Ppr for installation of structures. PPR
INDUSTRY STANDARD
INSTALLATION OF TECHNOLOGICAL
EQUIPMENT
AND TECHNOLOGICAL PIPELINES.
PROJECT OF WORK PRODUCTION.
DEVELOPMENT PROCEDURE
COMPOSITION AND CONTENTS
OST 36-143-88
Moscow
APPROVED by the Deputy Minister of Installation and Special Construction Works of the USSR on November 28, 1985.
PERFORMERS: Ph.D. tech. Sciences V.V. Kalenov (topic leader), V.D. Martynchuk, B.Ya. Moizhes, Ph.D. tech. Sci. HELL. Sokolova, S.B. Gitman
AGREED with C NIIOMTP Gosstroy USSR (V.D. Topchiy)
INDUSTRY STANDARD
INSTALLATION OF TECHNOLOGICAL EQUIPMENT AND TECHNOLOGICAL PIPELINES. PROJECT OF WORK PRODUCTION. DEVELOPMENT ORDER, COMPOSITION AND CONTENT. |
OST 36-143-88 |
This standard, in accordance with SNiP 3.01.01-85, establishes the procedure for the development, composition and content of work projects (hereinafter referred to as PPR) for the installation of process equipment and process pipelines (hereinafter referred to as installation work) carried out by organizations of the USSR Ministry of Installation and Special Construction during construction, reconstruction and technical re-equipment of industrial enterprises, technological complexes, their individual queues, structures, when installing individual equipment (hereinafter referred to as facilities).
The requirements of the standard are mandatory for the customer and PPR developers, and parts of the approval are mandatory for all construction participants.
The requirements of the standard also apply to PPRs developed on orders from other ministries (departments).
1. DEVELOPMENT PROCEDURE
3) technically complex (requiring the development of special installation technology or design documentation for special devices and equipment for individual use);
4) subject to reconstruction and technical re-equipment.
Note: For technically uncomplicated objects according to clause 1.1.4, it is allowed to develop PPR by installation organizations.
1.2. PPR for objects not specified in paragraph are developed by installation organizations.
Table 1
Division of large objects into categories according to the labor intensity of installation work
Labor intensity of installation work, thousand person-days |
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1st |
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Oil refining, petrochemical, chemical, gas processing, mineral fertilizer production |
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Pulp and paper |
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Microbiological, medical, forest chemical |
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Coal |
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Ferrous and non-ferrous metallurgy |
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Mechanical engineering |
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Building materials |
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Lightweight, fishing, printing, agro-industrial complex objects |
From 1.5 to 3.5 |
Note: The complexity of installation work for dividing large objects into categories should be determined on the basis of local estimates only for objects of primary production purpose.
1.3. When developing a PPR at the request of the general designer of the facility, placing an order and transferring limits for the development of the PPR are carried out in the prescribed manner.
1.4. When developing a project plan for an installation organization, the initial document for considering the inclusion of the development in the thematic plan of the design organization is the customer’s application, which must be submitted no later than 3 months in advance. until the end of the year preceding the planned one. The application indicates the development timeframe and the expected composition of the PPR, taking into account the requirements of Table. .
1.5. With the consent of the design organization to develop the PPR, the customer, taking into account its conclusion on the application, develops a task (Appendix).
By agreement of the parties, the task can be developed by the design organization.
1.6. The contract for the development of the project design is concluded after the assignment has been agreed upon with the design organization (if it is not its developer).
1.7. To develop the PPR, the customer transfers to the design organization the initial design, estimate and design documentation according to the agreed list, the approximate composition of which is given in the Appendix.
1.8. In the process of developing the PPR, when choosing optimal solutions for the organization and technology of installation work, in agreement with the customer, changes and additions can be made to the task, and, if necessary, adjustments are made to the timing and cost of developing the PPR. The assignment must be attached to the PPR.
2. COMPOSITION OF PPR
2.1. The composition of the PPR should be taken depending on the type of object based on the table. .
2.2. When constructing objects in stages, the composition of the PPR should first of all take into account the implementation of installation work during the construction of the following stages.
2.3. Taking into account the special conditions for the installation work, the assignment may take into account the need to develop additional sections as part of the PPR that are not provided for in the table. .
Table 2
List of documents and other materials developed as part of the PPR
Documents and materials included in the PPR |
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1.1.1) |
1.1. 2) |
1.1.3) |
1.1.4) |
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Title page |
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List of documents |
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Explanatory note |
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Assembly construction plan |
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Schedule plan for installation work |
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Schedule for transfer of equipment, structures and pipelines, including complete units, for installation |
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Movement schedule of main mechanisms |
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Work schedule |
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Equipment installation instructions |
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Installation diagrams of equipment, structures, complete units |
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Technological maps for equipment installation |
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Working drawings for mounting devices, fixtures and custom-made equipment |
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Pipe installation instructions |
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Pipeline installation diagrams (including support structures) |
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Technological maps for pipeline installation |
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Instructions for welding work |
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Basic data on welded joints of pipeline lines |
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Statements on welding work (scope of work on welding, heat treatment and quality control of welded joints, labor intensity; welding and auxiliary materials; equipment for the work) |
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Technological maps for welding joints of metal and non-metallic pipelines |
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List of volumes of installation work (by technological units, workshops, installations) |
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List of installation equipment and tools |
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List of materials and purchased items |
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Scheme of temporary power supply networks |
Notes: 1. Symbols: “+” - the document is subject to mandatory development; “3” - the need to develop a document is established in the task; “-” - the document is not being developed.
