Stadium curved special-shaped metal roof and construction method

Abstract

This invention proposes a curved, irregularly shaped metal roof for a stadium, comprising multiple roof units arranged along the circumference of the stadium. Each roof unit is equipped with a gutter unit. Each roof unit includes irregularly shaped profile roof units, polycarbonate sheet roof units, and perforated aluminum single-panel roof units. An inner eaves finishing unit is provided at the eaves of each roof unit. A construction method for the curved, irregularly shaped metal roof for a stadium is also provided, including steps S1-S18. The roof is adjustablely connected to the main steel structure of the stadium via purlins, purlin brackets, and keels, adapting to irregular curved surfaces and making roof installation simpler and more flexible. Based on a model, the curvature and fit of existing polycarbonate sheets and profile keels are analyzed. Using a BIM information model, coordinate positioning is extracted, and customized software is used to export three-dimensional coordinates, generating on-site installation control coordinates. Collaborative detailed design using the BIM information model is employed, and all components are pre-cut to improve processing accuracy and shorten the construction period.

Description

Technical Field

[0001] This invention belongs to the technical field of roof construction, specifically a curved irregular metal roof for a stadium and its construction method. Background Technology

[0002] Stadiums often have complex curved shapes, requiring roofs or coverings to adapt to these irregular surfaces. Metal roofs are a common type due to their advantages such as durability, aesthetics, and corrosion resistance. However, installing metal roofs on irregular curved surfaces is a challenging task, requiring consideration of the following technical issues: 1. Surface adaptability: Irregular curved surfaces may have multiple slopes and angles, and traditional metal roofing installation methods may not be able to adapt to these curves, leading to installation problems and possible leaks; 2. Structural support: To ensure the stable installation of the metal roof, the support structure under the curved surface must be considered, as well as how to adjust and customize the support to adapt to the curved surface; 3. Waterproofing and sealing: Special attention needs to be paid to the joints and connection points of curved metal roofs to ensure water tightness and prevent rainwater penetration.

[0003] Currently, existing technologies exist for installing metal roofs on irregular curved surfaces. The traditional method involves manually fabricating metal sheets on-site to fit the curved shape, but this presents the following problems: 1. It is impossible to guarantee a smooth transition in the overall shape and form of the roof, failing to replicate the architectural effect, and the smoothness of the surface dividing lines and keel is poor. Most of the time, it can only be viewed from a distance, making close-up photography with a drone impossible. 2. The overall effect of the profile roof and perforated aluminum single panel, the overall flatness of the panel surface, and the straightness of the dimensions of the detailed partitions have inconsistent sizes of misaligned joints. The partition dimensions of the polycarbonate sheet and the fit of the shape cannot guarantee a smooth transition. Since the roof shape is mainly controlled by the purlins, the installation of the purlins is the foundation of the entire roof system installation. The installation accuracy will directly affect the quality of the entire roof system, and the installation accuracy is difficult to control. 3. Hyperbolic roofs often have a wave-like shape. Non-perforated aluminum panels come in a variety of panel specifications, while perforated aluminum panels have different perforation rates, inconsistent perforation patterns, and diverse processing dimensions. Providing processing drawings is a large workload and the processing speed is slow. 4. The waterproofing and sealing performance of the roof cannot be guaranteed; 5. The perforated base plate is installed by reverse hanging, and the workers need to install it after the purlins are in place. The roof base plate is long and cannot be installed using an aerial work platform. The roof is also high, with the highest point of the roof at an elevation of +49.3000m, making it impossible for machinery to carry out construction.

[0004] Therefore, how to effectively improve the installation efficiency and quality of stadium roofs, ensure good waterproofing and sealing, and improve service durability are urgent technical problems to be solved. Summary of the Invention

[0005] To address the shortcomings of the aforementioned background technology, this invention proposes a curved, irregularly shaped metal roof for stadiums and a construction method therefor, which solves the problems of low installation efficiency, poor quality, and poor waterproofing and sealing of stadium roofs.

[0006] The technical solution of this application is as follows: A curved, irregularly shaped metal roof for a stadium includes multiple roof units arranged around the perimeter of the stadium. Each roof unit is equipped with a gutter unit. Each roof unit includes a profile roof unit with an irregular curved surface, a polycarbonate sheet roof unit, and a perforated aluminum single-panel roof unit. An inner eaves finishing unit is provided at the eaves of each roof unit.

[0007] Furthermore, the lower end of the profile roofing unit is connected to the upper end of the perforated aluminum single-panel roofing unit, and the polycarbonate sheet roofing unit is connected to the left or right side of the profile roofing unit.

[0008] Furthermore, the gutter unit includes an inner gutter and an outer gutter disposed on the profile roofing unit, and the profile roofing unit and the perforated aluminum single-panel roofing unit are provided with water guiding channels. The inner gutter and the outer gutter are arranged laterally along the roof unit, and the water guiding channels are arranged longitudinally along the roof unit.

[0009] Furthermore, the inner gutter is located at the eaves of the profile roof unit, and the inner eaves finishing unit is located outside the inner gutter. The inner eaves finishing unit includes connected inner eaves keel and inner eaves aluminum panel. The inner eaves keel is connected to the main steel structure and the inner gutter.

[0010] Further, the installation steps of the profile roofing unit are as follows: S201: Install purlin bracket one and purlin strip one; S202: Install aluminum single panel purlin bracket; S203: Install perforated profiled base plate; S204: Lay non-woven fabric; S205: Lay sound-absorbing cotton; S206: Install supporting profiled steel plate; S207: Lay vapor barrier membrane; S208: Lay rock wool; S209: Lay TPO flexible waterproof membrane; S2010: Install aluminum single panel main keel one; S2011: Install aluminum single panel secondary keel one; S2012: Install aluminum single panel.

[0011] Furthermore, the installation steps of the polycarbonate sheet roofing unit are as follows: S301: Install purlin bracket 2, purlin strip 2, and keel 2; S302: Install polycarbonate sheet; S303: Install pressure plate and cover.

