end(D)Self-

41、weight of a part of drill of RTP-200E-2 is 25tB、挖掘后期（使用液压进行手动压入）Excavation anaphase (Use hydraulic pressure with hand)进入挖掘中期，当采用自重压入速度变慢时，将液压动力站“压入力调整盘”向右旋转，液压会逐步上升，此时压拔钮在置于“压入”状态时，液压油缸向推力油缸供油，此时压入模式转为液压压入，此时压入力计算公式为：Entering the medium term of excavation, turn the jacking adjustment panel of hydrau

42、lic pressure power station right when the speed of self-weight pressure become slow, the hydraulic pressure will increase gradually, and feeding fuel to the push action cylinder when the press and pull button is in state of jacking, and the pattern turn the hydraulic pressure. The formula as below:压

43、入力F=钻机的一部分自重(W1)+套管自重(W2)+液压力（P）Jacking pressure F= Self weight of a part of drill (w1)+ self-weight of sleeve(w2)+hydraulic pressure(P)若“压入力调整盘”向右旋转到底，液压力过度上升，在超过下部机架自重时会出现下部机架浮起的情况.浮起的瞬间会增加使套管倾覆的负荷，导致套管垂直精度变差，为防止下部机架浮起，应在钻机两侧放置配重或使用“压入力调整盘”调整压入力。If the “jacking pressure adjustment panel” turn righ

44、t end, the hydraulic pressure will increase excessively. The bottom of rack will rise when it exceed the self-weight of the bottom of rack. The moment of float will increase the load which can make sleeve overturning, which lead to the perpendicularity precision become worse. To prevent the float of

45、 the rack bottom, we should lay additional weight or use “jacking pressure adjustment panel” at the two sides of drill to adjust the jacking pressure.Steel sleeveCrushing earthAvoiding the float by the additional weightFull rotation drillHydraulic pressure Pw3+w4在套管压入时必须根据土质的变化情况好压入力、回转(huzhun)速度，以获

46、得最佳的压入功效,图5为不同土层中比较合适的压入力和回转(huzhun)速度参考值。We should be in accordance with the change of earth, jacking pressure and rotation to get the excellent effect when the sleeve is jacking. The jacking pressure which is suitable for different soil horizon and the rotation speed value are shown in drawing5.Fo

47、undation conditionRotation speedPressure rotation & torque riseStandard of drilling efficiencyGrit stratum13m/minLow,(14)2030 ton-m1025min/mBowlder stone46 m/minLow,(35)1030ton-m30120 min/mSteel concrete510m/minLow,(58)1030ton-m3060 min/mSoft rock510m/minLow,(58)2030ton-m1030 min/mHard rock46m/minLo

48、w,(35)1020ton-m60300 min/m4 渣土(zh t)排出 Rubbish discharge渣土排出采用冲抓斗(zhu du)，根据本工程配备的1980管，选用相对(xingdu)应的冲抓斗。图7即为采用冲抓斗的现场照片。Percussion Clamshell is used to discharge muck. The percussion clamshell is chosen in accordance with the 1980 equipped by the project. The photos of percussion clamshell on the s

49、ite are shown in drawing7Crushing earth by percussion clamshellSteel sleeveCrushing earthFull rotation drill 图7 冲抓斗清除Disposal of percussion clamshell5 施工(sh gng)工艺流程 Construction procedure图8 拔出(b ch)流程图Pullout FlowchartBreaking down the pavement, chip away the grouting beam and measure the center of

50、 pipe positionSet up the platform for steel and lay steel plateFix the full rotation location and coordinate the equipment locationInstall the sleeves and cutting the earth around the pipeOperating roomBalanced RT,totation reverse rackSteel sleevePrefabricated steel plateReverse rackPower box图9 全回转设

51、备(shbi)安装图 Installation drawing for full rotation equipment6 施工(sh gng)过程描述 Description for construction process61 施工(sh gng)准备Mobilization检修机械设备，特别是液压系统的密封状况，最大限度避免液压油泄露。Maintain the equipment, especially the seal situation of hydraulic pressure system. Avoid the leakage of hydraulic fluid.针对迪士尼项目环

52、保要求严苛的特点，机械设备就位场地应铺设接油盘或者地膜、彩条布或者钢板，铺设吸附材料，把可能滴漏的液压油吸附，防止污染地表造成环境事故。According to the character of keeping strict with environment protection for Disney project, the equipment site should lay oil drip pan, mulching film, colorful strips, steel plate and sorbing materials which can sorb hydraulic fluid leaked to prevent the pollution of earths surface.包括组织、安排施工人员，物资、材料、机具准备，施工现场布置，机械设备拼装，安全、技术交底等施工前的所有准备工作。The preparation work Include organization, constructor, resource and materials, equipment preparation, layout of construction site, consolidation of equipm