2. The quantity, form and composition of the documentation included in the PPR, in the case of an automated method of its (or individual sections) development, may differ from those provided for by this standard, provided that the volume of information contained in it is preserved, and also, in agreement with the customer, the PPR or its individual sections may be issued on magnetic media.
3. For facilities that require the use of complete units assembled by the installation organization, in accordance with the assignment in the PPR, solutions for the organization of work, technological maps for assembly and block installation diagrams are developed.
3. CONTENT OF THE PPR
3.1. The PPR must ensure the organization and technology of installation of equipment and pipelines, as a rule, using the complete block method.
3.2. PPR for the objects specified in paragraphs. 1.1.1), 1.1.2), 1.1.4) of this standard are developed, if provided for in the assignment, with the elaboration of options for basic solutions and calculations of their comparative economic efficiency.
3.3. This section provides general requirements for the content of the PPR, which, by agreement with the customer, can be clarified in the assignment and (or) during the development of the PPR, taking into account the characteristics of the facility and the conditions of installation work.
brief technical description of the object;
terms of delivery of equipment and pipelines;
installation characteristics of equipment weighing more than 50 tons, indicating the features of its design position;
a list of large-sized and heavy equipment that is subject to additional production at the construction site by the manufacturer or an organization attracted by it (indicating, according to the customer, the manufacturing enterprises and the conditions and terms of additional production agreed with them by the customer);
features of process pipelines (material, operating parameters);
special conditions for welding and other pipeline installation work;
list and characteristics of special installation equipment and accessories;
solutions for the industrialization of installation work;
instructions for preparing equipment and pipelines for pre-installation thermal insulation (on the instructions of specialized design organizations).
When expanding, reconstructing and technically re-equipping existing enterprises, the following must be provided:
materials from the survey of existing production facilities, structures and structures;
list, technical characteristics and features of the location of equipment, pipelines and structures to be dismantled;
organizational and technological solutions for the manufacture and (or) expansion and supply of equipment units, mechanization of manual labor, performance of work using the method of team and collective contracting;
information on the approval of decisions made (if necessary);
data on ensuring safe working conditions;
information on organizing quality control of installation work;
features of work in winter;
environmental protection measures (during reconstruction and technical re-equipment - measures to protect buildings and structures from damage);
technical and economic indicators of PPR (if necessary, with variant development).
3.6. The installation construction plan shows:
plans for buildings and structures under construction, as well as existing and temporary ones;
above-ground and underground communications located in the work area and influencing the main decisions on the organization of the installation site;
location of railway (rail) tracks, roads and driveways (both existing and those to be constructed, including those allocated for use by the installation organization in the conditions of an operating enterprise), temporary roads and driveways;
sites for storage and larger assembly of equipment units, structures and pipelines;
permanent and temporary networks, made in accordance with the construction organization project (POS), used for installation needs (electricity, water supply, sewerage, compressed air, steam, etc.), with their supply to places of consumption;
places of installation of general lighting, as well as places of their connection to power supplies;
locations of distribution boards for connecting welding and heat treatment stations of pipelines, indicating the location of equipment power supplies;
temporary buildings and structures of the installation organization (industrial, administrative, household, warehouse, etc.);
coverage areas and directions of movement of main installation mechanisms and vehicles;
areas of work entrusted to self-supporting teams, the size and location of team sites for storing materials and equipment;
breakdown of the facility into construction phases and technological units that determine the installation sequence.
requirements for the qualifications of welders, cutters, thermal operators, flaw detectors and engineers for welding and quality control of welded joints;
requirements for the configuration of welding stations and the provision of special equipment and tools for flaw detectors;
requirements for welding and auxiliary materials (including materials of foreign production and their domestic analogues), for their testing, storage and release for work;
requirements for cutting, edge preparation, assembly and tack welding;
requirements for the choice of welding method and technology, heat treatment and quality control of welded joints, indicating operating modes, work technology, control operations and marking of joints.
3.17. Welding work sheets contain information:
1) on the number and length of welds for welding, heat treatment and control during the manufacture and installation of pipelines;
2) about the need for welding and auxiliary materials during manufacturing and installation;
3) on the need for basic equipment for welding, heat treatment and control, indicating its purpose and rated electrical power.
4. APPROVAL AND APPROVAL OF PPR
climate specifics, installation before construction of the building, as well as combined, in a finished building, in an operating enterprise; with increased fire and explosion hazard, etc. In addition, they indicate the possibility of enlarging aggregated units of factory delivery, as well as assembling units at the production base of the installation organization. In the case of reconstruction and technical re-equipment, special requirements are given for the sequence of dismantling structures and utility networks (or their transfer), as well as installation work in existing workshops (number of shifts, timing and duration of shutdown of individual workshops, sections, technological lines or units);
7) proposals for organizing work using the method of brigade and collective contracting;
8) list of equipment subject to pre-installation insulation.
APPENDIX 3
SCROLL
BASIC INITIAL DESIGN, ESTIMATE AND CONSTRUCTION DOCUMENTATION TRANSFERRED BY THE CUSTOMER TO THE DESIGN ORGANIZATION FOR THE DEVELOPMENT OF PPR
1. Drawings of general types of blocks (or information on the supply of equipment as complete blocks).
2. Drawings of general types of technological structures.
3. Drawings of general types of non-standardized equipment and specifications for its supply.
4. Working (installation) drawings of process pipelines.
5. Pipeline statements by lines.
6. Specification of pipelines of the installed facility.
7. Detailed drawings of process pipelines.
8. Construction organization project (COP). Section "Installation of process equipment and process pipelines".
9. Layout of technological and handling equipment.
10. Copying from the general plan.
11. Drawings of foundations with anchor plans.
12. Building plans with main sections.
13. Equipment specification according to GOST 21.110 -82.
14. List of process pipeline lines supplied complete in the form of pipe assemblies.
15. On-site and local estimates according to SNiP 1.02.01-85.
16. Working documentation for the agreed list according to SNiP 1.02.01-85.
17. Equipment documentation in accordance with GOST 24444-87.
Notes: 1. During reconstruction and technical re-equipment, as well as during the construction of facilities based on complete imported equipment, the list of source documentation is supplemented by agreement of the parties.
