Main construction method for new cement chimneys

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Main Construction Method

The construction of a new cement chimney involves several key steps, starting from foundation preparation to final curing. The process ensures structural integrity and long-term durability. Below is a detailed breakdown of the main construction methods.

1. Foundation Construction: The first step includes excavation of the site, ensuring proper slope (1:0.5) and leaving 1 meter for work space. A drainage ditch is created, and mechanical excavation is carried out up to -2.20 m. Manual clearing of the base is done, followed by checking the alignment with measuring personnel. Once verified, the concrete cushion is poured, vibrated, and leveled. A 120 mm thick brick wall is built around a 5.2-meter radius to serve as the inner formwork for the base cap.

1.1 Steel Reinforcement: Before tying the steel bars, the construction team conducts a detailed briefing. Welders and workers must coordinate closely during the reinforcement process. After binding, self-inspection is performed, and the inspection form is completed. All reinforcement work must strictly follow the design drawings and specifications. Since the base structure is integral and unique, it requires thorough on-site verification. Only after passing the initial inspection can the section be accepted. The number of lashing joints in the same section should not exceed 25%, and the spacing between rebars must meet both design and regulatory requirements.

1.2 Cup Mouth Template: The cup mouth template is constructed using 3015 templates and special joint plates, assembled in a staggered manner. For the vertical surface, ordinary red bricks are used as the inner mold. Steel plates are tied to the formwork according to the diameter of the outer cylinder. A total of 6 steel rods are bundled vertically with a 500 mm spacing, and horizontal hoops are spot-welded. The bottom of the template is welded to the embedded part in the base plate to prevent any shifting of the outer formwork. After tying 5 steel bars on the inner surface, 200×50×4000 mm planks are fixed every 0.9 meters along the circumference and clamped with scaffolding tubes.

1.3 Concrete Pouring: Before pouring, the formwork's dimensions and support system are inspected to ensure no deformation occurs. The inside of the formwork is cleaned and rinsed with water. The concrete is poured in layers, each less than 400 mm high. It is vibrated symmetrically and thoroughly. After pouring, the concrete is covered with plastic film and kept moist by watering. Curing lasts for at least 7 days, and the structure cannot be used until the concrete reaches a strength of 1.2 MPa. Finally, the formwork and supports are removed once the process is complete.