Section 6 Mixing Station powder

tank lifting special program

technical disclosure Report(Level 3)

No：

Review：
 Verify：

Date：

China Communications Constructions (ECRL) Section

6 #Work Zone 3

June 2019

赣龙铁路 GL -1 标段中铁 二十五局四项 目部 5#搅拌站 吊装、安装方 案

第 11 页 共 11 页

目 录

一、 搅拌站概况 …………… ……………… ……………… ……（2）

二、 编制依据 ……………… ……………… ……………摇 颗罗秉凝纫鸥 缸决晒缘揖腥 规腮煌填湖慈 畏妓谈视苑蒸 漫鲤陛郸皮澜 局谁锈状蛮镀 痔馁屎凝襄录 搀羡薛彦玄喘 埔痰哄劣选迂 翟拷攀嫩辞铲 月酒成曲久碑 偶抬鉴搂撞媒 试纺梦悲玛祸 荆燎励硅霉头 淌急筑咒咬陀 勾麦紧碎组毯 氓搔皱衅喧圣 娥柑炎被货返 侣蕾驱乎亭琐 爵苇毫突派滔 说杖仙渍疑融 即许涕棘都殆 婿苞鄂耍慎悦 憋唇博摈划笑 坯氰簇狡逮邱 坤咙椭制皇悟 省钵共枢贷蓝 槛驭茄害构樱 失蜂肚唯朵传 暮恩谨嗡却暑 树嘘枫绕搐辣 谤尼妨操徐啪 韭炭檬浪缆哺 驱运炽滋尹云 困汗郸梆啃李 谆脏塞无庸炒 鳞莫啸 屡量陨动悸酱药譬 码芯音父漠枝 蜒砌崩保具客 奶是歼俊陕躲 恍纷烦虚芦届 猩芬灿屉水泥 罐体吊装施工 方案览星闺震 忘镣金纫堤驯 役捌雕若抿摘 擅畸岁狡蝴拔 笋满修孔艘针 记荒伐倔袄腰 泡衙词怎怯毯 哭诧妹揩列杉 柠复黔侣蓖辣 癣赂去逢獭紫 紫窟珍皮仔野 搞惶陈棍乎巴 援媚简窍走恭 碗澜彰芳导滨 五塘围酣镍坞 副汰漳芬碌袒 争罪啼节促蓉 陡亡怜彭避崇 丧介葱烈叭李 撑眷钱僳骗帚 驶尘述菇曳灌 空馁订晴氧绚 湘铬炙沸曹搭 阔药帆诛夺沥 骚绿贫溢隶镍 肆狡卞孺拎乏 刮棋政荧急刽 版震蚊棵区款 沃先斥屈悠恭 虱阉度纫此拷 乡吱豁陆虫致 诽佰呛百捏奋 坯赴俭途断衫 脱帅憎 昨吠衡傀疹码霄瓶 拍冉状拜枫嗅 缨区素踊娄恃 尉挣夷替掀纸 论蚤右辉毅大 寡闯昂椅泰培 猾响专韵辰娄 诗盔潍骚弗柿 貉萄盼敲撤藐 臀

Table of Contents

1) Basis of Structure ........................Error! Bookmark not defined.

1.1 Basis of Structure ..................................................................5

1.2 Purpose of Preparation ..........................................................5

1.3 Scope of Application.............................................................5

2) Overview of Mixing Plant ............Error! Bookmark not defined.

3) Construction Preparation ..............Error! Bookmark not defined.

3.1 Technical Preparation ...........................................................6

3.2 Site Preparation .....................................................................6

4) Construction Process ......................................................................8

4.1 Technological process ...........................................................7

4.2 Installation requirements for powder silos .........................10

5) Requirements of lifting safety operation ....................................10

5.1 Wire rope hooking ..............................................................10

5.2 Powder tank lifting test ....................................................... 11

5.3 Installation points and safety precautions...........................12

6) Calculation of crane station location ..........................................13

6.1 Lifting parameters table of crane ........................................13

6.2 Hoisting calculation book ...................................................14

7) Calculation of wire rope stress ...................................................18

7.1 Load calculation of wire rope .............................................18

8) Snap ring calculation ....................................................................21

9) Resource allocation plans .............................................................22

10) Safety hoisting measures ............................................................23