[0012] Furthermore, the installation steps of the perforated aluminum single-panel roofing unit are as follows: S401: Install purlin bracket three and purlin strip three; S402: Install aluminum single-panel keel three; S403: Install perforated aluminum single panel.

[0013] A construction method for a curved, irregularly shaped metal roof of a stadium includes the following steps: S1: Based on the design drawings, use 3D modeling software to refine the main steel structure and roof surface model, and model the roof keel in the model. After design review and confirmation, the factory conducts pre-processing and pre-assembly tests based on the keel model; S2: Use 3D scanning technology to scan the installation points, verify the points of the main steel structure and roof keel, and import the points with deviations into the model again for adjustment; S3: Based on the final model, generate drawings and complete the material processing for each part; S4: The joists for the inner and outer gutters and the inner eaves are pre-assembled on the ground and hoisted after the main steel structure is completed; S5: Verify the measurements based on the provided benchmarks, baselines, and leveling points, and conduct comprehensive measurements and layout according to the roof layout plan, main structure axis, and elevation; S6: Before hoisting, install the roof purlin supports on the ground for the unlifted parts of the main steel structure, and install the lifted parts of the main steel structure using roof positioning; S7: Connect the main purlins of the profile roofing unit, polycarbonate sheet roofing unit, and perforated aluminum single-panel roofing unit to the roof, and connect the secondary purlins to the main purlins; S8: Install the perforated profiled base plate of the profile roofing unit between the roof and the main purlins; S9: A walking passage is set up above the main purlins and secondary purlins; S10: Non-woven fabric and sound-absorbing cotton are laid on the perforated profiled base plate; S11: Support profiled steel sheet is installed between the main purlins and the keel; S12: Vapor barrier membrane, rock wool, and TPO flexible waterproof membrane are laid sequentially on the support profiled steel sheet; S13: A temporary material stacking platform is set up on the roof, and the keels in the profiled roof unit, solid board roof unit, and perforated aluminum single-panel roof unit are all connected to the roof purlin brackets; S14: On the existing Mark the center line on the installed keel, and install the prefabricated aluminum panels according to the positions shown in the numbered diagram; S15: Install the polycarbonate panels in the polycarbonate roof unit; S16: Assemble the keel of the inner eaves finishing unit into units on the ground, and hoist them to the roof for connection; S17: During construction, use a total station to lay out the three-dimensional coordinates of each prefabricated aluminum panel, and mark them on the keel. It is required that the four corner points of each prefabricated aluminum panel coincide with the three-dimensional coordinate layout points and be consistent with the three-dimensional coordinate points in the model; S18: The keels of the inner and outer gutters are assembled on the ground and then hoisted to the roof for connection.

[0014] Furthermore, the installation is carried out using a three-point coordinate control method to improve installation accuracy.

[0015] Furthermore, both the perforated profiled base plate and the supporting profiled steel plate are beveled when they intersect with adjacent plates to ensure the connection effect at the overlap.

[0016] The specific beneficial effects of this invention include: 1. In this invention, the roof and the main steel structure of the stadium are adjustablely connected by purlins, purlin brackets and keel, which can adapt to irregular curved surfaces, making the roof installation simpler and more flexible. The keel is modeled at the node positions on the model. During the installation process, a three-point coordinate control method is used to ensure installation accuracy and ensure the smoothness of the keel. 3. This invention uses 3D scanning technology to scan installation points, imports the points into a 3D model, and analyzes them with the model's keel. 4. Based on the model, this invention analyzes the curvature and fit of existing polycarbonate sheet and profile keel, and clarifies which sheet materials need to be thermoformed and which need to be cold-bent on site. The model is analyzed to find that the aluminum profile is a bi-directional bending shape, which requires heat treatment. The aluminum profile is processed into a shape that matches the polycarbonate sheet through a mold to ensure that the polycarbonate sheet and the aluminum profile are tightly fitted and achieve a waterproof effect. 5. This invention uses a 3D laser scanner to reverse engineer the project site, ensuring accurate positioning of the canopy and the building structure, thereby reducing the cost of secondary demolition and modification during project implementation; 6. This invention establishes a final exterior skin model of the building, determines the spatial position of the roof, gutters, and inner eaves and their relative positional relationship with the main steel structure, and conducts drainage analysis by combining the outer contour section provided by the building construction drawings with the steel structure shell model. It makes fine adjustments to local areas, optimizes the setting of gutters, reduces the risk of leakage, calculates the location of expansion joints in the gutters through the model, calculates the stress generated by temperature changes, prevents stress concentration in local areas from causing weld cracking, and ensures smooth water flow. 7. This invention is based on BIM information model, coordinate positioning and extraction, customized software to export three-dimensional coordinates, generate on-site installation control coordinates, adopts BIM information model for collaborative detailed design, pre-cutting and processing of all components, improves processing accuracy, shortens construction period, verifies the pull-out force of fasteners under the most unfavorable load, and ensures that the stress performance of the roof system meets the requirements. 8. The ground pre-assembly and processing operation space in this invention is sufficient, which can save a lot of manpower and facilitate the inspection of the outdoor processing and manufacturing accuracy of components and whether the interfaces can meet the on-site installation needs and the specifications and design requirements. This allows problems to be left on the ground and resolved in a timely manner, rather than being discovered during on-site installation, which would affect the construction period and reduce the time for error adjustments during on-site installation, thus creating conditions for the overall progress and quality assurance of the project. 9. This invention minimizes the possibility of safety accidents. Attached Figure Description

