A saddle type multi-support point horizontal container support construction and storage tank installation method

Abstract

The application discloses a saddle type multi-support-point horizontal container support construction and storage tank installation method, and particularly relates to the field of building construction equipment foundation technology in the chemical industry. The BIM technology is adopted to establish a saddle support model, template reinforcement and aluminum tank installation are simulated, and a shaped saddle-shaped mold is processed and manufactured according to design drawings. After the template reinforcement is completed, a smart total station instrument is used for point position and model collision, so that the saddle forming effect is beautiful, the arc is smooth, the structural size deviation meets the design requirements, the matrix type row saddle forming is uniform, and the structural size deviation meets the aluminum tank installation requirements. After the aluminum tank is hoisted and positioned, a jack support is used for fine adjustment, so that the precise positioning of the aluminum tank can be realized. Rubber shock pads are arranged between the aluminum tank body and the saddle, and water glass mortar is used for secondary grouting of the gap between the shock pad and the saddle, so that the aluminum tank body and the saddle arc surface can be closely attached, and the safety of the tank body in use is ensured.

Description

Technical Field

[0001] This invention relates to the field of basic technology for construction equipment in the chemical industry, and specifically to a method for constructing a saddle-type multi-point horizontal container support and installing a storage tank. Background Technology

[0002] Storage tanks are used to store compounds obtained through refining and required for practical operations, such as alkalis, acids, salts, and other chemical substances, or compounds in air or liquid states. They are indispensable storage equipment in various fields, and in my country, they are mainly used in the chemical industry. Aluminum storage tanks are made of industrial pure aluminum, which has certain strength and corrosion resistance, making them ideal for storing concentrated nitric acid and glacial acetic acid. Horizontal storage tanks have a simple structure and are static equipment, requiring minimal maintenance; routine routine maintenance is sufficient.

[0003] The foundation of horizontal storage tanks is a concrete saddle support, and the construction quality of the support directly affects the normal use of the aluminum tank. Current construction techniques involve separate construction of the equipment foundation and the saddle support. Poor welding of the saddle support reinforcement to embedded parts or inadequate jointing between new and old structures directly affects the service life of the structure. Furthermore, gaps exist between the equipment and the saddle support after construction, leading to uneven stress on the aluminum tank surface and deformation. The process is complex, requiring repeated formwork and resulting in a long construction period. Using a steel structure saddle foundation results in higher overall costs and maintenance. In chemical plants, deformation of equipment containers could lead to concentrated nitric acid leaks, which, if released into the air, could irritate the respiratory tract and cause poisoning; leaks onto the ground could cause water and soil pollution. Therefore, a reliable saddle support construction method is needed to ensure a direct and tight fit between the aluminum tank and the saddle support. Since the concrete saddle support supporting large horizontal storage tanks is a multi-point support, it is crucial to ensure that uneven settlement of the rows of saddle support foundations does not cause uneven stress on the tank body, guaranteeing the stability and accuracy of the aluminum tank installation on top of the saddle support. Summary of the Invention

[0004] To overcome the aforementioned deficiencies of the prior art, embodiments of the present invention provide a method for constructing a saddle-type multi-point horizontal container support and installing a storage tank. This method addresses the problems mentioned in the background art, such as the separate construction of the equipment foundation and the saddle, weak welding of the saddle reinforcement and embedded parts, or inadequate jointing between the old and new structures, which directly affect the service life of the structure. Furthermore, gaps exist between the equipment and the saddle after the saddle construction, leading to uneven stress and deformation on the surface of the aluminum tank. Additionally, the process is complex, requiring repeated formwork and resulting in a long construction period.

[0005] To achieve the above objectives, the present invention provides the following technical solution: a construction method for a saddle-type multi-point horizontal container support, the specific steps of which are as follows:

[0006] S1: Construction preparation;

[0007] S2: Subbase construction;

[0008] S3: First measurement and layout;

[0009] S4: Binding of steel reinforcement cage, formwork and concrete pouring for integral raft foundation;

[0010] S5: Secondary measurement and layout;

[0011] S6: Binding, formwork erection, and concrete pouring of the steel reinforcement cage at the bottom of the saddle;

[0012] S7: Binding and formwork of the steel reinforcement skeleton of the upper saddle structure;

[0013] S8: Perform snap-in point alignment with the BIM model;

[0014] S9: Adjustment of the saddle-shaped arched formwork and pouring of concrete;

[0015] S10: Anti-corrosion coating for saddle concrete.