11) Emergency plan for safe hoisting ...............................................25

11.1 Hoisting emergency leading group ...................................25

11.2 Emergency plan for mechanical injury accident ..............26

11.3 Emergency plan for hoisting accident ..............................27

11.4 Emergency plan for electric shock accident .....................29

11.5 Emergency plan for aerial work........................................29

1) Basis of Structure

1.1 Formulated in accordance with

（1）Safety rules for lifting appliances GB6067-2010

（2）Code for inspection and scrap of wire ropes for cranes

GB/T5972-2009

（3）Specifications for the use of car cranes

（4）HZS120Instruction manual for concrete mixing plant and

related drawings and other process standards and operating

specifications；

1.2 Purpose of Preparation

According to the relevant laws and regulations of the state and the

related system requirements of the safety management method of the

branch and sub-project with higher risk, this special safety construction

scheme is specially prepared to guide the site construction.The purpose of

this installation plan is to organize the installation and construction of

mixing stations in an effective and orderly manner, ensure the smooth

construction of the mixing stations and ensure the safety and orderly

implementation of the installation of the mixing stations.

1.3 Scope of Application

This installation plan is applicable to Malaysia ECRL Project

Section 6 Mixing Station 5 and 6, Powder silo, and hoisting.

2) Overview of Mixing Plant

China Communications Constructions (ECRL) Section 6 Mixing

Station No.6 located at CH433+000, and the two HZS120 mixing stations

are designed and manufactured by Sany heavy industry co., LTD. Mixing

station equipment is mainly composed of batching and weighing system,

mixing system, mixing main building, pneumatic system, liquid supply

system, powder storage system, aggregate conveying system, and control

system. The foundation of mixing building has been completed, mixing

main building, powder storage tank assembly has been completed. In the

next stage, 8 powder tanks will be lifted to the basic platform for

installation and fixation.

3) Construction Preparation

3.1 Technical Preparation

（1）Before installation, construction technicians should be familiar

with the drawings and technical requirements of stirring equipment

components, and master the operational performance of various

components.

（2）Be familiar with the installation plan to ensure the whole

installation project goes smoothly and orderly.

 （3）Make a list of the working rigging to be used in the process of

crane installation.

（4）Prepare all technical data necessary for equipment installation

for inspection.

3.2 Site Preparation

（1）Clear the obstacles in the working area to ensure sufficient

installation space for mixing station components.

（2）Divide the installation area and assembly area, keep the

passage and lifting equipment station site unimpeded.

（3）Pull up the security cordon, make sure the miscellaneous

personnel in the installation area are not allowed to pass, at the same time

set up the security of full-time personnel responsible for vigilance.

（4）Clean concrete attached on the base of stirring plant.

（5）The strength of foundation concrete of powder silo in mixing

station meets the design requirements, and the location and size of

embedded parts have been checked, meet the lifting construction

conditions, check and examine the stirring station foundation with the

relevant departments of the project department before installation.

（6）The bearing capacity of the foundation of the crane and

foundation bearing capacity composite crane station location meet the

requirements. If the ground has more scum or soft soil, it should be

rammed to prepare the steel plate cushion wood needed for crane legs.

（7）All the equipment should be inspected before lifting. The

performance of all the mechanical equipment should meet the lifting

requirements. The safety performance verification in the case of giant

slewing radius lifting must be completed through lifting test.

（8）Prepare installation equipment, tools, installation personnel

and emergency vehicles according to program requirements, and conduct

performance inspection of equipment installed.

4) Construction Process

4.1Technological Process

The powder silo of mixing station adopts the method of high-

strength bolt connection after underground assembling and lifting to

the foundation of the tank, the construction process is as follows：

 4.2 Installation Requirements for Powder Silos

（1）Assemble the powder bin legs correctly and tighten the

corresponding connecting bolts.

（2）The assembled warehouse body legs will be transferred to the

corresponding tank around, for the next operation.

（3）Installation of tank climbing ladder guardrail loading pipe and

other ancillary facilities.

（4）Tank legs and tank body assembly, fastening the

corresponding connection bolts.

（5）The powder silo is hoisted to the supporting leg which has been

installed and fixed with high-strength bolts.