2. For facilities built on the basis of imported supply of pipelines, regulatory and technical documentation for welding of pipelines from the supplier company, as well as technical annexes to the contract, are additionally transferred.
3. The original documentation is transferred according to an act indicating the documents to be returned to the customer, and, if necessary, the deadline for the customer to submit the missing documentation.
4. If necessary, the installation organization must provide the organization developing the PPR with other materials, the need for which is identified during the development of the PPR.
Main material |
Welding method |
Welding materials |
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Pipe diameter, mm |
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Wall thickness, mm |
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Number of passes |
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Heating |
Welding modes |
Requirements for quality control of connections |
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Diameter of filler materials, mm |
Polarity |
Welding current, A |
Arc voltage, V |
Welding speed, m/h |
Gas consumption |
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per burner, l/min |
for blowing, l/min |
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Heat treatment |
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Heating temperature, °C |
Holding time, h |
Maximum heating rate, °C/h |
Maximum cooling rate, °C/h |
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special instructions |
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Developer |
Technological map for welding pipelines made of polymer materials |
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Material grade, diameter and pipe wall thickness, mm |
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Welding method |
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Edge cutting |
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Welding temperature conditions |
Butt and socket resistance welding modes |
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Wall thickness, mm |
Height of the roller at the end of the 1st stage of reflow, mm |
Time of the 2nd stage of reflow, s |
Technological pause, s, no more |
Upsetting pressure rise time, s, no more |
Cooling time, min |
Reflow pressure, MPa |
Upsetting pressure, MPa |
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Gas rod welding |
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Filler material grade |
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Diameter of filler material, mm |
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Number of layers |
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APPENDIX 7
LIST OF INSTALLATION MEANS AND TOOLS
Name |
Unit |
Quantity |
Note |
1. Lifting equipment |
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2. Transport equipment |
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3. Mounting mechanisms |
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4. Rigging equipment |
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5. Mounting devices |
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6. Tools and measuring instruments |
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7. Protective equipment for workers |
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8. Standard products, including fasteners |
Notes: 1. Section 1 contains the necessary: bridge, truck, pneumatic, crawler, gantry, railway and tower cranes; pipelayers and forklifts; retractable and rolling scaffolding brands PVS-8, PVS-12, VTK-9, etc.; auto hydraulic lifts.
2. Section 2 contains the following: motor vehicles, wheeled tractors; car trailers, semi-trailers, trailers and tractors: railway platforms and wagons; trolleys (transfer, mold, etc.).
3. Section 3 contains: electric, manual and lever winches (mounting traction mechanism); hoists (electric and manual), cats; jacks (hydraulic, rack and pinion, screw).
4. Section 4 contains: blocks; slings; clamps, thimbles, hooks, staples, loops; sling grips, screw ties, cargo screws, etc.
5. Section 5 includes the developed: portals, chevres, mounting beams, traverses, overpasses, rail tracks, guides, etc.; carts and sleighs; disputes, struts, connections, etc.; centralizers.
6. In section 6 they are placed in the following sequence: electric and pneumatic tools (grinders, nut and screwdrivers; flaring, drilling and threading machines; scraping mechanisms; pipe cutters; riveting hammers, sharpeners, etc.; hand tools (multiplier wrenches, keys, screwdrivers, chisels, files, hammers, sledgehammers, etc.); measuring instruments (tape tapes, meters, straight edges, squares, calipers, bore gauges, probes, protractors, threaded templates, levels, theodolites, levels, sight marks, laser sights etc.).