[0016] In a preferred embodiment, after the foundation pad construction is completed as described in S3, the raft foundation is surveyed and laid out. Based on the provided pile handover data and saddle design drawings, the overall outline of the raft foundation is laid out after the foundation pad is poured.

[0017] In a preferred embodiment, as described in S5, after the raft foundation concrete is formed, the outline of the saddle bottom foundation, the outline of the saddle top foundation, and the center line of the saddle foundation are laid out on the foundation surface.

[0018] In a preferred embodiment, the saddle reinforcement cage described in S7 is simulated and cut using BIM software. The reinforcement mesh is installed in sequence and tied. During the process, the placement of the reinforcement bars is measured with a steel tape measure in two directions. When laying the reinforcement mesh, the short reinforcement bars are laid first, and after the short reinforcement bars are laid, the long reinforcement bars are laid to form the reinforcement mesh. Supporting stirrups are set in the middle of the saddle. The diameter of the stirrups is the same as the diameter of the longitudinal reinforcement bars of the saddle, and the spacing is 1m.

[0019] In a preferred embodiment, the spacing of the saddle template support frame as described in S8 meets the template design calculation requirements. After the saddle-shaped foundation template is reinforced, the overall matrix saddle pull control line is used for verification, and the points are captured by the line laying robot. The model is then compared using computer BIM software.

[0020] In a preferred embodiment, the saddle template described in S9 is uniformly laid out and processed according to the shape and curvature of the design drawings, and the templates are assembled according to the number. After the templates are erected according to the calculated spacing and template scheme, the saddle template is checked.

[0021] Based on a storage tank installation method, the specific steps are as follows:

[0022] S1: The aluminum can body is positioned and finely adjusted in one go;

[0023] S2: Aluminum can body secured with rubber shock-absorbing pads;

[0024] S3: Sealing template erection (setting grouting holes);

[0025] S4: Secondary grouting;

[0026] S5: Remove the aluminum can support components.

[0027] In a preferred embodiment, as described in S1, a crane and a self-made auxiliary horizontal boom are used to lift the aluminum tank onto the matrix saddle. A jack is installed below the steel clamp of the aluminum tank to ensure that there is a sufficient gap between the aluminum tank and the support. The left and right and high and low positions of the aluminum tank are adjusted to ensure that the gap is sufficient for the injection of water glass mortar.

[0028] In a preferred embodiment, the curvature of the sealing template described in S3 is consistent with the curvature of the aluminum can body, and the elevation of the lower support points is consistent. Support points are set at a uniform elevation position on the foundation concrete structure at the bottom of the saddle. Grouting holes with a diameter of 60mm are set at 1m intervals along the curvature on the sealing plate.

[0029] The technical effects and advantages of this invention are as follows:

[0030] 1. The saddle-shaped foundation of this invention has a good forming effect. It uses BIM technology to process and manufacture a standardized template according to the saddle design requirements, so that the saddle shape is beautiful after forming, the longitudinal saddle dimensions are uniform, the arc is smooth, and the structural dimension deviation meets the design requirements.

[0031] 2. This invention results in minimal deformation of the aluminum can during use. Rubber shock-absorbing pads are installed between the aluminum can body and the saddle. Secondary grouting ensures a tight fit between the aluminum can body and the curved surfaces on both sides of the saddle, guaranteeing the safety of the aluminum can during use. The cost is low compared to steel saddle foundations and concrete saddle foundations. The process of corrosion prevention and maintenance is short, but the later maintenance cost is high. The service life of the saddle foundation is also short. Attached Figure Description

[0032] Figure 1 This is a schematic diagram of the overall installation structure of the present invention;

[0033] Figure 2 This is a schematic diagram of the saddle support structure of the present invention;

[0034] Figure 3 This is a schematic diagram of the workflow structure of the present invention. Detailed Implementation

[0035] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0036] according to Figure 3 The construction method of a saddle-type multi-point horizontal container support shown is as follows:

[0037] Step 1: Construction preparation. Familiarize yourself with the saddle design drawings, understand the content, annotations and specific construction requirements of the saddle drawings, record the important parameters reflected in the drawings, and communicate with the design unit regarding the installation, fine-tuning and secondary grouting of the aluminum tank body to ensure accurate installation.