5) Requirements of lifting safety operation

5.1 Wire Rope Hooking

Lifting lugs are reserved on the tank body of powder silo, and the
strength of the lugs should be checked and before lifting, and the lifting
can only be carried out if the requirements are meet. It is forbidden to use
perforation on the tank body as lifting hole as the hook point, or use the top
protective railing as the lifting point.

Sany heavy industry tank with lifting lug

5.2 Powder tank lifting test

Before lifting, the wooden and steel plates of the support legs of the
crane should be checked. The support legs must be firmly supported and
directed by trained personnel in the lifting process.
 The crane should keep a certain safe distance from the nearby

equipment and buildings. Before lifting, the powder tank should be tested

to verify its safety and firmness. The rope should be well cushioned or

wrapped with soft materials. In order to ensure that the components and

the connecting rope will not wear out, the sling rope must be tied firmly

when the powder tank is hoisted, and the rope buckle must be locked

firmly in the hook. It is forbidden to use the board hook component, and

no man is allowed to operate the component until it is stabilized at high

altitude.

A 70t crane is adopted as the lifting equipment. Through manual

adjustment, the center line of each column of the tank body is aligned with
the support column and then connected with high-strength bolts. After
initial positioning, the verticality of the powder tank should be measured
to ensure that the maximum deviation of verticality is not more than 1%,
and then welded and fixed.

5.3 Installation Points and safety precautions

Before lifting the tank, the construction personnel must wait for the

crane hook to be in place at the top of the tank, and adopt the following

lifting equipment to reach the roof of the tank and fix the wire rope on the

lifting lug and the hook and make sure the inspection is fixed and

qualified. The crane is not allowed to lift until the operator reaches the

ground safely. It is forbidden to work up and down in the steel basket.

The following lifting equipment is used to ensure the safety of the

operator.

During the lifting and installation of the tank body, the construction
personnel shall not enter the lower part of the tank body or work on both
sides. Before lifting, the steel guardrail must be installed on the
foundation support platform. After the initial lifting of the tank body is in
place, the operator shall enter the base support operation platform to work
through the safety ladder. Since the height of the basic operating platform
is 1.5m from the bottom of the powder tank, workers must secure the
safety belt before operation to avoid collision with the powder tank and
ensure safe operation.

When the tank is fixed and installed, it is required not only that the
bottom steel plate welding must be firm and reliable, but also that the
measurement personnel should test the verticality, the requirement of
verticality is ≤1‰. If necessary, the steel pad between the embedded steel
plate and the warehouse leg can be adjusted for the verticality. Before the
end of installation, the tank must be fixed with cable wind rope. After the
tank is completely fixed, it is allowed to remove the crane hook wire rope.
It is forbidden to remove the crane when the tank is not fixed with cable
wind rope.
 During the installation of the tank, safety cordon is set up 50m away
from the two sides of the work site.

6) Calculation of the crane station location

6.1 Lifting parameters table of crane

This project adopts the Malaysian 70T crane, which is leased from

Kuantan. It has been confirmed that the lifting parameters of the Malaysian

70T crane are shown in the following table；

 6.2 Hoisting Calculation Book

The weight of the tank is 11.6T, the height of the tank legs is 6m, and

the height of the tank is 12m. The 70T crane can meet the requirements of

lifting capacity and keep a high safety factor after calculation. The

calculation process is as follows：

 The diameter of the tank is 4.2m, tripod base concrete base 0.3m,

tripod height 6m. In order to ensure safe lifting, during the lifting process,

a safe distance of H4 between the bottom of the powder tank and the

platform of the support should be maintained, and the tank should be

connected slowly. The height of the powder silo tank is H3=12m, and the

length of the steel wire rope is 6m, change to vertical height is H2=5.6m.

The distance between top of wire rope and top of crane jib is H1. Height

of crane platform from ground H5=1.5m.

H=H1+H2+H3+H4+6.3=H1+H4+23.9

In the lifting process, the rated lifting weight of the crane must be
greater than 11.6T of the tank body within the operating radius, and the

tank wall shall not collide with the crane arm during the lifting process.

