This project is a renovation and upgrading project for an existing inflatable rubber dam. The core principle of the construction is to completely preserve the original concrete foundation, base slab, anchoring trench, and main structure of the bank wall. Only the aged and ineffective dam bags, anchoring components, filling and drainage pipelines, and electrical control systems will be removed. The entire set of equipment for the new dam will be installed and commissioned using the existing qualified foundation. This plan makes full use of the existing foundation, eliminating the need for concrete removal, pouring, and curing, effectively shortening the construction period and saving costs, while preserving the original foundation's seepage prevention, load-bearing capacity, and scour resistance. Throughout the construction process, zero-damage protection of the foundation is the core principle, strictly controlling potential hazards such as impacts, cracks, and anchoring trench deformation to ensure a tight connection between the old and new structures, unified stress distribution, and stable operation.
The main challenges of this project are: protective removal of the original foundation, non-destructive dismantling of corroded components, precise repair of defects in the old foundation surface, symmetrical and precise anchoring of the new dam, and precise adaptation of the old and new electromechanical pipelines and control systems to ensure that the dam's water-stopping, lifting, and seepage prevention performance meets the standards after the renovation.
Before construction, technical personnel will conduct on-site surveys to re-measure foundation flatness, anchor groove dimensions, and hole position deviations; check for cracks, leaks, and scour defects; verify the compatibility of parameters between new and old equipment; and complete technical and safety briefings for all personnel. Based on the river's hydrological conditions, upstream and downstream closed-loop earth-bag cofferdams will be constructed, impermeable geotextiles will be laid, accumulated water will be pumped out, and silt will be cleared to create a dry working environment.
Small equipment such as small cranes, rust removal equipment, torque wrenches, and repair tools will be provided on-site. Large crushing equipment is strictly prohibited from entering the site due to vibration and damage to the foundation. All main and auxiliary materials, including dam bags, stainless steel bolts, sealing materials, and repair mortar, must be inspected and certified before use. Certified technicians, quality inspectors, and a professional construction team will be on-site. Key areas of the foundation and anchor grooves will be covered with membranes and padded for protection, ensuring the preservation of finished products.
Demolition will strictly follow the principles of demolishing auxiliary structures before the main structure, demolishing the upper part before the lower part, and demolishing in sections symmetrically and slowly. First, the water and gas in the dam bag are drained and the pressure is released to relax it. The guardrails, external pipelines, and electrical control equipment are then removed, and the interfaces are clearly marked. Old pipelines, valves, and sensors are loosened and dismantled in sections, and the pre-reserved pipe openings in the foundation are promptly sealed.
The removal of the anchoring system is the core process. Rusty bolts are ground loose and disassembled, and the upper part of jammed bolts is precisely cut, avoiding damage to the foundation concrete throughout the process. The pressure plates and strips are removed sequentially from both ends towards the middle, and the anchoring grooves are thoroughly cleaned of rust, residual adhesive, and debris. The dam bag is gently peeled off manually and lifted steadily, strictly avoiding dragging and scratching the base surface. After completion, waste materials are uniformly removed and the work surface is cleaned.
After demolition, a comprehensive inspection of the foundation's appearance, flatness, hole position accuracy, and seepage prevention performance will be conducted to verify that the foundation's bearing capacity meets the operational requirements of the new dam. For surface sanding, pitting, and minor cracks, hydraulic repair mortar will be used for leveling and sealing. The anchoring grooves will be derusted, leveled, and coated with anti-corrosion paint. Slightly misaligned bolt holes will be precisely repaired, and aged waterstops and expansion joint sealants will be replaced to restore the overall seepage prevention performance of the foundation. After repair, a curing period of 3 to 5 days will be required, and installation work can only commence after acceptance.
The existing foundation baseline will be accurately laid out, and the positioning will be re-inspected. After the new dam bags pass appearance inspection, they will be laid smoothly, ensuring no twisting, no stretching, and precise alignment. Anchoring construction will follow a three-stage, symmetrical tightening process: downstream first, then upstream; middle first, then both ends; and sealing strips will be added, with layered compaction and sealing to ensure uniform stress and tight seepage prevention in the dam body.
New drainage pipes, valves, and automatic control equipment will be installed using existing interfaces, and waterproofing, corrosion prevention, and grounding treatments will be implemented. The joints between the dam body and the bank wall and bottom slab are sealed with flexible sealant in an arc shape. After installation, a 24h pressure stabilization and sealing test and a multi-level lifting test run are conducted to check for leakage, loosening, and abnormal operation.
Construction will strictly adhere to the process inspection and reporting system, with all concealed works documented throughout. Strict control will be exercised over foundation protection, anchoring accuracy, and the quality of multi-layered sealing to prevent issues such as hollow areas, leaks, and uneven stress. On-site measures will include cofferdam inspections, electrical safety, hoisting control, and civilized construction practices, ensuring a reasonable workflow and meeting the project schedule. After completion, finished products will be properly protected, and a routine inspection and maintenance mechanism will be established to ensure the long-term safe and stable operation of the inflatable rubber dam.
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