Method Statement For Foundation Construction

Aktogay Copper project Sulphide Plant

阿克托盖硫化矿项目

Method Statement

For Foundation Construction of 3700 and 0400

3700 0400 基础施工方案

11250-ZB-NFC-0000-MS-C-0031

Issued for Review / Comment APPROVAL REASON Yu Huaibo Chen Liu Baoguo Sun Yuanpeng CHECKED Guan Chengming Xu Xu APPROVED B 05/Mar/2016 A REV#

7/MAR/2015 DATE Zhengyong ORIGINATOR Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B

目 录 Content

第一章 程概况.............................................................................................................. 3 Chapter 1. Project Overview .......................................................................................... 3 第二章 施工部署.......................................................................................................... 4 Chapter 2. Construction Deployment ............................................................................ 4 第三章 施工方法.......................................................................................................... 6 Chapter 3. Construction Method .................................................................................... 6 第四章 风险评估........................................................................................................ 12 Chapter 4. Risk Analysis .............................................................................................. 14

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Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B

第一章 程概况

Chapter 1. Project Overview

1. 建设概况

本工程为哈萨克铜业公司投资新建的项目，处理矿石2500吨/年。3700尾矿回收部分，基础为钢筋混凝土工程，上部为硫化矿残渣泵和硫化矿残渣浓缩槽罐设备及钢结构，采用螺栓连接；整体成L型，每一边为长88.55米、宽12.2米。基础为基础和筏板基础。筏板基础高度为1.5米。 1. Project Overview

Atogay copper project is a new project invested by Kazminerlas, yearly dealing amount of the copper ore is 25 million tons. The foundation of tailing reclaim is reinforced concrete ,with the upper part sulphide ore residue pump and sulphide residue thickening tank and structure steel, connected with bolt; The shape of the structure is L shape , the length of every side is 88.55m, and width 12.2m. The foundation of the structure is single foundation and raft foundation, and the height of the raft foundation is 1.5m. 2. 设计概况

本工程基础混凝土强度等级：B40 基础垫层厚度为50mm 本工程钢筋保护层厚度：

① 砼所有暴露的内外边缘做20mm的凹角 ② 砼直接与地面接触部分-75mm ③ 砼直接与碎石接触部分-50mm ④ 砼暴露在外面的表面-65mm ⑤ 砼非暴露在外的表面-40mm 2. Design Overview

The strength grade of the concrete for this project is :B 40 The thickness of the foundation blinding is 50 mm. The thickness of the reinforcement cover layer is :

① All the exposing external and internal edge should be made into 20mm re-entrant angle.

② The directly contacting part of the concrete with the ground -75mm ③ The directly contacting part of the concrete with the gravel-50mm ④ The exposing surface of the concrete-65mm ⑤ The non-exposing surface of the concrete-40mm

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Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B

第二章 施工部署

Chapter 2 . Construction Deployment

劳动力资源配置

施工操作人员需根据作业任务及相关要求合理安排，实际情况及时调整，作业人员安排如下：

专业 人数 专业 人数 管理人员 3 木工 55 技术员 4 电工 3 质量员 2 混凝土工 15 安全员 3 钢筋工 35 决策层 测量员 3 作业层 架子工 10 电焊工 2 火焊工 2 吊车司机 2 普工 20 合计 15 合计 136 1. 施工作业前应根据作业特点进行方案和安全技术交底。 2. 作业时周边应设置警戒区域并设醒目的警示标志，特别危险应设监护人员。 3. 属于特种作业的人员必须按有关规定经过专门安全作业培训，取得特种作

业操作资格证书，方可上岗作业。

Man Power Plan

The construction worker should be reasonably assigned according to the task and relative requirements, and be adjusted by the actual condition if it’s required . The deployment is as follows: Specialization Number of Specialization Number of people people Managing Carpenter 3 55 personnel Technical Electric 4 3 personnel Quality Concreter 2 15 personnel Decision Safety Rebar 3 35 making Operation worker personnel layer Layer Surveyor 3 Scaffolder 10

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Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B Welder 2 Fire welder 2 Crane 2 operator General 20 worker 15 136 Total Total 1. Communication of the method and safety technology should be conducted before the construction, and the communication should rely on the feature of the operation.