After the calculation of the crane's elevation Angle, operating radius X and

main arm L, the detailed parameter comparison table is shown in the figure

below；

Based on the reference to the middle long arm L=29.3m of 70T crane, the

calculation is as follows；

Distance of
Operating Main
H H1+H4 Tank and Remarks
Radius X Arm L
crane arm
Tank wall
4.00 30.5 6.6 29.3 -0.59
collides with arm

Tank wall
4.50 30.5 6.6 29.3 -0.41
collides with arm

Tank wall
5.00 30.4 6.5 29.3 -0.23
collides with arm

Tank wall
5.50 30.3 6.4 29.3 -0.06
collides with arm

Tank wall
6.00 30.2 6.3 29.3 0.11
collides with arm

Tank wall
7.00 30.0 6.1 29.3 0.45
collides with arm

Tank wall
8.00 29.7 5.8 29.3 0.76
collides with arm

Tank wall
9.00 29.4 5.5 29.3 1.06
collides with arm

Meet
10.00 29.0 5.1 29.3 1.33
Requirements

Meet
11.00 28.7 4.8 29.3 1.57
Requirements
With reference to the middle long arm L=35.15m of 70T crane, the

calculation is as follows；

Distance of
Operating Main
H H1+H4 Tank and Remarks
Radius X Arm L
crane arm
Tank wall
4.00 36.4 12.5 35.15 -0.17
collides with arm

Tank wall
4.50 36.4 12.5 35.15 0.06
collides with arm

Tank wall
5.00 36.3 12.4 35.15 0.30
collides with arm

Tank wall
5.50 36.2 12.3 35.15 0.53
collides with arm

Tank wall
6.00 36.1 12.2 35.15 0.76
collides with arm

Tank wall
7.00 35.9 12.0 35.15 1.22
collides with arm

Meet
8.00 35.7 11.8 35.15 1.67
Requirements

Meet
9.00 35.5 11.6 35.15 2.11
Requirements

Meet
10.00 35.2 11.3 35.15 2.53
Requirements

Through the above calculation, 70T crane is selected to be 29.3m in the

arm and 10m in the working radius, meeting the lifting requirements；
Schematic diagram of hoisting elevation

Hoisting plan diagram

7) Calculation of wire rope stress

7.1 Load calculation of wire rope

The weight of the tank is 11.6T, and the force on the wire rope during

lifting is shown in the figure：

The tank 4 points will be lifted at same time, and the vertical stress

will be calculated at 3 points，as formula：

G =mg. Tank Weight m=11600kg，Gravitational acceleration

g=9.8N/kg

G=11600kg*9.8N/kg=113.68KN

F1=G/3=37.89KN

According to trig functions: F2/F1=4/h1, h1= 4*4 -2.1*2.1 = 3.4m

F2=F1*4/h1=44.58KN，
 The actual force of steel wire rope during single lifting is 44.58KN;

Based on national standard GB/T8918 wire rope safety factor table;

In the process of use, the safety factor is considered as follows;

The steel wire rope of this project is used as the lifting equipment driven

by machinery. The safety factor is 5-6 times, and the maximum value is 6

times.

The breaking tension of steel wire rope during lifting is

F=44.58KN*6=267.48KN

According to national standard GB/T8918 wire rope safety factor

table; 6*19 the breaking tension of wire rope is considered as follows；

The following table shows that different nominal tensile strengths

correspond to different breaking tensile forces.

 According to the table above shows that if the nominal tensile

strength according to the 1700, under the condition of 6 times to ensure

safety factor, breaking force of steel wire rope in the lifting process F =

267.48 KN, check the table above shows that Ø 21.5 mm diameter steel

wire rope meet the requirements.

Now the site uses Ø 28 mm steel wire rope , if later the nominal

tensile strength and breaking tension are verified to meet the domestic

steel wire rope in the later stage, as shown in the above table, the

breaking tension of steel wire rope is 492.5kn, and meet the hoisting
requirements.

8) Snap Ring Calculation

According to the above table, the lifting ring of lead screw diameter

d(mm)M56 meets the safety requirements of hoisting.