7. Section 7 contains: inventory scaffolding; newly developed scaffolding means; safety and signal barriers, etc.
APPENDIX 8
LIST OF MATERIALS AND PURCHASED PRODUCTS
Name |
Unit |
Quantity |
Note |
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Rolled metal |
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Methodological documentation in construction JSC "TSNIIOMTP" PROJECT OF WORK PRODUCTION MDS 12-60.2011 Moscow 2011 The document provides a standard design for the installation of steel structures. In accordance with the structure and content of the work project according to MDS 12-46.2008, decisions on the organization and technology of installation work, rules and techniques for performing technological operations, norms and procedures for assessing the quality of work, and the need for mechanization are provided. Developed by employees of the “Central Research and Design and Experimental Institute of Organization, Mechanization and Technical Assistance to Construction” (principal executor - Yu.A. Korytov). The standard project can be used directly or serve as the basis for drawing up individual installation projects taking into account local conditions. The document is intended for design organizations developing work projects, and construction and installation organizations performing work on the installation of steel structures. INTRODUCTIONThe work plan is the main organizational and technological document for the installation of metal structures, the typical elements of which are columns, beams and purlins (trusses). The project contains measures to organize work using modern technology and information. The project provides for advanced technologies for installation work using high-performance mechanization tools that help improve quality, reduce the time and cost of work. The project ensures the safe execution of work and contains measures to comply with safety requirements in construction. The presence and use of work projects largely determine the competitiveness of a construction organization. Projects are used when licensing a construction organization as documents confirming the organization’s readiness to carry out work, and when certifying the organization’s quality system and construction products - in the status of regulatory documents of the enterprise. Projects are developed, as a rule, by design and design-technological organizations. Having qualified personnel, a construction organization can develop a work project on its own. This document is intended to assist design, engineering and construction organizations in drawing up a project for the installation of steel structures. This document has been developed taking into account the recommendations of MDS 12-46.2008 on the preparation of work projects, on the composition and content of their sections, as well as on presentation and design. This work project is typical for rural, industrial and civil construction projects; it can be used for new construction, as well as for the reconstruction and repair of existing buildings and structures. After adjustment, the project can be used directly or serve as the basis for drawing up an individual project, taking into account local conditions. The document takes into account the results of work and the experience of TsNIIOMTP and other design and technological institutes in the field of installation of steel structures. 1. GENERAL PROVISIONSThe project for the installation of metal structures is developed on the basis of the initial data provided by the customer and the technical specifications attached to the contract. In this project, the installation of metal structures is carried out mainly using manual arc welding. The project provides a brief description of the metal structures being erected. Thus, according to this project, a building is being erected in an L-shaped plan with overall dimensions of 64x29 m. The building is two-story with a mezzanine and an underground floor under part of the building. The total area of the building is 4 thousand m2, the construction volume is 22 thousand m3, including the underground floor - 3 thousand m3. The upper elevation of the roof relative to ground level is 8 m. The frame of the building is metal, made of rolled steel, I-beam with parallel flange edges: columns from I-beams No. 25 and No. 35, beams from I-beams No. 60, No. 55, No. 35 and No. 20. Floors - monolithic reinforced concrete on metal girders. Welds are made using electric arc welding, electrodes E42A, E50A, E55A. The work project should be used together with working drawings for the metal structures of the building. Schemes for linking the assembly crane are developed separately from the general plan of the facility in the part necessary for the installation of steel structures. When developing the project, regulatory and technical documents were used, the main ones of which are indicated in the section. 2 REGULATIONS AND TECHNICAL DOCUMENTSPicture 1. Scheme of horizontal attachment of an assembly crane (fragment) The diagram shows how the installation work area should be organized and equipped. The site has a temporary fence that prevents strangers from entering the work area. A temporary road has been laid along the perimeter of the building under construction to move the installation crane clockwise from the parking lot of St. 1 to parking lot St.7. The crane's coverage areas at these seven sites support the erection of the building's steel structures. At the work site, danger zones are marked with lines: from moving the load by an installation crane - at a distance of 4.0 m from the hook and from the possible fall of objects from the height of the building - at a distance of 3 m from the wall of the building. Calculation of the distances of dangerous zones is given in the section. According to the diagram, the site includes: a storage area for removable load-handling devices, a storage area for control loads, a stand with slinging diagrams and a table of load weights, spotlights for illuminating work places, and a crane wheel washing station. The diagram of the vertical connection of the installation crane to the building under construction is shown in cross-section N - N in the parking lot of St. 2 (Figure). Distance from the crane axis to the building wall A= 4 m is not less than the largest radius of the turning part of the crane R n and the standard approach clearance is 1 m. The minimum distances from the boom to the metal structures of the building and to the signal fence correspond to the standard - 0.5 m. The danger zone from the movement of moving parts of the crane is accepted at a distance of 5 m. Figure 2. Vertical attachment of an assembly crane 3.4 Installation work begins after delivery and acceptance of the foundations - supports of the building columns, if there is an act for hidden work. During the acceptance process, an instrumental quality check of previously completed work must be performed. When checking, the position of the transverse and longitudinal axes of the foundations - supports in plan and the elevation marks of the supporting surfaces of the foundations must be determined. 