[0038] Step 2: Subbase construction. The foundation subbase is constructed by pouring concrete. The concrete subbase is made of unreinforced concrete with a thickness of 100mm.

[0039] Step 3: Initial measurement and layout. After the foundation layer construction is completed, the raft foundation measurement and layout are carried out. Based on the provided stake handover data and saddle design drawings, the overall raft foundation outline is laid out after the foundation layer is poured. The control line on the top surface of the raft foundation is 200mm away from the outline line. The longitudinal control line runs through all saddles for easy later verification. To ensure that the longitudinal and transverse positions of all saddles in the entire tank area are consistent, multiple control stakes are set on the outside of the tank area to verify the position and elevation of the saddles during the saddle construction process. The measurement progress should be in accordance with the verification specifications. The spacing between adjacent control points is determined based on the spacing between saddles and between tank foundations.

[0040] Step 4: Binding, Formwork Erection, and Concrete Pouring of the Overall Raft Foundation Reinforcement Skeleton. Multiple control points are set on the raft foundation and marked with red paint. All control points for changes in the saddle structure's shape must be folded onto the raft foundation to control the overall dimensions of the saddle. During the installation of the overall raft foundation reinforcement skeleton, longitudinal and transverse reinforcement mesh control lines are laid on the foundation pad. The longitudinal and transverse reinforcement meshes are bound according to the control lines, and the spacing of the reinforcement bars is measured with a steel tape measure during the binding process. The ends of the reinforcement mesh are treated with edge sealing. The raft foundation stirrups are made of 20mm diameter steel bars in a Z-shape and quincunx pattern, with an adjacent stirrup spacing of 1m. During the installation of the overall raft foundation formwork, formwork installation control lines are laid on the foundation pad. The side formwork of the foundation is fixed according to the control lines. The formwork uses multi-layer plywood, 18mm thick. The secondary joists are made of 50×100mm square timber, and the main joists are made of ￠48×3.5mm steel pipes, using 16mm tie bolts. The spacing between secondary joists is 250mm, and the spacing between main joists is 500mm. The surface of the subgrade should be flat before formwork erection. After formwork erection, use a plumb line and steel ruler to check the verticality and installation position. When pouring the concrete for the integral raft foundation, the raft foundation should be poured in layers. Proceed sequentially, reaching the top in one go; pouring should proceed from one end of the long side to the other. During pouring, the vibrator should be inserted quickly and withdrawn slowly, penetrating 50mm into the next layer of concrete. After the raft foundation concrete is poured, use a string line to level it, smooth and press it as needed, and cover it with plastic film. The curing time should be no less than 28 days.

[0041] Step 5: Secondary measurement and layout. After the raft foundation concrete has been formed, the outline of the bottom foundation of the saddle, the outline of the top foundation of the saddle, and the center line of the saddle foundation are laid out on the foundation surface.

[0042] Step 6: Binding, formwork erection, and concrete pouring of the saddle base structural steel reinforcement cage. The saddle reinforcement cage is simulated and cut using BIM software. The steel mesh installation must be carried out sequentially, with the steel reinforcement placement measured in both directions using a steel tape measure. When laying the steel mesh, the shorter reinforcing bars are laid first, followed by the longer reinforcing bars to form the mesh. Supporting stirrups are installed in the middle of the saddle, with the same diameter as the longitudinal reinforcing bars and a spacing of 1m. The vertical reinforcing bars of the saddle base foundation are pre-embedded during the installation of the overall raft foundation reinforcement and bound according to the designed transverse reinforcement spacing. Ladder reinforcement is used to control the transverse reinforcement spacing. The ladder reinforcement is made of 14mm steel bars welded at the designed spacing. The saddle base foundation formwork reinforcement and concrete pouring are the same as the raft foundation, with the concrete poured in 500mm layers.