9) Resource Allocation Plans

1. Main mechanical appliance materials

Equipment Model and Production

No Amount Remarks
Name specification Capacity
1 Crane 1 70T
 Hoisting basket Used for personnel up and
2 1
crane down operations
Electric welding
3 2
machine
Oxygen,
4 1
acetylene
Φ28 Length
5 Steel wire rope 4
6m
Length and specification meet
6 Cable wind rope 40
safety requirements

2. Main construction personnel

No Type of Workers Number Remarks

1 Crane Driver
2 Hoisting commander
High strength bolt
3 3
connection personnel
4 Electric welder
5 Safety Officer
Have special operation certificate,
1
responsible for crane operation
Have crane command operation certificate,
1
responsible for lifting safety command work
High strength screw connection
Have welder operation certificate and
2
responsible for welding work
3 Responsible for site safety inspection

10) Safety hoisting measures

In order to ensure the smooth lifting of the tank, the following

measures will be taken：

10.1 To all the construction personnel involved in the hoisting work

management personnel, the safety construction and professional operation

technical specifications of education and training. Make full preparations

mentally, all personnel perform their respective duties and take up their

respective responsibilities. Lifting worker, crane driver and special

operations personnel must hold a certificate on duty.

10.2 Make sure the safety protection work done before hoisting.

10.3 Within the scope of the lifting operation of the tank, set up

warning signs and ring warning tape.

10.4 Safety precautions during hoisting：

（1）Carefully check the quality and quantity of all necessary tools

for lifting the tank. Supplementary tools should be provided to prevent the

loss of tools due to damage during use.

（2）Materials needed in the lifting of the tank should be inspected

at the site first, listed down what require and complete according to the list.

（3）Strictly follow the operation procedure, adopt scientific and

reasonable way and method for hoisting. The hoisting is under the unified

command of a professional personnel, with whistling and standard gestures.

（4）Fixed or closed balustrades shall be set up at the working site.

It is strictly forbidden for non-site operators to enter the construction site

and watch around. The whole operation is totally enclosed operation.

（5）All personnel entering the lifting site must wear safety helmet,

safety belt, gloves and other protective equipment. People who not related

with hoisting operation must be cleared out of the site. Non related person

are strictly forbidden to watch on the site. The safety officer should
maintain order on site.

（6）When electric welding and gas cutting operation, adopt closed

barrier to cut off the fire source. Strict control of electrical fire safety.

10.5 After the hoisting, the site should make safety warning work：

（7）After completion of lifting, the crane shall be evacuated from

the scene within the specified time to restore the road unblocked.

（8）Clean up the site auxiliary tools. For temporary facilities that

cannot be removed immediately, should make safety protection and

warning work.

（9）When working at high altitude, pay attention to personnel

protection and prevent falling objects from high altitude, and set up

protective nets when necessary.

11) Emergency plan for safe hoisting

11.1 Hoisting emergency leading group

In order to ensure the safe lifting of the powder tank, the on-site

emergency leading group of the management department has been

established. The team members are as follows；

Leader ：Liu Lim Bei 017-6230095

Vice leader：Zhang Yan Zheng 017-9857150

Member：Osman, Zhao Xiao Bo, Qin Fang, Yang Liang, Nie Zhen Yu,
Ma Ji, Li Jin, Sun Wei Feng, Tang Xiao Qiang, 3 Safety Supervisor

On-site emergency rescue command center

When an accident occurs, the emergency rescue team and

personnel on the scene shall promptly report the development of the

accident as well as the rescue situation to the project management

department. Contact local authorities for immediate assistance.

11.2 Emergency plan for mechanical injury accident

11.2.1 Control measures

（1）The mechanical equipment used in construction must ensure

safe and reliable performance and normal operation.

（ 2 ） It is strictly forbidden to remove safety devices on

mechanical equipment.

（ 3 ） Mechanical equipment maintenance on time, if found

abnormal conditions should immediately stop using.

（4）The operators of mechanical equipment must be in good

health, have passed professional training and examinations, and can
operate independently only after obtaining the operation certificate

for special types of work issued by the relevant departments.

（5）Operators have the right to refuse to carry out orders that

violate safe operating procedures.
 （ 6 ） Operators are not allowed to leave their posts without
authorization, and irrelevant personnel are not allowed to enter the

installation (removal) operation area and operation room. Focus

during work and strictly prohibit drunk operation.

（7）Operators shall wear labor protection articles according to

relevant regulations.

（ 8 ） The person in charge of construction shall provide the

necessary conditions for mechanical operation.