2. Warning region and eye-catching warning sign should be set surround the

operation area, extremely dangerous area should be with safety supervisors.

3. The person of special work shall go through training for safety work ,only the

person who obtain the certification of special operation can join in the work. 主要机械设备计划 序号 设备名称 规格型号 单位 数量 1 砼物料运输车 10m3 台 5 2 混凝土搅拌站 120m3/小时 座 2 3 汽车吊 25T 台 2 4 砼输送泵车 100-160m3/小时 台 2 5 平板汽车 10T 台 2 6 交流弧焊机 B*3-500 台 2 7 发电机 50KW 台 8 8 柴油加热器 20KW 台 10 9 挖掘机 330 台 3 10 自卸土方车 15吨 台 10 11 抽水机 11KW 台 2 12 水车 10吨 台 2 Main Equipment Plan NO Description Model Type Unit Number 31 Concrete transporting 10m Set 5 truck 2 Batch Plant 120m3/Hour Set 2 3 Truck with crane 25T Set 2 4 Concrete pump 100-160m3/Hour Set 2 5 Trailer Truck 10T Set 2 6 AC Arc Welder B*3-500 Set 2 7 Generator 50KW Set 8 8 Diesel Heater 20KW Set 10 9 Excavator 330 Set 3 10 Self-unloading truck 15 Ton Set 10

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Method Statement For Foundation Construction of 3700 and 0400 11 12 11250-ZB-NFC-0000-MS-C-0031 REV.B

Set Set 单位 台 台 台 台 台 根 台 Unit Set Set Set Set Set Piece Set 2 2 数量 1 2 2 2 6 30 2 NO 1 2 2 2 6 30 2 Water pump Water cart 主要机具计划 序号 设备名称 1 全站仪 2 台锯 3 钢筋切断机 4 钢筋弯曲机 5 插入振动器 6 振动棒 7 水准仪 Main Machine Plan No Equipment name 1 Total Station 2 Bench saw 3 Rebar Cutting machine 4 Rebar Bending machine 5 Inserting vibrator 6 Vibrating bar 7 Level Gauge 11 KW 10 Ton 规格型号 徕卡 ,6-,32 S3 Model Type Leica ,6-,32 S3 第三章 施工方法

Chapter 3 . Construction Method

1. 土方工程

由于现场积水较多，最深的地方达到2m深。挖土前先用抽水机将积水抽干。挖基槽土方采用挖掘机及人工配合进行开挖。先测量放线，确定出开挖边线及开挖深度。施工工作面为基础边沿宽出3米。设立桩标，注明高程及轴线位置。桩标需设立在不易扰动，易于测量的地方，做好维护及固定措施。待监理工程师批准及业主检查后，用反铲挖掘机开挖。可用于回填料的土方运至基坑边缘100m外就近堆放。不合格及多余土方外运弃土。开挖过程中应按1:2放坡，保证边坡稳定。根据实际需要设置排水管及集水坑进行施工排水，保证工作面干燥以及基底不被水浸。超挖部分用B10混凝土回填。开挖至设计标高，待各方验槽后方可进行混凝土浇筑。

1. Earthwork Project

Because of the water logging on the site( the deepest area is 2 m), water pump will be utilized before the excavation of the soil. Combined method ,which is

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Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B

excavator and manual method are used for excavation, is utilized for the excavation of the base trench. Survey will be conducted firstly to determine the excavate edge and excavation depth. The distance between the foundation and the bottom of the slope shall be 3 meters to leave the operating space Stakes will be set to mark the elevation and the location of the axis, which shall be set at the place where it is not easily disturbed and easily to be measured. The maintenance and fixation shall be conducted well. After the inspection and approval of the superintendent of NFC and KPBV , back-acting shovel shall be utilized for the excavation job. The soil which can be used as backfilling material shall be transported 100 m from the base pit. Unqualified and extra soil shall be abandoned outside of the construction site. The slope degree shall be 1:2 to guarantee the stability of the slope. Drain-pipe and sump pump shall be set to drain the water according to the actual situation to guarantee the dryness of the working surface. The over-digging area shall be backfilled with B10 concrete. Pouring concrete shall be conducted after it’s excavated to the designed elevation and inspected by each 2. 钢筋工程