[0043] Step 7: Binding and formwork the steel reinforcement skeleton of the upper saddle structure. The steel reinforcement of the saddle-shaped part of the saddle must be firmly welded to the foundation steel reinforcement at the bottom of the saddle. When binding the foundation steel reinforcement at the bottom of the saddle, embedded steel bars are set at 400mm intervals. Diagonal steel bars are processed according to the steel bar shape in the design drawings. The diagonal steel bars of the saddle shape are welded to the foundation steel reinforcement at the bottom of the saddle on one side, with a weld length of 200mm. When binding the foundation steel reinforcement at the bottom of the saddle, embedded steel bars are set at 400mm intervals, with a height of 200mm. The saddle-shaped formwork adopts a bottom-supported and top-pulled method. Double steel pipes are used to reinforce the two ends of the saddle on both sides. Two steel bars are set at the top for connection, with a spacing of 300mm between the steel bars. V-shaped grooves are cut every 100mm to ensure that the reinforcing square timber is consistent with the curvature of the formwork. Steel bars are used as longitudinal keels on the inside, and square timber is used as transverse keels, with step-by-step tightening for reinforcement.

[0044] Step 8: Align the snap points with the BIM model. Ensure that the spacing of the saddle formwork support frame meets the design calculation requirements. After the saddle-shaped foundation formwork is reinforced, check the overall matrix saddle control line and use a line-laying robot to snap points. Use computer BIM software to compare the model and check the snap points. Snap points are taken every 50 cm from the bottom arc point of the saddle upwards.

[0045] Step 9: Adjust the saddle seat arc formwork and pour concrete. The saddle seat formwork is uniformly laid out and processed according to the design drawings and arc. The formwork is assembled according to the number. After the formwork is erected according to the calculated spacing and formwork plan, the saddle seat formwork is checked. The concrete is poured in layers with a layer thickness of 500mm. Low frequency vibrators are used for vibration. The concrete is left to stand until it is formed. The pouring should be continuous. During the pouring process, a small hammer is used to lightly tap the outside of the formwork to ensure that the concrete is dense. The construction joint should be treated before the formwork is erected. After the concrete is demolded, plastic film, cotton felt, etc. should be used for watering and moisturizing curing in a timely manner. The curing time should not be less than 28 days.

[0046] Step 10: Anti-corrosion coating of saddle concrete. After cleaning the concrete surface, apply anti-corrosion coating. Before applying the anti-corrosion coating, the base layer should be ground to ensure that the joints are smooth and the surface is free of laitance. After treatment, apply epoxy fiberglass anti-corrosion coating. The number of coats and thickness of the coating must meet the design requirements, and there should be no drips on the surface.

[0047] Based on a storage tank installation method, the specific steps are as follows:

[0048] Step 1: The aluminum tank body is positioned and finely adjusted in one go. A crane and a self-made auxiliary horizontal boom are used to lift the aluminum tank onto the matrix saddle. Jacks are set under the steel clamps of the aluminum tank to ensure that there is enough gap between the aluminum tank and the support. The left and right and high and low positions of the aluminum tank are adjusted to ensure that the gap is sufficient for the injection of water glass mortar.

[0049] Step 2: Fixing the rubber shock-absorbing pads on the aluminum can body. Rubber shock-absorbing pads are installed at the bottom of the aluminum can along each saddle position. After the aluminum can body is installed and fine-tuned, rubber shock-absorbing pads are installed between the aluminum can body and the saddle to ensure uniform force on the aluminum can. The steel clamps of the aluminum can are made of steel plates, flat steel and square steel. The steel plates are welded from 14mm thick steel plates, 10mm thick flat steel and 160mm×160mm square steel pipes.

[0050] Step 3: Set up the sealing template (set grouting holes). The curvature of the sealing template should match the curvature of the aluminum tank body, and the elevation of the lower support points should be consistent. Support points should be set at the same elevation of the foundation concrete structure at the bottom of the saddle. Grouting holes with a diameter of 60mm should be set on the sealing plate at 1m intervals according to the curvature.

[0051] Step 4: Secondary grouting. Grouting is carried out using a special grouting machine. Grouting starts from the bottom of the tank and continues until the other grouting holes are full and grout is discharged.