[0017] To more clearly illustrate the embodiments of the present invention, the accompanying drawings used in the description of the embodiments will be briefly introduced below. Obviously, the accompanying drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0018] Figure 1 This is a schematic diagram of the overall invention; Figure 2 This is a schematic diagram of a single roof unit in the present invention. Figure 1 ; Figure 3 This is a schematic diagram of a single roof unit in the present invention. Figure 2 ; Figure 4 This is a schematic diagram of the water guiding channel in this invention; Figure 5 This is a schematic diagram of the measurement and control setup; Figure 6 This is a top view of the inner eaves trim unit; Figure 7 This is a side view of the inner eaves trim unit; Figure 8 Schematic diagram of the installation and positioning plane for aluminum single-panel keel; Figure 9a This is a purlin layout diagram for profile roofing units and polycarbonate sheet roofing units; Figure 9b This is a purlin layout diagram for perforated aluminum single-panel roofing units and polycarbonate sheet roofing units; Figure 10 A schematic diagram of independent unit partitioning for aluminum single-panel panels; Figure 11 This is a schematic diagram showing the connection between the main purlins and secondary purlins in a profile roofing unit; Figure 12 This is a schematic diagram of purlin brackets and purlin connections in a polycarbonate sheet roofing unit. Figure 13 This is a schematic diagram of purlin connections in a perforated aluminum single-panel roofing unit. Figure 14a Schematic diagram of roof floor slab layout Figure 1 ; Figure 14b Schematic diagram of roof floor slab layout Figure 2 ; Figure 15 Schematic diagram of the installation nodes for the roof base plate; Figure 16 This is a schematic diagram of the walking passageway; Figure 17 This is a schematic diagram of step 1 for installing the profile roofing unit; Figure 18 This is a schematic diagram of step 2 for the installation of the profile roofing unit; Figure 19 This is a schematic diagram of step 3 for the installation of the profile roofing unit; Figure 20 This is a schematic diagram of step 4 in the installation of the profile roofing unit; Figure 21 This is a schematic diagram of step 5 for the installation of the profile roofing unit; Figure 22 This is a schematic diagram of step 6 for the installation of the profile roofing unit; Figure 23 This is a schematic diagram of step 7 for the installation of the profile roofing unit; Figure 24 This is a schematic diagram of step 8 for the installation of the profile roofing unit; Figure 25 This is a schematic diagram of step 9 for the installation of the profile roofing unit; Figure 26 This is a schematic diagram of step 10 for the installation of the profile roofing unit; Figure 27 This is a schematic diagram of installation steps 11 for the profile roofing unit; Figure 28 This is a schematic diagram of step 12 for the installation of the profile roofing unit; Figure 29 This is a schematic diagram of step 1 for the installation of a polycarbonate sheet roofing unit; Figure 30 This is a schematic diagram of step 2 for the installation of a polycarbonate sheet roofing unit; Figure 31 This is a schematic diagram of step 3 for the installation of a polycarbonate sheet roofing unit; Figure 32 This is a schematic diagram of step 1 for installing a perforated aluminum single-panel roofing unit; Figure 33 This is a schematic diagram of step 2 for the installation of a perforated aluminum single-panel roofing unit; Figure 34 This is a schematic diagram of step 3 for installing a perforated aluminum single-panel roofing unit.

[0019] Explanation of icon numbers: 1. Single roof unit; 2. Profile roof unit; 3. Polycarbonate sheet roof unit; 4. Perforated aluminum single panel roof unit; 5. Inner eaves trim unit; 6. Inner gutter; 7. Outer gutter; 8. Drainage channel; 9. Inner eaves joists; 10. Inner eaves aluminum single panel; 11. Walkway; 15. Purlin bracket 1; 16. Purlin 1; 17. Purlin bracket; 18. Perforated profiled base plate; 19. Non-woven fabric; 20. Sound-absorbing cotton; 21. Supporting profiled steel sheet; 22. Vapor barrier membrane; 23. Rock wool; 24. TPO; 25. Main keel one; 26. Secondary keel one; 27. Aluminum single panel; 31. Purlin bracket two; 32. Purlin strip two; 33. Keel two; 34. Polycarbonate sheet; 35. Pressure plate; 36. Cover; 41. Purlin bracket three; 42. Purlin strip three; 43. Keel three; 44. Perforated aluminum single panel. Detailed Implementation

[0020] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0021] A type of curved, irregularly shaped metal roof for stadiums, such as Figure 1 , Figure 2 As shown, the structure includes multiple roof units 1 arranged around the perimeter of the stadium. Each roof unit 1 is equipped with a gutter unit. Each roof unit 1 includes a profile roof unit 2 with an irregular curved surface, a polycarbonate sheet roof unit 3, and a perforated aluminum single-panel roof unit 4. The eaves of each roof unit 1 are equipped with an inner eaves trim unit.

[0022] Based on the above implementation methods, such as Figure 3 As shown, the lower end of the profile roofing unit 2 is connected to the upper end of the perforated aluminum single-panel roofing unit 4, and the polycarbonate sheet roofing unit 3 is connected to the left or right side of the profile roofing unit 2.

[0023] Based on the above implementation methods, such as Figure 3 , Figure 4 As shown, the gutter unit includes an inner gutter 6 and an outer gutter 7 disposed on the profile roof unit 2. The profile roof unit 2 and the perforated aluminum single-panel roof unit 4 are provided with water guiding channels 8. The inner gutter 6 and the outer gutter 7 are arranged laterally along the roof unit 1, and the water guiding channels 8 are arranged longitudinally along the roof unit 1.

[0024] Specifically, both the inner and outer gutters use 3mm thick stainless steel gutters, made of austenitic 316. The cross-sectional height of the stainless steel gutters varies in different areas of the stadium, but all are U-shaped. The roof stainless steel gutters are manufactured by segmented bending and forming in the engineering process, followed by on-site welding and assembly.

[0025] Based on the above implementation methods, such as Figure 6 , Figure 7 As shown, the inner gutter 6 is located at the eaves of the profile roof unit 2, and the inner eaves finishing unit 5 is located outside the inner gutter 6. The inner eaves finishing unit 5 includes connected inner eaves keel 9 and inner eaves aluminum single panel 10. The inner eaves keel 9 is connected to the main steel structure and the inner gutter 6.