制作：钢筋表由施工员负责编制，经项目技术负责人审核后，方可进行制作

加工成型，现场绑扎，制作工艺严格按规范及标准执行。钢筋不得随意更换代用，如需代换需业主同意。钢筋不允许焊接或加热，所有结构钢筋需遵守GOST12004-B1。

除锈：钢筋表面应洁净，油渍、漆污和铁锈等在加工前清除干净，带有颗粒状或片状老锈的钢筋不得使用。

断料：根据配料单复核料牌所写钢筋级别，规格尺寸，数量是否正确，对同规格钢筋应分别进行长短搭配，统筹排料，避免浪费。一次切断钢筋根数严禁超过机械性能规定范围。

钢筋搭接长度按照SNIP2.03.01-84，设计图纸中未显示的搭接长度按下表： Bar splicing length comply with SNIP2.03.01-84，those could not found in drawings comply with the under table. 直径10 12 16 20 24 28 32 36 diameter 搭接长度 260 320 420 600 0 1100 1365 1680 Splicing length 2.Rebar Fabrication Manufacture: Rebar material schedule is made by construction crew, Rebar shall only be fabricated ,shaped and banded on site after the technical supervisor reviewed the rebar material schedule. The processing method of the rebar should strictly comply with the specification and standard. Rebar shall not be changed or replaced at liberty, approval from KPBV is required if the rebar is intended to be replaced . Welding or heating to the rebar is not permitted. All structural steel must comply with GOST12004-B1.

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Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B

Rust Removing: Surface of the rebar shall be clean, oil stain, painting dirty, rust shall be cleaned before processing, rebar with granular or strips of rust is not acceptable when using.

Severed Rebar: check whether the steel grade, specification ,size, and the quantity, which are written on the material board ,are right. Assort the rebar which is the same standard into groups according to the length of the rebar in general to avoid the wasting of the rebar. The quantity of the rebar cutting per time is strictly limited within the scope of the mechanical capacity. rebar overlap length as the table below: 12 16 20 24 28 32 36 Diameter 10 260 320 420 600 0 1100 1365 1680 Overlap Length 3. 模板工程 基础模板采用木工加工场加工配制成型，现场支设的方法。加固采用100*50方木及对拉螺栓，如图所示。

螺栓固定安装：为保证螺栓的准确安装，根据螺栓相对尺寸，用4mm厚的钢板预先加工螺栓定位钢板（如图所示），待螺栓定位准确，混凝土浇筑终凝后取出。

模板安装流程：检查核对标高中心线→安装预埋件→安装模板→校正垂直对角线→安装对拉螺栓→自检验收

3.Formwork Fabrication

Formworks are processed and prepared in the wood workshop, and erected on the site ,the 100*50 bracing for the formwork and split bolt is used to strengthen the formworks, seen in the drawing.

The fixation and installation of the bolt: to insure the accurate installation of the bolt, steel plate which is 4 mm thick is used to processed into typified form according to the size of the bolt, the typified form is removed when the bolt is accurately positioned and when the concrete is poured and hardened.

Installation process of the formwork: check and review the relative level center line→ installation of the embedded parts→ installation of the formwork→ check the vertical diagonal →installation of the split bolt → self-inspection and acceptance

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Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B

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Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B

4.混凝土工程

浇筑砼前应对设计图纸进行检查，检查内容包括预留孔、预埋螺栓、预埋件、预埋插筋、模板尺寸（包括机械、电气、管道及其它预埋件）

如果气候条件合适，砼应在加水后的60分钟内运输并浇筑完毕，砼浇筑完成后应立即开始养护。

在寒冷天气下进行混凝土浇筑作业，参照混凝土规范的12.4条规范施工。 应使用变频振捣器密实所有砼，禁止砼从超过1500mm的高度自由落下。 所有接触有冻融循环土壤的砼其表面要涂沥青油（2mm厚）。