3.5 Installation work using a crane consists of the following operations: preparation of installation sites and fastening of columns and beams; slinging of columns and beams; lifting, aiming and installing them at the mounting location; reconciliation and temporary fixation (if required); unfastening of columns and beams. In a separate process, using the mounted frame, the installation of purlins (trusses) and built-in steel structures is carried out. 3.6 One of the common methods of column installation is shown in Figure. Before installation, the column is laid on wooden pads ( 1 ). The column is moved by an assembly crane from a horizontal ( 2 ) to vertical ( 3 ), and then to the design position ( 4 ). Figure 3. Column installation The column is moved to the design position at a minimum speed. The position of the column is verified relative to the alignment axes, its verticality and elevation are checked. Basic tolerances for column installation are given in section. Temporary fastening of the installed column is carried out using mounting equipment (struts, ties, conductors, etc.), the size of which depends on the design of the column. One of the options for temporarily securing a column with braces is shown in the figure. Inventory brace with tension device ( 1 ) attached to the column ( 2 ) and to a previously installed element of a metal structure (or, for example, to an inventory reinforced concrete block) ( 3 ). Figure 4. Temporarily securing a column Permanent fastening of columns, beams and purlins is carried out by welding according to the project. Slings can be removed from a column, beam, or purlin after they are temporarily secured. The mounting equipment is removed after the steel structure is permanently secured according to the design. 3.7 Before starting the installation of the beam, the columns must be mounted and the supporting platforms for installing the beam must be prepared. Scaffolding equipment with platforms (installation ladders, mobile scaffolding, towers, etc.) are attached to the columns. With the help of guys, the beam is lifted and brought to a position close to the design one. After this, the installers climb to the scaffolding platforms and install the beam in the design position. In this case, the beam sling can be lowered by 5 - 10 cm. The structures are welded according to the design, after which the beam is unslinged. 3.8 Methods and means of slinging must ensure that beams and columns are installed in the design position the first time. Slinging is done using slings with locking devices on hooks. Unused branches of the sling are hung on the connecting link. The angle between the branches of the sling should not exceed 90°. The hooks of the sling should be directed away from the center of gravity of beams and columns. When slinging beams, inventory spacers are used to prevent chafing of the rope. Slinging diagrams are shown in the figure. Figure 5. Slinging of columns and beams Column slinging ( 1 ) is produced by a sling ( 2 ) type 1SK-4.0/2000 according to GOST 25573 and a pincer gripper with remote control of the sling KZ-3.2 (Figure , a). Slinging beams ( 1 ) is produced by a sling ( 2 ) type 4SK1-2/2000 according to GOST 25573 (Figure , b). When slinging, various removable load-handling devices are used, the sizes of which depend on the design and weight of columns and beams. Grips for columns and beams are shown in the figure. For columns, in addition to the pincer grip (see figure, a), friction grips (see figure and figure, a), finger grips with a sling hole in the column (figure, b), eccentric and other grips can be used. For beams, in addition to the loop grip (see Figure , b), for example, lever grips (Figure , c), pin grips (Figure , d) and other grips can be used. Figure 6. Grips for columns and beams Slinging diagrams must be placed on a stand, the location of which on the work site is indicated in the figure. 3.9 When slinging columns and beams, they are guided by information about their mass, slinging schemes and corresponding removable load-handling devices. This information in relation to this project is given in the table. A table of load masses, slinging diagrams and data on removable load-handling devices must be placed on the stand mentioned above. The storage location for removable lifting devices is shown in the crane horizontal tie-down diagram (see figure). Before starting installation work, the crane operator and slingers must be familiarized with the sling diagrams, the table of load weights and removable lifting devices. 3.10 Installation of steel structures is carried out “from the bottom up”, using grips, using the “crane” method. The installation sequence must ensure stability and geometric immutability of structures. The breakdown into sections and the sequence of installation of columns and beams are indicated in the project on the breakdown plan at marks 0.0; +4.0; +8.0; +10.0 on A3 sheets (the entire breakdown plan at different marks is not given here). A fragment of the breakdown plan in axes A - D and 1 - 5 into grips and the installation sequence, for example at the + 4.0 m mark, is shown in the figure.
Figure 7. Sequence of installation of columns and beams at the 4 m mark (fragment) Installation on the first grip is carried out in axes A - B and 1 - 5, on the second - in axes B - D and 1 - 5. On the structure grid in plan, the sequence of installation of standard sizes of columns (K1, K2, K3, etc.) and beams (B1, B2, B3, etc.) are indicated by numbers. The installation sequence, for example on the first grip of the first seven columns and beams, is as follows: K1-1, K1-2, B4-3 (in axes B and 1 - 2), K1-4, B2-5 (in axes 1 and B - B), K1-6, B3-7 (in axes B and 2 - 3). In the same way, the installation sequence on the second and other grips is established. 3.11 Welding work is carried out after checking the correct installation of structures. Welding is carried out - manual arc, covered with electrodes of types E-42A, E-50A and E-55A. Dimensions of seams and edges - according to working drawings for welding joints, with beads with a cross-section of at least 20 - 35 mm 2. Welding areas should be cleaned: the edges of the welded parts at the seam locations and adjacent surfaces with a width of at least 20 mm must be cleaned to remove rust, grease, paint, dirt and moisture. Welding is carried out in a stable mode: deviations from the specified values of welding current and arc voltage should not exceed 5% - 7%. The electrodes are dried (calcined) in drying ovens. The number of calcined electrodes at the welder’s workplace should not exceed three to four hour requirements. Electrodes should be protected from moisture - stored in sealed cases. Welds of joints of parts with a thickness of more than 20 mm are made using methods that reduce the cooling rate of the welded joint: sectional reverse-stage, sectional double layer, cascade, sectional cascade. When double-sided welding of butt, T-joints and corner joints with full penetration, it is necessary to remove its root to bare metal before making the seam on the reverse side. The use of starting and leading strips should be provided according to the working drawings of welded joints. It is not allowed to excite the arc and bring the crater onto the base metal beyond the weld. Each subsequent layer of a multilayer weld should be performed after cleaning the previous layer from slag and metal splashes. The cracked area of the seam should be corrected before applying the next layer. After completion of welding, the surfaces of the welds are cleaned of slag, splashes, beads and metal deposits. Welded mounting fixtures are removed (by gas cutting with an allowance) without damaging the base metal or impact. Their welding areas are cleaned mechanically flush with the base metal. Welding work for this project is carried out at an outside air temperature of at least -20 °C. The strength of the welding current must be increased in proportion to the temperature decrease: when decreasing from 0 °C to -10 °C - by 10%, when decreasing from -10 °C to -20 °C - by another 10%. At negative temperatures, welding work is performed in compliance with the following rules: The closing sections of the seams are welded especially carefully; remove moisture and snow at a distance of at least 1 m from the welding site; dry the welding area, for example using a torch flame. Near the seam of the welded joint, at a distance of 40 mm from the border of the seam, the number of the welder’s mark must be affixed. 