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Quy trình sản xuất nhà thép tiền chế – nhà thép công nghiệp

Bản vẽ kiến trúc: Dựa vào mặt bằng yêu cầu sử dụng, Kiến trúc sư sẽ thiết kế sơ bộ kiến trúc tổng thễ, sau đó sẽ trình bày các giải pháp thiết kế, phân tích đánh giá và hướng dẫn chủ đầu tư lựa chọn phương án tối ưu.

Quy trình sản xuất

Trong các công trình kiến trúc, công nghiệp, Nhà thép tiền chế là loại nhà làm bằng các cấu kiện bằng thép và được chế tạo và lắp đặt theo bản vẽ kiến trúc và kỹ thuật đã chỉ định sẵn. Vì vậy, quá trình làm ra sản phẩm hoàn chỉnh được thực hiện gồm 3 bước chính: Thiết kế, gia công cấu kiện và lắp dựng tại công trình. Những công trình kiến trúc thường sử dụng loại nhà này gồm: nhà xưởng, nhà kho, nhà trưng bày, siêu thị, công trình thương mại, nhà cao tầng,… Sau đây chúng tôi xin trình bày các bước chính để hòan thiện một nhà thép công nghiệp đảm bảo yêu cầu kỹ thuật, an toàn và thẩm mỹ.

1.Thiết kế:

Bản vẽ kiến trúc: Dựa vào mặt bằng yêu cầu sử dụng, Kiến trúc sư sẽ thiết kế sơ bộ kiến trúc tổng thễ, sau đó sẽ trình bày các giải pháp thiết kế, phân tích đánh giá và hướng dẫn chủ đầu tư lựa chọn phương án tối ưu.

Sau khi thống nhất phương án, Kiến trúc sư kết hợp với Kỹ sư thiết kế sẽ hoàn chỉnh phương án thiết kế kiến trúc, kết cấu, vật liệu… trình lên Chủ Đầu Tư phê duyệt.

Tất cả các bản vẽ kiến trúc cũng như bản vẽ kết cấu phải được thẩm định đảm bảo an toàn về khả năng chịu lực, tải trọng theo yêu cầu sử dụng, môi trường, mỹ thuật, …

Sau khi đảm bảo các điều kiện trên, các Kỹ sư sẽ tiến hành thực hiện các bản vẽ gia công chi tiết, bản vẽ lắp dựng.

Bản vẽ gia công: Toàn bộ bản vẽ gia công phải đảm bảo được tính chính xác, đầy đủ kích thước, số hiệu, số lượng cấu kiện, chi tiết, yêu cầu kỹ thuật của từng cấu kiện, …

Bản vẽ lắp dựng: Phải mô tả sơ đồ bố trí từng cấu kiện (dựa vào số hiệu bản vẽ gia công) đê tránh sai xót, nhầm lẫn trong quá trình lắp dựng.

Những sai xót trên bản vẽ sẽ ảnh hưởng lớn đến chất lượng công trình xây nhà xưởng nên cần phải quản lý, kiểm soát bản vẽ một cách chặt chẽ, vì đây là bước rất quan trọng, ảnh hưởng xuyên suốt đến toàn công trình.

2.Gia công cấu kiện:

Gia công cấu kiện: Khi gia công cấu kiện, phải tuyệt đối tuân thủ các yêu cầu kỹ thuật trên bản vẽ. Trong quá trình gia công phải luôn kiểm tra, giám sát để đảm bảo thực hiện đúng kỹ thuật, tránh sai xót.

Đa phần các chi tiết được liên kết với nhau bằng hàn, vì vậy tất cả phải được kiểm tra chặt chẽ ở giai đọan này. Tùy theo yêu cầu sử dụng của kết cấu mà ta có thể kiểm tra đường hàn mắt, bằng phương pháp siêu âm hoặc thử từ để đảm bảo độ liền lạc giữa 2 tấm ghép.

Sau khi hoàn thành cấu kiện, ta phải kiểm tra độ cong vênh của cấu kiện và chỉnh sữa thông qua máy nắn để đảm bảo cấu kiện hoàn chỉnh đúng kỹ thuật.

Vệ sinh cấu kiện: Vì đặc thù các cấu kiện là thép, nên công tác vệ sinh cũng là một phần quan trọng, 30% tuổi thọ của công trình nhà thép được quyết định bởi chất lượng vệ sinh và sơn phủ.

Để sơn có độ bám cao và chịu được sự phá hoại do thời tiết, trước khi sơn, tùy theo yêu cầu sử dụng, các cấu kiện thép được làm sạch bằng bàn chải sắt, phun cát hoặc phun bi (theo tiêu chuẩn SA 1.0 – 2.5).

Sơn: Cuối cùng là công đoạn sơn phủ cấu kiện. Có tất cả 3 lớp sơn phủ. Đầu tiên là sơn chống sét tiếp đến là 2 lớp sơn phủ, độ dày phủ sơn tùy theo yêu cầu sử dụng nhưng không thấp hơn 80μm để đảm bảo tuổi thọ của thép được tốt nhất.

Các cấu kiện hoàn chỉnh được kiểm tra, xếp kiện để vận chuyển ra công trình chuẩn bị cho công tác lắp dựng.

3.Lắp dựng:

Phương án lắp dựng: Trước khi lắp dựng phải đưa ra phương án lắp dựng, tùy theo vị trí công trường, khẩu độ nhà, chiều cao nhà mà ta có phương án lắp dựng cụ thể, nhưng tất cả phải đưa công tác an toàn lên hàng đầu.

Lắp dựng: Tuân thủ theo phương án lắp dựng, ta tiến hành lắp dựng từng phần của công trình. Bắt đầu là cột, kèo đầu tiên, phải dùng cáp để chằng, neo giữ cho khung đứng vững, không xe dịch. Kế đến lắp khung thứ 2, phải giữ cẩu và lắp đặt toàn bộ xà gồ của gian đó. Cứ như thế ta lắp cho đến khung cuối cùng.

Trong quá trình lắp dựng, nếu chiều dài nhà lớn, thì cách khoảng 3 khung nhà thép tiền chế ta lại neo, chằng cáp như khung đầu tiên và chỉnh sữa khung đúng vị trí để tránh sai số lũy tuyến của toàn bộ nhà

Sau khi lắp xong khung kèo, xà gồ, ta tiến hành kiểm tra, cân chỉnh lại toàn bộ hệ khung để đảm bảo được tính chính xác, đứng vững.

Kế đến, ta tiến hành lắp đặt các chi tiết phụ (ty giằng, cáp giằng, …..), sơn dặm lại như cấu kiện bị trầy xướt, hoàn thiện công tác lắp dựng, chuẩn bị lơp tole.

Lưu ý: Chi tiết rất quan trọng là trong suốt quá trình lắp dựng, hoàn thiện khung kèo, tuyệt đối không được tháo dỡ cáp neo chằng ban đầu mà ta cố định khung cho đến khi hoàn tất xong công tác lợp tole mái.

Lợp tole: Sau khi hoàn tất xong khung kèo, ta tiến hành lợp tole mái, tole bao che (nếu bao che vách bằng tole), chỉ diềm, mái che và những chi tiết phụ trợ khác.

 

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