基础砼必须认真浇筑每一层，每层约为300-500mm，并由受过专业培训的操作员来操作使用高频插入式振捣器振实每一层。

搅拌站砼应使用加热水来进行，除霜或加热的水蒸气用于保证砼的准备工作在低于15℃的温度下进行, 根据下表的计算来进行： 温度℃ 水 沙子 碎石 水泥 混凝土 1 80 -30 -30 -30 -10 2 80 -20 -20 -20 5 3 80 -10 -10 -10 21 砼运输用经过保温措施粉粒物料运输车运到现场，确保砼在5℃以上。 养护时间：基础砼B40（28天），柱脚柱子砼B40（28天） 砼浇筑保温用保温棚见混凝土冬季施工方案。

砼搅拌及运输见砼搅拌工艺流程及运输保温措施方案。

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Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B

4. Concrete Project Design drawing shall be inspected before the pouring of the concrete, inspection including opening ,embedded bolt, embedded parts, starter bars , size of the formwork ( including mechanical ,electrical, piping and other embedded parts)

If the weather is suitable for the pouring, the concrete shall be transported and poured 60 minutes after added the water, the curing of the concrete started once the pouring is completed.

Comply with concrete specification 12.4 to conduct concrete pouring under cold weather.

Variable frequency vibrator shall be used to compact all the concrete, the

free-fall of the concrete from the height of 1500mm is not acceptable.

All the surface of the concrete which in contact with the freezing and thawing cycling soil shall be painted with asphaltic oil(2 mm thick).

Foundation concrete shall be poured every layer carefully, the thickness of every layer shall be 300-500mm, high frequency vibrator shall be utilized to compact each layer, and the machine shall be operated by the trained and professional operator.

Heated water is used for the mixing of the concrete in the batch plant, defrost and heated steam is used for the preparation of the concrete under the temperature15 ℃ , the mixing is conducted as per the calculation below: Temperature℃ Water Sand Gravel Cement Concrete 80 -30 -30 -30 -10 1 80 -20 -20 -20 5 2 80 -10 -10 -10 21 3 The concrete shall be transported by the bulk powder goods tank truck which has been heat reserved to guarantee the temperature of the concrete is above 5 ℃.

Curing time: foundation concreteB40(28 days), column base ,column concrete B40(28 days)

Warming house is utilized to reserve the heat when pouring the concrete, seen in the ‘Method statement for Concrete Construction Warming house in winter’

Method of concrete mixing and transportation seen in the ‘Concrete mixing processing flows’ and the ‘Heat reserving method during transportation’.

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Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B

第四章 风险评估

风险评估: 编号 风险评估 危害因素 可能后果 几后风险率 果 值 无安全措施，不做培训，没有许可证 引发事故人员伤亡 控制措施 做好安全措施的准备，严格执行不培训不上工原则 安排责任心强，有经验的人进行监控，作业过程中不得脱离岗位 由机修人员进行维修加固、更换、零配件更换检查符合安全要求方可投入使用 钢筋加工，手把与切割机切口处要大于200mm以上。 何人 何时 几后风险率 果 值 降低风险方案 剩余风险评估 结论 1 2 4 6 监督人作业人 作业前 1 2 3 2 监护不足， 监护人不到位 出现事故未及时处理，造成事故扩大 1 4 5 监督人作业人 作业过程中 1 1 2 3 机械设备缺陷 机械伤害，人员伤害 2 5 7 监督人作业人 作业过程中 1 2 3 切割（弹、切伤）4 伤害 人员伤害 2 4 6 监督人作业人 作业过程中 2 2 4 5 木工作业区未设置“禁止吸烟”及“禁止烟火”的标志 火灾 2 5 7 严禁吸烟，同时设置吸烟点 监督人作业人 作业过程中 1 1 2 6 电缆任意拖拉，随意绑在钢筋上 触电伤害 2 4 6 现场电工时常巡查，加强作业人员安全教育 监督人作业人 作业过程中 2 2 4 7 在潮湿的地方照明没有使用安全电压 触电伤害 2 5 7 潮湿环境下必须使用安全电压，比如：36V、24V、12V等 监督人作业人 作业过程中 1 1 2