4 QUALITY REQUIREMENTS AND ACCEPTANCE OF WORK4.1 Quality control of installation work 4.1.1 Quality control of installation work includes: incoming inspection of structures and products according to working documentation; control of technological operations; acceptance control. 4.1.2 Incoming inspection involves checking the availability and completeness of working design and technological documentation, and the compliance of designs and products with this documentation. For control, working drawings, a construction organization project, a work execution project, technical passports, certificates for metal products and structures and other documents specified in the working drawings must be submitted. 4.1.3 Control of technological operations is carried out during their implementation and provides for timely measurement of parameters, identification of their deviations (defects) and measures to eliminate and prevent them. The maximum deviations of the parameters of the mounted steel structure are given in the table. Welds with identified defects must be corrected. Correction of welds is carried out by manual arc welding, using electrodes of the same type with a diameter of 3 or 4 mm. Lifting height up to 10 m 6.5 The construction site must have a fence, work areas (locations) must be marked with safety signs and inscriptions of the established form in accordance with the requirements of GOST R 12.4.026.. 6.6 Installation work should be carried out, as a rule, during daylight hours. The construction site, work areas, workplaces, passages and approaches to them in the dark must be illuminated in accordance with the requirements of GOST 12.1.046. 6.7 When performing installation work using a crane, the following safety requirements must be observed: work according to the slinger's signal; lifting, lowering, moving mounting elements (columns, beams, etc.), braking during all movements should be performed smoothly, without jerking; During movement, mounting elements must be raised at least 0.5 m above objects encountered along the way; It is necessary to lower the mounting elements into places designated and prepared for them, ensuring their stable position and ease of removal of the slings. 6.8 When performing welding work, it is necessary to comply with the requirements of the mentioned SNiP, GOST 12.3.003 and GOST 12.3.036, as well as sanitary rules for welding, surfacing and cutting of metals. Each properly organized construction must have well-written construction documentation, which, as a rule, includes the development of documents such as a traffic management project (abbreviated as POD), construction organization project (abbreviated as POS) and work production project (abbreviated as PPR). All these documents are capable of ensuring the safety of employees during construction and installation work, ensuring the correct organization of the actual construction of the facility itself, as well as improving the quality of construction work performed. Today, due to the fact that construction work has become characterized by the highest degree of severity, there is a need for the creation and more responsible development of technological and technical solutions that are used in the production of work. That is why the main and most significant document in the system of organizational and technological training becomes the PPR document in construction - download for free, which can be found at the end of this article. This document contains a list of technological rules, requirements for labor protection and safety and environmental safety, among other things. Based on the work project, construction work is organized, the necessary materials and resources are determined, the deadlines for completing the work are determined, and possible risks are worked out. Who develops the PPR?Work projects for the construction of new structures or for the reconstruction or expansion of any facility are developed by general contracting construction and installation enterprises. If PPRs are ordered by a general contracting or subcontracting construction and installation organization, then they can be developed by design and technology institutes or design and engineering organizations. It should also be noted that sometimes, when carrying out large volumes of work, PPRs are drawn up not for the object as a whole, but for a specific type of work, for example, for the installation of prefabricated structures, for excavation work, for roofing work, etc. Previously, such documents were called work organization projects (abbreviated POR), but in the current standards SNiP 12-01-2004 instead of SNiP 3.01.01-85, they are also called WPR with the proviso that these are projects for the production of specific works. When carrying out certain types of work related to general construction, special or installation work, PPRs are developed by companies that are directly involved in this. Composition of PPR
But it is worth noting that only 4 documents remain the main ones in the PPR: construction plan, work schedule, explanatory note and technical map. Let's look at them in more detail. The key PPR document in construction is, of course, the work schedule. The success of the entire project largely depends on the literacy of its development. In short, the calendar plan is a model of construction production, in which the sequence and timing of construction work at the site are clearly and accurately established. The second most important PPR document remains the construction master plan (or abbreviated construction plan). The quality of its preparation primarily determines the reduction of costs for organizing a construction site, which at the same time allows for the creation of safe working conditions for workers. When developing a construction plan, specialists take into account various methods of organizing a construction site, from which the most rational one is subsequently selected. The next no less important PPR document is the technological map, which determines the most optimal methods and sequence of performing a particular type of work. In addition, labor costs are calculated here, the necessary resources are determined and the organization of labor is described. Technological maps, as a rule, include graphic and text documents, which may include workplace diagrams, which indicate the scope of work and the boundaries of the areas into which the object is divided. In principle, technological maps can be of three types:
And the last important element of the PPR can be called an explanatory note, in which, as mentioned above, all kinds of labor protection measures are indicated, the conditions and complexity of construction are determined, the presence of warehouses and temporary structures is justified, etc. In addition, the explanatory note provides technical and economic indicators of construction. You can download the PPR for construction.