[0026] Specifically, the main steel structure of the stadium is a truss structure, with an overall shape that is basically circular, with a diameter of about 270m. It is mainly composed of 18 roof units with the same area and structure. The roof is an irregular hyperboloid shape, with the slope between the inner and outer gutters ranging from 15% to 25%, and the slope of the roof outside the outer gutters greater than 45%, with the maximum roof slope approaching 90°.

[0027] Specifically, in section 2 of the profile roofing unit, the upper decorative aluminum panel consists of flat and single-curved aluminum panels with visible seams. The decorative aluminum panels have a wave-like shape and drainage channels on their surface. Rainwater flows along the panel seams and these channels into the upper part of the single-layer TPO roofing membrane, then flows into the stainless steel gutters inside and outside the roof, and is discharged through rainwater pipes. In the stadium's polycarbonate sheet roofing system, the upper part is a double-curved polycarbonate sheet. Rainwater flows along the surface of the polycarbonate sheet into the gutters inside and outside the roof, and is discharged through rainwater pipes.

[0028] Based on the above implementation method, the installation steps of the profile roofing unit 2 are as follows: S201: As Figure 17 As shown, install purlin bracket 15 and purlin 16; S202: as Figure 18 As shown, install aluminum single-panel purlin bracket 17; S203: as Figure 19 As shown, install the perforated profiled base plate 18; S204: as shown Figure 20 As shown, non-woven fabric 19 is laid; S205: as Figure 21 As shown, 20 mm of sound-absorbing cotton is laid; S206: as shown Figure 22 As shown, the profiled steel sheet 21 is installed and supported; S207: as shown Figure 23 As shown, a vapor barrier membrane 22 is laid; S208: as shown Figure 24 As shown, rock wool 23 is laid; S209: as Figure 25 As shown, lay TPO flexible waterproof membrane 24; S2010: as Figure 26 As shown, install the main keel of the aluminum single panel - 25; S2011: as shown Figure 28 As shown, install the secondary keel for the aluminum single panel - 26; S2012: as shown Figure 28 As shown, aluminum single panel 27 is installed.

[0029] Based on the above implementation method, the installation steps of the polycarbonate roofing unit 3 are as follows: S301: As Figure 29 As shown, install purlin bracket 2 31, purlin 2 32, and keel 2 33; S302: as shown Figure 30 As shown, install polycarbonate sheet 34; S303: as Figure 31 As shown, install pressure plate 35 and cover 36.

[0030] Based on the above implementation method, the installation steps of the perforated aluminum single-panel roofing unit 4 are as follows: S401: As Figure 32 As shown, install purlin bracket 3 41 and purlin 3 42; S402: as Figure 33 As shown, install aluminum single-panel keel three 43; S403: as Figure 34 As shown, perforated aluminum panels 44 are installed.

[0031] Specifically, in order to ensure that the roof has good sound absorption and noise reduction functions, the bottom plate of the profile roof unit 2 is made of 0.6mm thick aluminum zinc magnesium perforated profiled sheet, YX25-210-840 type, with a perforation rate of 23%, a perforation diameter of 2.5mm, a hole center distance of 5mm, and an equilateral triangle arrangement. The outermost decorative panel of profile roofing unit 2 is a non-perforated aluminum single panel. Perforated aluminum single panel roofing unit 4 uses perforated aluminum single panels. The solid polycarbonate sheet roofing unit 3 uses 8mm thick solid flat polycarbonate sheets. Both sides of the sheet are processed with a UV layer using advanced technology. The UV-resistant layer thickness is ≥80μm on the illuminated side and ≥50μm on the shaded side, with a milky white color and diffuse reflection function. The light transmittance is 50%±3%. The solid polycarbonate sheet roofing unit has a double-curved shape within a single roofing unit. The width of the sheet is 750-1200mm, and the longest length is 5000mm. All solid polycarbonate sheets are double-curved. Some sheets have a larger curvature and require pre-fabricated arcs, cold bending, and thermoforming to achieve the desired shape. The inner eaves trim unit 5 uses a non-perforated aluminum single panel. When bending aluminum single panels, the bending radius should meet design requirements. When using a plate rolling machine, the bend must be made before folding the edge. The spacing of the folded edge openings must be strictly processed according to 15mm and the dimensions must be 2-3mm. It must be ensured that there are no defects such as burrs, bumps, or sharp corners at the folded edge bends, and that the folded edge lines are smooth and straight.

[0032] A construction method for a curved, irregularly shaped metal roof of a stadium includes the following steps: S1: Based on the design drawings, use 3D modeling software to refine the main steel structure and roof skin model, and model the roof keel in the model. After the design is reviewed and confirmed, the factory conducts pre-processing and pre-assembly tests based on the keel model.

[0033] Specifically, based on the design drawings, Takla was used to refine the main steel structure truss members, clarifying the nodes of each member. Rhino was used to refine the metal roof skin model. On the model, the keel was modeled according to the positional relationship of the node diagram. The completed model was reviewed by the design team. After the design was confirmed, the model was sent to the processing plant for processing. The double-curved keels that needed to be spliced ​​were pre-assembled and tested at the processing plant before being sent to the site for installation. During the installation process, a three-point coordinate control method was used to ensure installation accuracy and guarantee the smoothness of the keel.

[0034] S2: Use 3D scanning technology to scan the installation points, verify the main steel structure and roof keel points, and import the points with deviations into the model again for adjustment.

[0035] Specifically, before the aluminum veneer keel is cut, the steel structure and roof are checked to identify any deviations. During the keel installation process, the keel is installed according to its designated points. Figure 9a , 9b As shown, ensure that the finished surface of the keel has minimal deviation from the model. Adjustment plates are installed every three spans at the junction of aluminum panels and polycarbonate sheets, at gutter locations, and in large areas. Dimensions are verified on-site before material cutting. Material cutting is performed according to the model at other locations. Each roof unit is processed as a separate processing unit, with perforated and non-perforated panels processed separately. The panel surface is coated with film to indicate the installation direction, and the inner surface is marked with the processing number. The re-measured aluminum panels are imported into the model based on the verification points and dimensions for remodeling. The dimensions are compared with the original aluminum panels to check for misalignment or significant deviations. Panels with problematic dimensions are re-measured. The processing list sent to the processing plant mainly consists of the model and template processing styles. Re-measured panels are primarily cut from the model, supplemented by CAD processing drawings.