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Method Statement For Foundation Construction of 3700 and 0400 高处作业未按规定采取防护措施、作业人员未按规定系挂安全带 11250-ZB-NFC-0000-MS-C-0031 REV.B 8 坠落伤害 3 5 8 高处作业必须佩戴并按规定使用安全带 脚手架搭设必须有经过培训合格的人员进行单设，脚手架使用前必须经过HSE部门检查并挂牌 固定式设备需要使用专用开关箱，并执行“一机一闸一漏”的规定 监督人作业人 作业过程中 1 3 4 9 脚手架搭设不规范/脚手架未经过安全检查 各种事故 4 4 8 监督人作业人 作业过程中 1 1 2 固定式设备未使用专用开关箱，10 未执行“一机一闸一漏”的规定 吊索没有捆绑在重物的重心以上，如因特殊情11 况必须摁绑在重物的重心以下时，没有采取安全措施 触电伤害 2 4 6 监督人作业人 作业过程中 1 1 2 起重事故 2 6 8 吊索捆绑在重物的重心以上，如因特殊情况必须摁绑在重监督人物的重心以下时，必作业人 须有采取安全措施 使用培训合格的起重工作人员 作业过程中 1 2 3 起重作业 人员不熟知吊装方案、起重设备性12 能、操作规程、指挥信号和安全要求 起重作业 人员应熟知吊装方案、起重设备性能、操作规程、指挥信号和安全要求 起重事故 2 6 8 监督人作业人 作业过程中 1 2 3

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Method Statement For Foundation Construction of 3700 and 0400 11250-ZB-NFC-0000-MS-C-0031 REV.B

Chapter 4 Risk Analysis

Risk Analysis Schedule Conclusion Hazard Analysis SN. Consequence Control Measures Remaining hazard analysis Consequence Risk Rating Hazards Consequence Risk Rating Likelihood 2 Likelihood Control Measures Action BY Action When 1 No safety measures, no Cause fatality training, no work or injury permit Accident goes worse due to delayed actions Equipment damage and personnel injury 4 6 Prepare well for Supervisors, Ex-actisafety, no training, no riggers and vity working operators 1 2 3 2 Inadequate supervision 1 4 5 Assign dedicated supervisors to monitor all the time Supervisors, During riggers and activity operators 1 1 2 3 Defects of equipment 2 5 7 Do inspection before Supervisors, lifting to make sure During riggers and lifting equipment is activity operators safe in condition Distance between rebar tool handle and Supervisors, During cutting machine cut riggers and activity should be more than operators 200mm Smoking not allowed, erect smoking area Supervisors, During riggers and activity operators 1 2 3 4 Cutting injury Personnel injury 2 4 6 2 2 4 5 \"No smoking\" and \"no fire\" signs not available in activity area Random cable extending and attaching to rebar Fire 2 5 7 1 1 2 6 Electrical hurt 2 4 6 Electricians check site regularly, intensify training Supervisors, During riggers and activity operators 2 2 4

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Method Statement For Foundation Construction of 3700 and 0400 Unsafe voltage of lighting in damp area No protection for working at height, no body harness used Electrical hurt 11250-ZB-NFC-0000-MS-C-0031 REV.B 7 2 5 7 Apply safe voltage in Supervisors, During damp area, such as riggers and activity 36V、24V、12V operators 1 1 2 8 Falling 3 5 8 Must wear body harness when working at height Scaffolding must be erected by certified scaffolding workers, before use, must be inspected by HSE department and tag out Stationary type equipment use proprietary switch cabinet, and follow the regulations Supervisors, During riggers and activity operators 1 3 4 9 Scaffolding is not proper, not Other injuries certified 4 4 8 Supervisors, During riggers and activity operators 1 1 2 10 No proprietary switch cabinet, not following regulations The sling is not attached to over the center of gravity of the load; no protection when sling has to be tied to under the center of gravity of the load Riggers and operators not understand lifting procedures, crane function ,signals and safety rules Electrical hurt 2 4 6 Supervisors, During riggers and activity operators 1 1 2 11 Lifting accident 2 6 8 The sling attaches to over the center of gravity of the load; provide protection Supervisors, when sling has to be During riggers and tied to under the activity operators center of gravity of the load, arrange qualified and certified riggers Riggers and operators understand Supervisors, lifting procedure, During riggers and equipment functions, activity operators signals and safety regulations. 1 2 3 12 Lifting accident 2 6 8 1 2 3

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