Dismantling of reinforced concrete structures at the facility of PJSC “MMK” Stan 2500 Rolling Shop No. 4.
Dismantling of reinforced concrete structures at the section of Mill 2500 of Sheet-rolling shop No. 4 of the Magnitogorsk Iron and Steel Works (PJSC MMK), which REFORMA successfully completed in 2019, is an integral part of a strategic investment project to modernize hot rolling mill 2500.
The large-scale reconstruction of the mill in the conditions of the existing production began in 2007.
The general contractor was Prokatmontazh OJSC. Since 2013 GCC “REFORMA” has been taking part in the project as a subcontractor and carries out work on cutting reinforced concrete structures in accordance with the modernization project.
In 2019, GCC REFORMA performed diamond cutting of reinforced concrete structures of the mill in the area of coiler No. 6, designed for continuous coiling of long strips into coils.
Features of the project:
1. Short terms of work
The project had to be completed in 3 months. In this regard, a round-the-clock work schedule was organized.
2. The work was carried out in cramped conditions at the existing production.
In order to prevent violations of safety regulations and emergencies, as well as to meet the specified deadlines, the responsible employees of REFORMA State Corporation maintained constant interaction with the services of the plant throughout the entire period of the project implementation.
In addition, an active roller conveyor ran directly above the work area, along which hot rolled products were transported. This made the use of lifting equipment much more difficult.
It was not possible to suspend the lifting equipment directly above the dismantled unit. Specialists of GCC “REFORMA” developed and applied technological solutions that allow transporting the sawn blocks at an angle.
3. Since it was not a complete dismantling of the facility, but its modernization, part of the foundation was preserved and was intended for the installation of new equipment and mill structures. In this regard, dismantling works were an important stage of modernization. Diamond cutting of the foundation was required to be carried out strictly under the marks in accordance with the project documentation. Violation of the project execution plan jeopardized the timing of the implementation and the entire project as a whole. To minimize the risks at this stage, a contractor with the highest qualifications and reliability was required, who would be able to ensure the quality of the work performed. GCC REFORMA became such a contractor for OJSC Prokatmontazh.
4. In the cutting area there were transit networks that needed to be preserved for future use: a technological water collector, a lubricant tunnel, a cable tunnel. At the same time, the received technical documentation did not fully reflect the real design features of the facility. There are practically no contractors on the market who are able to fulfill this requirement in a timely manner.
The specialists of GCC “REFORM” had to bypass the networks at different levels. The cutting was carried out with a complex profile: steps, at an angle, with an inclination of the cut surface. The lifting equipment was hung at an angle to the block being lifted (due to the passing roller table). With the help of a system of winches and blocks, the dismantled elements were pulled out at an angle and thus removed from the work area.
Due to the incomplete correspondence of the technical documentation to the real structure of the object, diamond drilling had to be carried out with caution so as not to damage the engineering networks. At the same time, it is necessary that the work was completed in a short time.
5. Material of dismantled structures: heavy, highly reinforced concrete. Dismantling required the use of high-performance HILTI diamond cutting equipment.
Result:
The renovation was completed in mid-2020. Mill 2500 at Rolling Shop No. 4 was put into operation. To understand how important this project is for the Magnitogorsk Iron and Steel Works and the entire metallurgical industry in Russia, it is enough to cite the following facts:
1. According to the results of the first quarter of 2021, the mill produced 1,077.7 thousand tons of hot rolled products. This is the maximum indicator of quarterly production for this unit in the entire post-Soviet history. The last time the 2500 mill crossed the mark of 1 million tonnes of hot rolled steel was in three months of operation in 2008, and the result obtained in the first quarter has not been achieved since 1991. A significant increase in the performance of the unit, which celebrated its 60th anniversary in December last year, was made possible by the comprehensive reconstruction completed in 2020.
2. The completely modernized hot rolling mill 2500 at PJSC MMK is today one of the most modern and highly productive in the world.
3. Large-scale reconstruction made it possible to expand the size and grade assortment of the mill. The quality of the products has significantly improved, and the production capacity of the unit has increased to 5.2 million tons of rolled metal per year. Today it is a highly automated unit whose products meet the highest international standards.
4. In November last year, the reconstruction of the hot rolling mill 2500 of PJSC MMK was awarded the prize “The main event of 2020 in the metallurgy of Russia”.
We are proud that we took part in such a large-scale project and contributed to the receipt of this prestigious award by PJSC MMK. GCC “REFORMA” did not disappoint either the general contractor or the plant.
Customer satisfaction
The customer represented by the General Director A.V. Sinyogin highly appreciated the quality of work of REFORMA. In a letter to the company’s management, he noted:
“We would like to express our gratitude to the REFORMA Group of Construction Companies in Yekaterinburg for participating in the implementation of complex and unique projects at PJSC Magnitogorsk Iron and Steel Works.
The specialists of your organization carried out work (in cramped conditions with the existing production) on the dismantling of reinforced concrete structures by the method of diamond cutting at the facility of PJSC MMK Stan 2500, Rolling Center 4, Coiler Zone.
I would like to note the high training of employees, who promptly and competently organized the dismantling, preparation of the necessary documents and the uninterrupted round-the-clock operation of the production site.
We are ready to recommend GCC “REFORMA” as a reliable professional Contractor capable of handling any task. We hope for further mutually beneficial cooperation. “