[0036] S3: Based on the final model, generate drawings and complete the material processing for each part, such as roof purlins, purlin strips, keels, profiled sheets and perforated profiled sheets, aluminum single panels, polycarbonate sheets and matching aluminum profiles, and stainless steel gutters.

[0037] S4: The inner gutter 6, outer gutter 7, and inner eaves joists are all pre-assembled on the ground and hoisted after the main steel structure is completed.

[0038] Specifically, both the gutter frame and the inner eaves frame are pre-assembled on the ground, with the inner eaves assembly unit divided into three facade sections. If the pre-assembly is accurate, it can be pre-assembled on-site according to the fabrication drawings during the steel structure installation period. Once the steel structure is completed and meets the installation requirements, it can be directly hoisted, significantly saving construction time.

[0039] S5: Verify the measurement benchmarks, baselines, and leveling points provided, and conduct comprehensive measurement and layout according to the roof layout plan, main structure axis, and elevation.

[0040] S6: Before hoisting, the roof purlin supports for the unlifted portion of the main steel structure should be installed on the ground. For the lifted portion of the main steel structure, the roof positioning should be used for installation.

[0041] Specifically, such as Figure 5 As shown, after the steel structure has been re-measured and confirmed to be correct, the positioning points for the roof purlins and connectors are first marked on the installed main structure using a total station. The positions of the purlins and connectors are then marked on the main structure, and the purlins and connectors are welded to the installed main structure. During welding, measures to reduce deformation should be taken, and symmetrical spot welding should be performed first. The positions of the purlins and connectors are checked; welding continues only after they are deemed acceptable, and any unacceptable ones are corrected. Spot welds must be firm. The aluminum single-panel purlins in the profile roof area are installed after the main roof purlins are installed. The welding current should be appropriate, and the weld should be free of porosity, cracks, undercut, and weld beads. The weld dimensions should meet design requirements, the weld bead should be uniform, and the weld formation should be aesthetically pleasing. After welding, anti-corrosion measures should be promptly implemented at the weld joints of the aluminum single-panel purlins to prevent rust. After the roof purlins are protected against corrosion, the visible surfaces are treated with fluorocarbon spraying.

[0042] S7: As Figures 11-13 As shown, the main purlins in the profile roofing unit 2, polycarbonate sheet roofing unit 3, and perforated aluminum single-panel roofing unit 4 are connected to the roof, and the secondary purlins are connected to the main purlins.

[0043] Specifically, the main purlins are manufactured according to the model, with their processing dimensions and bending radii derived from the model. After bending at the factory, they are sent to the site for drilling and installation. The main purlins are bolted to the roof. The secondary purlins are manufactured according to the model, with their processing dimensions and bending radii derived from the model. After forming and drilling, they are sent to the site for installation. C-shaped purlins are connected to the main purlins via T-shaped connecting plates. Galvanized square tube secondary purlins are connected to the main purlins via connectors. The secondary purlins are bolted to the connecting plates, which are then welded to the main purlins. The profile secondary purlins are arranged along the roof slope and require bending. Each section of the purlin is installed using coordinate points derived from the model. Each curved section of the purlin has at least three installation control points.

[0044] The following are precautions for purlin installation: 1) Remeasure the dimensional deviations of the main steel structure. The main steel structure must be remeasured before installation because there are significant installation errors in structural dimensions, especially in the height direction. Some structural deviations with large discrepancies need to be corrected using purlin supports to ensure the roof's appearance quality.

[0045] 2) The purlin brackets are connected to the main steel structure by welding. During installation, the purlin brackets are positioned according to the drawing's grid requirements and measured coordinate points, and the installation positions of the upper main purlins are marked. They are then adjusted to the required elevation and welded securely. After welding, the weld quality is checked, weld slag is promptly removed, and rust-preventive paint is applied to prevent rusting.

[0046] 3) The main purlins and purlin brackets are connected by stainless steel bolts. The main purlin brackets have vertically elongated oval holes, allowing for vertical adjustment. During installation, the main purlins and purlin brackets are initially bolted together. After all the purlins in the area are installed, a specialist, under the guidance of a technician, will perform the final fine-tuning and positioning of the main purlins and tighten all bolts.

[0047] 4) The secondary purlin supports are directly welded to the main purlins. Before welding, the secondary purlin supports are measured and marked out according to the drawings to determine their welding positions. The secondary purlin supports are connected to the secondary purlins using stainless steel bolts. After initial fixing of the bolts, the surface of the secondary purlin is adjusted to be level with the surface of the main purlin before tightening. For the welded areas, the weld quality is checked, weld slag is promptly removed, and rust-preventive paint is applied to prevent rusting.

[0048] 6) After completing the installation and touch-up painting of the purlin system and purlin brackets of the area roof, and after passing the self-inspection, report to the supervisor for concealed acceptance. After the acceptance is passed, proceed to the next process of installing the base plate.

[0049] 7) The main purlin installation positioning dimensions refer to the purlin installation positioning diagram, and the installation deviation shall not exceed 5mm; the purlin brackets have a variety of lengths, and care should be taken to select them according to the drawings during installation, and substitution is not allowed.

[0050] S8: Install the perforated profiled base plate 18 in the profiled roof unit 2 between the roof and the main purlin.

[0051] Specifically, the perforated profiled base plate 18 adopts an overlapping form with an overlap length of not less than 80mm. According to the layout drawing, the base plate is beveled on both sides of the gutter, at the junction with the polycarbonate sheet, and at the beveled junction with the purlin to ensure the appearance quality of the base plate. At the same time, the base plate edge trim is installed on both sides of the gutter and at the junction with the polycarbonate sheet to ensure the appearance quality of the base plate.