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No. |
Sequence of operations |
Job title |
Group according to EB |
Qty, people |
Preparatory work. Preparing the installation site (clearing snow) |
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Assess the installation site where it is necessary to clear snow (relief, swampiness, soil condition, presence of uncleaned forest, large stones, fresh stumps). At the installation site, determine the direction of the bulldozer's route moves. |
Master Electrician |
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Conduct targeted briefing to the brigade with registration in the work permit. The briefing must indicate safety measures during the work, the order of operations, the technology for performing the work, indicate the directions of route moves of the bulldozer, and, upon completion of the work, indicate the parking place of the bulldozer. The brigade is allowed to work. |
Master -responsible work manager; Electrician -performer of the work (permitting); |
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Complete the work to prepare the installation site and place the bulldozer in its parking area. Clear the foundations of snow manually (with shovels). |
Electrician -performer of the work (permitting); Bulldozer driver- crew member |
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Complete the work. |
Master -responsible work manager; Electrician -performer of the work (permitting); |
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Fastening the metal rack of the anchor-corner support U2 to the foundation with mounting hinges |
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Check the compliance of the dimensions at the centers of the reinforced concrete footings (foundations) with the dimensions of the support, as well as the vertical marks of the foundations. If deviations exceeding the established tolerances are detected, the support may be lifted only after the detected defects have been eliminated. Inspect the structure of the support post being installed and make sure that there is no possibility of it falling. The presence of all bolted connections and structural elements of the support. Check tools, devices, protective equipment and materials. Protect the danger area with tape. |
Master -responsible work manager; Electrician -performer of the work (permitting); |
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Conduct targeted briefing to the brigade with registration in the work permit. The briefing must indicate safety measures during work, the order of operations, technology for performing work, and the danger zone. The brigade is allowed to work. |
Master -responsible work manager; Electrician -performer of the work (permitting); Brigade |
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Install the truck crane at the workplace in accordance with Appendix No. 1. |
Truck crane operator- crew member Master (responsible |
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Install the hinges onto the support leg foundations (using wood blocks to align the hinge after installing the support) and onto the support shoes. |
Truck crane operator- crew member |
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Sling the support post. Using a truck crane, bring the support stand and shoes to the foundations. Secure the support shoes to the hinges. At the place where the cable support is attached, install wooden spacers to prevent the support from touching the ground and to level the support horizontally. |
Truck crane operator- crew member Electrician (slinger) - team member |
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Attach two loop slings to the support post (at a distance of 17 m from the base of the support) and insert a Ø 23 mm mounting rope to the traction mechanism (in accordance with Appendix No. 2). Similarly, from the opposite side of the support, lead the cable to the brake mechanism. |
Electrician - team member |
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Install a sling for lifting the support column with a release device, securing it to the crane hook. Install wooden pads under the sling (or inventory pads under the sling). (in accordance with Appendix No. 2). |
Truck crane operator- crew member Electrician (slinger)- crew member |
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Lifting and securing the support. |
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Arrange the vehicles in accordance with Appendix 1. Before starting to lift the support, remove uninvolved personnel from the danger zone (during the process of installing the stand, before moving the mechanisms, it is also necessary to remove uninvolved personnel from the danger zone). |
Master -responsible work manager (responsible for safe performance of work using PS) Bulldozer driver- team member; |
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The truck crane smoothly lifts the support. The traction machine smoothly begins to move from the support column, the brake machine moves towards the traction machine so as to prevent the creation of slack. Raise the support post to a height of 200-300 mm. |
Master -responsible work manager Bulldozer driver- team member; Truck crane operator- crew member |
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Check the serviceability of traction mechanisms, rigging devices, installation of braces, as well as the correctness and reliability of fastening of all rigging under load. |
Master -responsible work manager (responsible for safe performance of work using PS) |
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The truck crane smoothly lifts the support. The traction machine smoothly begins to move from the support column, the brake machine moves towards the traction machine so as to prevent the creation of slack. Raise the support post to an angle of 35-40 degrees from ground level. Remove the load from the truck crane and transfer it to the traction mechanism. |
Master -responsible work manager(responsible for the safe performance of work using PS) Bulldozer driver- team member; Truck crane operator- crew member |
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Pull out the release device, releasing the hook of the truck crane. Move the truck crane to the transport position and remove it from the danger zone. |
Truck crane operator- crew member Electrician -performer of the work (permitting); |
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The traction machine smoothly begins to move from the support column, the brake machine moves towards the traction machine so as to prevent the creation of slack. Install the support stand on the foundations. |
Master -responsible work manager Bulldozer driver- team member; |
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Install square washers on the rack shoes and screw nuts onto the anchor bolts. In this case, the nuts should not reach close to the surface of the rack shoes. |
Electrician - team member |
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Use a traction machine to apply tension to the cable to slightly tilt the support post. Remove the hinges. Move the traction machine back smoothly to place the support stand on the foundations. |
Master -responsible work manager Bulldozer driver- team member; |
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Align the support post according to tolerances. If necessary, to level the support post, install shims between the fifth support and the foundation. |
Master -responsible work manager Electrician -performer of the work (permitting); |
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Tighten the nuts and locknuts of the anchor bolts. Weld the pads to the heel of the rack. Weld the washers of the anchor bolts on three sides. |
Master -responsible work manager Electrician - team member Electric and gas welder- crew member |
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Completion of work. |
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The electrician climbs onto the support post with the endless rope block to the place where the rigging is attached, stands on the lanyard, securing the safety harness lines to the support structure, and secures the endless rope block to the support post. |
Electrician -performer of the work (permitting); Electrician - team member |
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Electricians on the ground should lift the installation tool along an endless rope in a cotton bag. |
Electrician -performer of the work (permitting); Electrician - team member |
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Electricians on the ground must hold the endless rope to prevent sudden lowering of the rigging. Lower the rigging and tools to the ground one by one. |
Electrician -performer of the work (permitting); Electrician - team member |
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The electrician, located on the support, lowers the endless rope block to the ground. |
Electrician -performer of the work (permitting); Electrician - team member |
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Remove the workplace, rigging, tools, equipment. |
The whole brigade |
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Remove the team from the workplace |
Electrician -performer of the work (permitting); |
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Complete the work. |
Master -responsible work manager Electrician -performer of the work (permitting); |
Here you can see examples of work projects
PPRk (Crane Work Project)
The installation and safe operation of three tower cranes during the construction of a series of monolithic residential buildings is considered. Due to cramped conditions, the cranes operate with a limited service area.