[0052] Step 5: Remove the aluminum can support components to complete the installation of the aluminum can.

[0053] Finally, the following points should be noted: First, in the description of this application, it should be noted that, unless otherwise specified and limited, the terms "installation", "connection", and "linkage" should be interpreted broadly, and can be mechanical or electrical connections, or internal connections between two components, or direct connections. "Up", "down", "left", "right", etc. are only used to indicate relative positional relationships. When the absolute position of the described object changes, the relative positional relationship may change.

[0054] Secondly: The accompanying drawings of the embodiments disclosed in this invention only involve the structures involved in the embodiments disclosed in this invention. Other structures can refer to the general design. In the absence of conflict, the same embodiment and different embodiments of this invention can be combined with each other.

[0055] In conclusion, the above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the protection scope of the present invention.

Claims

1. A construction method for a saddle-type multi-point horizontal container support, characterized in that: The specific steps are as follows: S1: Construction preparation; S2: Subbase construction; S3: First measurement and layout; S4: Binding of steel reinforcement cage, formwork and concrete pouring for integral raft foundation; S5: Secondary measurement and layout; S6: Binding, formwork erection, and concrete pouring of the steel reinforcement cage at the bottom of the saddle; S7: Binding and formwork of the steel reinforcement skeleton of the upper saddle structure; S8: Perform snap-in point alignment with the BIM model; S9: Adjustment of the saddle-shaped arched formwork and pouring of concrete; S10: Anti-corrosion coating for saddle concrete; After the S3 cushion layer is completed, the raft foundation is measured and laid out. Based on the provided pile handover data and saddle design drawings, the overall raft foundation outline is laid out after the foundation cushion layer is poured. According to S5, after the raft foundation concrete is formed, the outline of the bottom foundation of the saddle, the outline of the top foundation of the saddle, and the center line of the saddle foundation are marked on the foundation surface. According to S7, the saddle steel reinforcement skeleton is simulated and cut using BIM software. The steel mesh installation must be carried out in sequence. During the process, the placement position of the steel reinforcement is measured with a steel tape measure in two directions. When laying the steel mesh, the short steel reinforcement is laid first, and after the short steel reinforcement is laid, the long steel reinforcement is laid to form the steel mesh. Supporting stirrups are set in the middle of the saddle. The diameter of the stirrups is the same as the diameter of the longitudinal steel reinforcement of the saddle, and the spacing is 1m. According to S8, the spacing of the saddle template support frame meets the template design calculation requirements. After the saddle-shaped foundation template is reinforced, the overall matrix saddle pull control line is checked and the points are captured by the line laying robot. The model is compared using computer BIM software. According to the design drawings, the S9 saddle template is laid out and processed in a unified manner. The templates are then assembled according to their numbers. After the templates are erected according to the calculated spacing and template scheme, the saddle templates are checked.

2. The construction method for a saddle-type multi-point horizontal container support according to claim 1, characterized in that, It also includes the tank installation method, the specific steps of which are as follows: Step 1: The aluminum can body is positioned and fine-tuned in one go; Step 2: Secure the aluminum can body with rubber shock-absorbing pads; Step 3: Set up the sealing template and install grouting holes; Step 4: Secondary grouting; Step 5: Remove the aluminum can support components.

3. The construction method for a saddle-type multi-point horizontal container support according to claim 2, characterized in that, According to step 1, the aluminum tank is lifted onto the matrix saddle using a crane and a self-made auxiliary horizontal boom. Jacks are set under the steel clamps of the aluminum tank to ensure that there is a sufficient gap between the aluminum tank and the support. The left and right and high and low positions of the aluminum tank are adjusted to ensure that the gap is sufficient for the injection of water glass mortar.

4. The construction method for a saddle-type multi-point horizontal container support according to claim 3, characterized in that, According to step 3, the curvature of the sealing template is consistent with the curvature of the aluminum can body, and the elevation of the lower support point is consistent. The support point is set at the same elevation position of the foundation concrete structure at the bottom of the saddle. Grouting holes are set on the sealing template at intervals of 1m according to the curvature, and the grouting hole diameter is 60mm.

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