[0052] S9: A walking passage is provided above the main purlin and secondary purlin; such as Figure 16 As shown, the roof purlins are secured with hemp ropes, and the walking passage is set in 6-meter sections, spanning four purlins with a total span of 5 meters. The roof base plate is lowered to the bottom of the roof purlins through the gaps between the purlins for installation.

[0053] Preferably, the walkway frame is made of Q235B D25*2 round tube, and each section of the walkway is 6m long.

[0054] S10: Lay non-woven fabric and sound-absorbing cotton on the perforated and profiled base plate 18; Specifically, after the profiled perforated panels have passed inspection, the water-repellent non-woven fabric is laid. Before laying, the base surface of the profiled panels must be cleaned to remove any sharp foreign objects from the roof. Adjacent non-woven fabric panels should overlap by 100mm. The non-woven fabric must be flat, tightly adhered, fully laid, and without obvious wrinkles. To ensure good overall integrity, the lateral overlaps must be tight and seamless.

[0055] Specifically, the sound-absorbing cotton material used is 50mm thick glass wool with a density of 32kg / m³. Glass wool is a non-combustible inorganic material with good sound insulation, sound absorption, and fireproofing functions.

[0056] S11: According to the layout diagram, the profiled steel sheet is beveled on both sides of the gutter, at the junction with the polycarbonate sheet, and at the junction with the purlin. At the same time, edge trim is installed on both sides of the gutter and at the junction with the polycarbonate sheet.

[0057] Specifically, the profiled steel sheets are installed using an overlapping method, with an overlap length of not less than 80mm. Before installing the profiled steel sheets, the edge lines of the positioning plates are marked out, and then the positioning plates are installed. Figure 14a , 14b As shown, install the base plates sequentially according to the positioning plate. A check line is placed every ten rows of plates to check and adjust the installation dimensions to avoid large cumulative errors. After the first profiled sheet is fixed in place, a continuous guide line is drawn at both the end and top of the sheet. These two lines, along with the first sheet, will serve as guide lines to facilitate the rapid fixing of subsequent profiled sheets. After installing a section, periodic checks are necessary by measuring the width of the fixed profiled sheets, once at the top and once at the bottom, to ensure no movement occurs. The steel sheets are laid along the roof slope, secured with self-tapping screws wave by wave. At the perforations in the aluminum veneer purlin supports, short boards are used to seal the profiled steel sheets, which are then nailed around the perimeter to ensure stability at the perforation locations.

[0058] S12: A vapor barrier membrane, rock wool, and TPO flexible waterproof membrane are laid on the supporting profiled steel plate; the vapor barrier membrane is not less than 0.25mm thick and is made of polypropylene to prevent it from being blown away by the wind during the laying process.

[0059] Specifically, the TPO for the profile roofing unit is mechanically fixed, while the TPO roll for the gutter unit is adhesively fixed. The TPO for the profile roofing unit is 1.5mm thick, and the TPO for the gutter unit is 2mm thick.

[0060] S13: Set up a temporary material storage platform on the roof and connect the keel in the profile roof unit 2, solid board roof unit 3, and perforated aluminum single panel roof unit 4 to the roof purlin. Specifically, temporary material storage platforms are set up at appropriate locations on the roof. Decorative aluminum panels are located on top of the aluminum panel keel, and the working surface can be erected using the keel during construction. The main keel is processed according to the model, with the main processing dimensions and bending radius derived from the model. After bending at the processing plant, it is sent to the site for installation. The main keel is connected to the purlin brackets through the roof connecting plate; the main keel is connected to the secondary keel through connectors.

[0061] S14: Draw the center line on the installed keel, and install the prefabricated aluminum panels according to the positions shown in the numbered diagram.

[0062] Specifically, preliminary measurements are the foundation of installation accuracy and a crucial step. For example... Figure 11 As shown, the proposed operation will be carried out through regional layout and point-by-point measurement. First, based on the original measurement benchmark, planar measurement control points will be established. Coordinate points will be measured from the periphery, axes will be projected, closed, and measurement errors adjusted. To ensure the installation accuracy of the decorative panels and control overall errors, and to prevent a situation where an installation error in one area leads to a sequential error throughout the entire system, the measurement axes will be densified, dividing the area into independent installation zones for installation and accuracy control. This way, even if an error occurs in one zone, it will only affect a local area and will not cause a chain reaction leading to a large deviation in overall installation accuracy. A total station will be used for installation positioning within each unit area. First, the structural deviations at each location will be measured and data obtained. Then, adjustments will be made based on the deviations to ensure the bearing surface meets the roof curvature and elevation requirements. Based on the measurement data, adapters will be installed on the upper part of the purlin brackets. Measurements will be taken using a total station and theodolite to ensure the installation accuracy of the connectors. The elevation of the bearing end face of the adapter will be measured using a total station. If the elevation differs from the design, it will be adjusted using the connector's own adjustment system.

[0063] S15: Install polycarbonate sheet 34 in polycarbonate sheet roofing unit 3.

[0064] Specifically, the processing dimensions of the polycarbonate sheets are derived from the model. Since all polycarbonate sheets are four-sided irregular curved panels, they can only be processed into rectangular sheets. On-site or during the project, the four sides are cut according to the processing dimensions. Cutting is required at locations such as gutters, junctions with roof profiles, bottom molding areas, and irregularly shaped sections. For polycarbonate sheets with large curvatures, cold bending or thermoforming is used. The surface of the polycarbonate sheets undergoes UV treatment to improve their durability and anti-aging properties. The keel is bent according to the processing curvature at the factory. The keel surface undergoes fluorocarbon spraying treatment.

[0065] S16: The keel of the inner eaves finishing unit 5 is assembled into a unit on the ground and then hoisted to the roof for connection.