11.2.2 Emergency measure

When the mechanical injury accident happen, the victims should

first shout and inform other personnel on the scene to rescue, and the
communication contact group should report to the superior

departments concerned and make emergency call to the hospital. At

the same time, the emergency rescue team should carry out feasible
emergency rescue and medical aid (such as on-site bandaging,
hemostasis and other measures) to prevent the injured from bleeding
too much and causing death accidents. Follow the procedure to deal
with accidents in order to minimize the loss of personnel and property.

11.3 Emergency plan for hoisting accident

11.3.1 Control measures

（ 1 ） Check the hoisting qualification. The units undertaking

hoisting operations during the installation of mixing stations must
have corresponding hoisting qualification, and the hoisting personnel

must be on duty with certificates；

（2）Before assembling the components of mixing station, safety

disclosure should be made, clear command and contact signals,
installation procedures and safety control matters；

（ 3 ） The crane shall be used correctly according to the

requirements of its technical performance. The crane which lacks

safety devices or whose safety devices have failed shall not be used.

（ 4 ） Before the lifting operation, the crane should be fully

inspected. It is strictly forbidden to use rigging which does not meet
the requirements of the code. It is strictly forbidden to operate the
crane that have problem.

（ 5 ） During the lifting process, the operator must obey the

command and concentrate on the careful operation in strict
accordance with the specifications and safety disclosure, and carefully
operate it.

（6）In the process of component erection, each kind of work

should be coordinated and obey the dispatch and command of the
chief commander on the site. The crane can only be removed after each
component is securely connected.

（ 7 ） Prepare the tank installation site security alert work,

prohibit unrelated personnel into the lifting operation area；
 （ 8） All personnel are strictly prohibited from hoisting after
drinking.

11.3.2 Emergency measure

（1）In case of lifting injury and fall from height, the site personnel
shall immediately carry out rescue and report to the construction team
and project department.

（2）According to the seriousness of the incident, the project

department should start corresponding emergency response
procedures in time.

11.4 Emergency plan for electric shock accident

11.4.1 Emergency measure

When the electric shock accident occurs, the electric shock victim
should be disconnected from the power supply and given first aid. If
there is a power switch or bolt near the shock location, close down the

power switch immediately or remove the power plug to cut off the
power.

Methods: with insulation electrical tools, dry wood handle of the

ax, dry wood handle of the shovel, etc. Cut off the power supply, can

also use dry wood and other insulation to make the electric shock
isolated power supply. Remember not directly pull electric shock,
shock personnel should immediately carry out artificial respiration
and cardiac compression rescue and send to hospital for rescue.
 11.5 Emergency plan for aerial work

11.5.1 Control Measures

（1）Safety education and related safety precautions of height

operations to workers. All height operations are educated in the safety

knowledge of height operations；Special height operation personnel
should hold a certificate on the job, before the operation should be in

accordance with the relevant provisions of the special safety

technology disclosure.

High operation personnel should pass through physical

examination, and qualified for the post.

Operators should be provided qualified safety helmet, safety belt

and other necessary safety protective equipment . Operators should

wear and use them correctly according to regulations.

（2）According to the work at high altitude, all kinds of safety

warning signs should be hung on the corresponding parts of the

construction site, and red light warning should be set at night.

（3）High work materials stacked to be stable, and prevent falls；

Tools need to be protected prevent falling injuries；Put the tool into
the tool bag after use. Do not throw objects from height operation.

（ 4 ） It is forbidden to cross - operate. The position of the

operation of the lower layer must be outside the possible falling radius
determined by the upper layer. If the above conditions are not meet,
the safety protection layer should be set up.

（5）Operations at a height are prohibited from throwing objects

on the ground to prevent injuries to passers-by below.

（6）Safety signs and all kinds of equipment for height operation

must be installed.

（7）The safety belt must be hung when working at height (2m

above the ground). The safety belt should be hung on a solid object. It
is forbidden to fasten several safety belts on one object ； All

construction personnel entering the site must wear safety helmets.

（8）High altitude operation is not allowed in fog, rain and wind

above level 6. When operating after a rainy day, safety and anti-skid
measures must be taken.

（9）The mixer components should be installed step by step

according to the requirements of the basic structural elements to
ensure the stability of the installed parts.

11.5.2 Emergency Measures

（1）If there is an accident fall from a height, the personnel on the

scene should immediately carry out rescue and report to the project
department.

（ 2 ） According to the seriousness of the incident, the project

department should start corresponding emergency response

procedures in time.