Stationary tower cranes of the Jaso J110N and Jaso J140N brands erect structures of a 19-story building from elevation 0.000 to elevation. +63.000. The cranes are mounted on foundation supports with a slab elevation of -2.200, with tower anchorage.
The maximum load lifted by cranes at a reach of 2.5-15 m is 5 tons, at a reach of 15-40 m - 2.5 tons.
Tower cranes are used at all stages of construction of the underground and above-ground parts of the building, namely:
- for unloading from vehicles and storing materials and products as they arrive at the construction site
- for supplying packs of reinforcement, reinforced mesh and formwork, as well as for supplying concrete in buckets during the construction of monolithic structures
- for supplying small-piece materials and mortar to the installation horizon
- for supplying and removing construction equipment, equipment, consumables, etc. from the building.
Project scope: Explanatory note A4 - 35 sheets, drawings A1 - 5 sheets
This is an example of a work permit for the excavation of a pit under the protection of a sheet piling fence. Excavation is carried out in 3 stages.
- Stage 1. Work at the level of 135.50÷134.60 is carried out by a Hitachi ZX 200 excavator with a bucket capacity of 0.8 m3 (maximum digging radius - 9.75 m, maximum digging depth - 6.49 m) equipped with a backhoe bucket with loading of soil into dump trucks. With a lag of 4 meters from the operation of the Hitachi ZX 200 excavator, the installation of the strapping belt (1 I-beam N45 B2) is carried out. Installation is carried out using a truck crane according to a separately developed design and maintenance plan.
- Stage 2. Work at level 132.50 is carried out with a Hitachi ZX 200 excavator. At this level, a pit is developed to a design depth of 127.84÷127.84 m, by excavating and moving the soil into a dump truck. With a lag of 4 meters from the operation of the ZX 200 excavator, a spacer structure is made, consisting of a strapping belt (2 I-beams N45 B2), spacers made of pipes 426x10mm in axes 1÷10 and struts, as well as pipes 630x12mm in axes 11÷16. Installation is carried out using a truck crane according to a separately developed design and maintenance plan.
- Stage 3. Excavation of slopes is carried out by developing and moving soil with a Bobcat S330 excavator into the work area of a Hitachi ZX 225 grab. The grab brings the developed soil to the surface and loads it into a dump truck. The Bobcat S330 excavator is released from the pit upon completion of the work by a truck crane according to a separately developed work permit.
At the last stage, the berm soil is excavated under the installed jibs of the sheet pile fencing of the pit using a mini excavator.
Project scope: Explanatory note A4 - 28 sheets, drawings A1 - 5 sheets
Project for the installation of a water pipeline using the auger method
Laying a water pipeline in a case constructed using a closed auger tunneling method. The excavation of a rectangular working pit and a round receiving shaft is also being considered.
Work on laying pipes using auger tunneling is carried out in several stages:
- 1st stage. Pushing the pilot line, consisting of rods and a pilot head, to the length of the interval from the starting pit to the receiving pit. The exact direction of the route is ensured by a system for monitoring the position of the pilot head, information about the position of which is displayed on the monitor screen suspended in the launch shaft.
- 2nd stage. Punching of casing steel pipes and expander mounted in the starting pit on the last rod of the pilot line within the length of the entire interval between the pits. Pushing out working pipes from the starting pit with simultaneous removal of the squeezed out casing steel pipes in the receiving pit. The casing pipes are being pressed with a drilling head at the head of the pipe string, which serves to develop soil in the face; soil is transported from the face to the bucket in the starting pit by a screw conveyor.
- 3rd stage. Pushing working pipes with a diameter less than or equal to the diameter of the casing pipes, with simultaneous pushing of the casing pipes and screw conveyor links into the receiving pit and their disassembly. When the diameter of the working pipes is less than the diameter of the casing, the construction gap (space) formed between the working pipeline and the inner surface of the excavation must be filled with cement mortar.
Project scope: Explanatory note A4 - 25 sheets, drawings A1 - 4 sheets
PPR for installation of sheet piling and bored piles
An example of a PPR for the installation of sheet piling fencing for a pit in the security zone of a power transmission line (power lines). Making bored piles: drilling a well with augers, installing the reinforced frame of the pile with a drilling rig, filling the pile with concrete mixture using the bottom-up method.
Drilling of bored piles Ø620 mm is carried out using a Hitachi-based drilling rig
Drilling of each well should begin after an instrumental check of the grades of the planned surface of the earth and the position of the contour axes on the site.
Concreting of piles is carried out by supplying concrete mixture into the well through hollow augers.
As concrete is fed into the well, the auger sections are lifted and dismantled, and the level of concrete in the well must be at least 1 m higher than the bottom of the auger. The distance between the bottom of the well and the lower end of the auger when concreting begins should not exceed 30 cm.
Project scope: Explanatory note A4 - 20 sheets, drawings A1 - 6 sheets
Project for the installation of scaffolding
Example of a project plan for installing scaffolding on the facade of a building under construction
Rack-mounted attached clamp scaffolding is a spatial frame-tier system mounted from tubular elements: racks, crossbars, longitudinal and diagonal braces, which are connected to each other using node connections - clamps.
The scaffolding is fastened to the wall using anchors placed in holes punched in the walls with a diameter of 14 mm.
Scaffolding must be attached to the wall of the building under construction. Fastening is carried out through at least one tier for fastening racks, through two spans for the upper tier and one fastening for every 50 sq.m of projection of the scaffolding surface onto the building facade.
Project scope: Explanatory note A4 - 38 sheets, drawings A1 - 4 sheets
On what basis are you required to have a PPR? List of normative documents.
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