[0066] Specifically, the eaves support positions are measured and determined before the eaves joists are installed. The inner eaves joists are assembled into units on the ground, hoisted to the roof, and then assembled and welded on the roof. For the aluminum single-panel joists, three gaps form one unit, with adjacent units filling in the gaps. During unit assembly, the layout is carried out according to the processing drawings, and the angles are adjusted.

[0067] S17: During construction, use a total station to lay out the three-dimensional coordinates of each precast aluminum panel and mark them on the keel. It is required that the four corner points of each precast aluminum panel coincide with the three-dimensional coordinate layout points and are consistent with the three-dimensional coordinate points in the model.

[0068] Specifically, after the aluminum panels are processed in the factory, they are transported to the site and work area covered with a protective film. Before installation, the positioning lines for the aluminum panel joints are marked on the steel keel to control the installation position. Before installation, the panel numbers, quantities, installation directions, and positions should be carefully checked. Aluminum panel fixing brackets should be pre-installed, ensuring a secure and stable installation without any omissions. During construction, a total station is used to lay out the three-dimensional coordinates of each panel, and markings are made on the decorative frame. During installation, the four corner points of each panel must coincide with the three-dimensional coordinate laying points to ensure that each panel matches the three-dimensional coordinate points in the model, thus guaranteeing the overall roof shape.

[0069] S18: The keel of the inner gutter 6 and the outer gutter 7 is assembled on the ground and then hoisted to the roof for connection.

[0070] Specifically, the roof gutters are curved, with the inner gutters arranged in an S-shape and the outer gutters arranged in an arc. They are curved along the circumferential plane of the roof, and the processing dimensions and bending radii are derived from the model. The gutter keel is assembled on the ground, with each gutter along the axis as an independent unit. After assembly, it is hoisted to the roof and then assembled and welded to be fixed on the roof.

[0071] Specifically, roof purlin supports undergo two surface treatments: non-exposed components are galvanized, while exposed components are fluorocarbon coated. Roof purlins and joists also undergo two surface treatments: non-exposed components are galvanized, while exposed components are fluorocarbon coated.

[0072] Specifically, non-perforated aluminum panels are divided into profile roof aluminum panels, inner eaves aluminum panels, and roof junction aluminum panels, with exposed surfaces treated with fluorocarbon spraying. Perforated aluminum panels are treated with double-sided fluorocarbon spraying, with a perforation rate of 10% to 40%. Profile roof aluminum panels and perforated aluminum panels are reinforced with subframes and stiffening ribs.

[0073] Based on the above implementation methods, such as Figure 8As shown, installation is performed using a three-point coordinate control method. For single-curved or double-curved keels, reflective stickers are affixed to control points on the keel surface. During installation, control is achieved using at least three coordinate points. After installation, the points are re-measured using a total station, adding more measurement points. If necessary, 3D scanning technology is used to scan the installation points, importing them into the 3D model for analysis against the model keel. Keels with significant deviations are adjusted. For example... Figure 10 As shown, the measurement control points for each zone are the intersections of the grid lines between the wide seams, dividing the entire decorative aluminum panel roof into zones. The measurement and installation of the decorative aluminum panel keel are carried out independently in each zone, with errors absorbed within the zone and not carried over to the next zone.

[0074] Based on the above embodiments, the perforated profiled base plate 18 and the supporting profiled steel plate 21 are both beveled when they meet with adjacent plates. Beveled cuts are made on both sides of the gutter, at the junction with the polycarbonate sheet, and at the beveled junction with the purlin. At the same time, edge trimming is installed on both sides of the gutter and at the junction with the polycarbonate sheet to ensure visual quality.

[0075] In this invention, the roof and the main steel structure of the stadium are adjustablely connected by purlins, purlin brackets, and keels, which can adapt to irregular curved surfaces, making roof installation simpler and more flexible. The keel is modeled at the node positions on the model, and a three-point coordinate control method is used during installation to ensure installation accuracy and the smoothness of the keel. 3D scanning technology is used to scan the installation points, importing them into the 3D model for analysis against the model's keel. Based on the model, the curvature and fit of existing polycarbonate sheets and profile keels are analyzed to determine which sheets require... Which thermoforming processes require on-site cold bending? Model analysis reveals that the aluminum profiles, being bi-directionally curved, require heat treatment. A mold is used to create a shape that matches the polycarbonate sheet, ensuring a tight fit for waterproofing. A 3D laser scanner is used for reverse engineering of the project site to ensure precise positioning of the canopy and building structure, reducing the cost of secondary demolition and alterations during project implementation. A final exterior skin model of the building is created to determine the spatial positions of the roof, gutters, and inner eaves relative to the main steel structure, using the outer contours provided in the architectural construction drawings. The cross-section, combined with the steel structure shell model, was used for drainage analysis. Fine-tuning was performed in localized areas, and the gutter layout was optimized to reduce leakage risks. The model was used to calculate the location of expansion joints in the gutters and the stress generated by temperature changes, preventing stress concentration in localized areas that could cause weld cracking and ensuring smooth water flow. Based on the BIM information model, coordinate positioning was extracted, and customized software was used to export 3D coordinates, generating on-site installation control coordinates. Collaborative design using the BIM information model was employed, and all components were pre-cut to improve processing accuracy, shorten the construction period, and verify the pull-out force of fasteners under the most unfavorable load, ensuring the roof system's structural performance meets requirements. Sufficient ground-based pre-assembly and processing space saved significant manpower and facilitated inspection of the outdoor processing accuracy of components and whether the interfaces met on-site installation needs and design specifications. This allowed for timely resolution of problems at ground level, rather than discovering processing accuracy issues during on-site installation, thus reducing time spent on incorrect adjustments during installation and creating conditions for overall project progress and quality assurance. This also minimized the possibility of safety accidents.

[0076] All aspects not detailed in this invention are conventional technical means known to those skilled in the art.

[0077] The above content shows and describes the basic principles, main features, and beneficial effects of the present invention. The above description is merely a preferred embodiment of the present invention and is not intended to limit the invention. Any modifications, equivalent substitutions, or improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A construction method for a curved, irregularly shaped metal roof of a stadium, characterized in that: It includes multiple roof units (1) set along the perimeter of the stadium. Each roof unit (1) is equipped with a gutter unit. Each roof unit (1) includes a profile roof unit (2) with an irregular curved surface, a polycarbonate sheet roof unit (3), a perforated aluminum single-panel roof unit (4), and an inner eaves trim unit (5) at the eaves of the roof unit (1). The construction method for the roof is as follows: S1: Based on the design drawings, use 3D modeling software to refine the main steel structure and roof skin model, and model the roof keel in the model. After the design is reviewed and confirmed, the factory conducts pre-processing and pre-assembly tests based on the keel model; S2: Use 3D scanning technology to scan the installation points, check the main steel structure and roof keel points, and import the points with deviations into the model again for adjustment; S3: Based on the final model, generate drawings and complete the material processing for each part; S4: The inner gutter (6), outer gutter (7), and eaves keel components are all pre-assembled on the ground and hoisted after the main steel structure is completed; S5: Verify the measurement benchmarks, baselines, and leveling points provided, and conduct a comprehensive measurement and layout according to the roof layout plan, main structure axis, and elevation. S6: Before hoisting, the roof purlin support components for the unlifted part of the main steel structure should be installed on the ground. The lifted part of the main steel structure should be installed using roof positioning. S7: Connect the purlin components in the profile roofing unit (2), polycarbonate sheet roofing unit (3), and perforated aluminum single-panel roofing unit (4) to the roof; S8: Install the perforated profiled base plate (18) in the profiled roof unit (2) between the roof and the purlin components; S9: A walking passage (11) is provided on the upper part of the purlin component; S10: Lay non-woven fabric (19) and sound-absorbing cotton (20) on the perforated molding base plate (18). S11: Install a supporting profiled steel sheet (21) between the purlin member and the keel member; S12: Vapor barrier membrane (22), rock wool (23), and TPO flexible waterproof membrane (24) are laid sequentially on the supporting profiled steel sheet (21); S13: Set up a temporary material storage platform on the roof and connect the keel components in the profile roof unit (2), polycarbonate sheet roof unit (3), and perforated aluminum single-panel roof unit (4) to the roof purlin support components. S14: Mark the center line on the installed keel components, and install the prefabricated aluminum panels according to the positions shown in the numbered diagram; S15: Install the polycarbonate sheet (34) in the polycarbonate sheet roofing unit (3); S16: The keel components of the inner eaves finishing unit (5) are assembled into units on the ground and hoisted to the roof for connection; S17: During construction, use a total station to lay out the three-dimensional coordinates of each precast aluminum panel and mark them on the keel components. It is required that the four corner points of each precast aluminum panel coincide with the three-dimensional coordinate layout points and are consistent with the three-dimensional coordinate points in the model. S18: The keel components of the inner gutter (6) and the outer gutter (7) are assembled on the ground and then hoisted to the roof for connection.

2. The construction method for the curved irregular metal roof of a stadium according to claim 1, characterized in that: The lower end of the profile roofing unit (2) is connected to the upper end of the perforated aluminum single-panel roofing unit (4), and the polycarbonate sheet roofing unit (3) is connected to the left or right side of the profile roofing unit (2).

3. The construction method for the curved, irregularly shaped metal roof of a stadium according to claim 1 or 2, characterized in that: The gutter unit includes an inner gutter (6) and an outer gutter (7) set on the profile roof unit (2). The profile roof unit (2) and the perforated aluminum single-panel roof unit (4) are provided with water guide channels (8). The inner gutter (6) and the outer gutter (7) are set horizontally along the roof unit (1), and the water guide channels (8) are set vertically along the roof unit (1).

4. The construction method for the curved irregular metal roof of a stadium according to claim 3, characterized in that: The inner gutter (6) is located at the eaves of the profile roof unit (2), and the inner eaves finishing unit (5) is located on the outside of the inner gutter (6). The inner eaves finishing unit (5) includes the connected inner eaves keel (9) and inner eaves aluminum single panel (10). The inner eaves keel (9) is connected to the main steel structure and the inner gutter (6).

5. The construction method for the curved irregular metal roof of a stadium according to any one of claims 1-2 and 4, characterized in that: The installation steps of the profile roofing unit (2) are as follows: S201: Install purlin bracket 1 (15) and purlin 1 (16); S202: Install aluminum single-panel purlin brackets (17); S203: Install perforated profiled base plate (18); S204: Lay non-woven fabric (19); S205: Lay sound-absorbing cotton (20); S206: Install support for profiled steel sheet (21); S207: Laying a vapor barrier membrane (22); S208: Laying rock wool (23); S209: Lay TPO flexible waterproof membrane (24); S2010: Install aluminum single panel main keel one (25); S2011: Install aluminum single panel secondary keel one (26); S2012: Install aluminum single panels (27).

6. The construction method for the curved irregular metal roof of a stadium according to any one of claims 1-2 and 4, characterized in that: The installation steps for the polycarbonate roofing unit (3) are as follows: S301: Install purlin bracket 2 (31), purlin 2 (32), and keel 2 (33); S302: Install polycarbonate sheet (34); S303: Install pressure plate (35) and cover (36).

7. The construction method for the curved irregular metal roof of a stadium according to any one of claims 1-2 and 4, characterized in that: The installation steps of the perforated aluminum single-panel roofing unit (4) are as follows: S401: Install purlin bracket 3 (41) and purlin 3 (42); S402: Install aluminum single-panel keel three (43); S403: Install perforated aluminum panels (44).

8. The construction method for the curved irregular metal roof of a stadium according to any one of claims 1-2 and 4, characterized in that: The installation was carried out using the three-point coordinate control method.

9. The construction method for the curved irregular metal roof of a stadium according to any one of claims 1-2 and 4, characterized in that: The perforated profiled base plate (18) and the supporting profiled steel plate (21) are both beveled when they meet with adjacent plates.

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