A steel shell-concrete composite orthotropic bridge deck structure and preparation method thereof

Abstract

The present invention belongs to the technical field of bridge engineering, and specifically discloses a steel shell-concrete composite orthotropic bridge deck structure and a preparation method thereof. It includes a steel shell structure, in-filled concrete, longitudinal and transverse stiffeners arranged at the bottom of the steel shell structure, and a plate end connection structure. Among them, the steel shell structure includes upper and lower steel plates arranged in parallel and multiple open-hole T-shaped ribs arranged longitudinally in parallel. The web of the open-hole T-shaped rib is welded to the upper steel plate, and the flange is riveted to the lower steel plate to connect the upper and lower steel plates into a steel shell structure. The reinforced concrete tenons formed by the open-hole T-shaped ribs and core bar reinforcements and shear studs anchor the upper and lower steel plates in the in-filled concrete to form a steel shell-concrete composite plate that jointly bears force. The present invention has a large flexural stiffness, solves the fatigue problem of the weld between the stiffener and the steel roof plate, gives full play to the performance of the steel shell and concrete, and solves the problems of easy cracking and excessive weight of the traditional composite bridge deck under negative bending moment.

Description

Technical Field

[0001] The present invention belongs to the technical field of bridge engineering, and relates to a steel shell-concrete composite orthotropic bridge deck structure and a preparation method thereof. More specifically, it relates to a steel shell-concrete composite orthotropic bridge deck structure with mutual strong restraint between steel and concrete and a manufacturing method thereof. Background Art

[0002] A steel orthotropic plate is a structure that jointly bears loads composed of longitudinal and transverse stiffeners (or diaphragms) perpendicular to each other and a steel top plate. The self-weight of a steel orthotropic plate is about 1 / 4 to 1 / 5 of that of a reinforced concrete bridge deck or a precast prestressed concrete bridge deck. Moreover, it is convenient for transportation and erection, has a short construction period, strong load-bearing capacity, and excellent tensile and compressive properties, which promotes the improvement of the spanning ability of bridges and becomes the preferred bridge deck form for long-span bridges. Since it was proposed in the 1930s of the last century and the Kurpfalz Bridge was built using this technology in 1950, which is the world's first steel structure bridge that uses the steel orthotropic plate structure as an integral part of the main beam to jointly bear forces and at the same time bears local traffic loads as the carriageway. Since then, it has been widely used in steel structure bridge engineering.

[0003] However, in the more than 70 years of use, several problems have also emerged in the steel orthotropic bridge deck: First, the U-rib is welded to the steel top plate. Due to the existence of initial weld defects and welding residual stresses, the U-rib, the top steel plate, and the weld connecting the two are prone to fatigue cracking; second, the U-rib is welded to the diaphragm on the side, and the diaphragm near the U-rib and the weld between the U-rib and the diaphragm are prone to fatigue cracking. The main reason is that the stiffness of the top plate of the orthotropic bridge deck is small and the deformation is large. In addition, the influence line of the bridge deck is short, resulting in frequent alternating changes in the stress of the above-mentioned welds. The key to solving this problem is to increase the stiffness of the top plate, reduce the deformation, and reduce the stress amplitude. According to this idea, domestic and foreign engineering and technical personnel have proposed a steel-concrete composite bridge deck. The stiffness of the top plate can be greatly improved through the concrete layer, and the stress of the weld between the U-rib and the top plate can be reduced by more than 2 / 3, and the stress between the side of the U-rib and the diaphragm can be reduced by 1 / 3. However, engineering practice shows that the traditional steel-concrete composite bridge deck has the following problems: the tensile strength of concrete is low and it is prone to cracking under the tensile stress caused by negative bending moment, resulting in a reduction in the effective cross-section of the concrete layer, and the effects of large stiffness and reduction of steel structure stress are greatly reduced; in addition, due to the large thickness and weight of the concrete layer, its weight can reach more than 3 times that of the steel orthotropic bridge deck; the construction of the concrete layer is carried out on-site at the bridge location, which is a typical cast-in-place structure, with high labor input and great difficulty in environmental protection control.

[0004] Based on the above-mentioned defects and deficiencies, there is an urgent need in the art to propose a steel shell-concrete composite orthotropic bridge deck structure to solve the fatigue problem of the weld between the stiffener and the steel top plate of the steel orthotropic bridge deck, and at the same time avoid the problem that the traditional composite bridge deck is prone to cracking under negative bending moment and the stiffness drops significantly. Summary of the Invention

[0005] In view of the above-mentioned defects or improvement requirements of the prior art, the present invention provides a steel shell-concrete composite orthotropic bridge deck structure and a preparation method thereof. In a narrow space, the upper and lower steel plates attached with shear studs are connected into a steel shell structure assembly that can jointly bear forces; the reinforced concrete tenon formed by the perforated T-shaped ribs and the core bar steel bars and the shear studs anchor the upper and lower steel plates in the filled concrete. The T-shaped stiffeners reduce the free plate width of the upper and lower steel plates and jointly form a strong constraint on the upper and lower steel plates with the shear studs, ensuring that the upper and lower steel plates do not undergo elastic buckling before tensile and compressive yielding, and giving full play to the material properties of the upper and lower steel plates in the structure; the steel shell structure strongly restricts the filled concrete by enclosing the space, the reinforced concrete tenon and the shear studs, improves its crack resistance and crack constraint ability, effectively improves the performance of the concrete structure, and combines the steel shell structure assembly and the filled concrete into a steel shell-concrete composite plate with coordinated deformation and joint force; the intermediate insertion plate converts the connection between concretes into the connection of steel plates. The upper steel plates of adjacent composite plates are connected by welds, and the lower steel plates are connected to the bottom connecting steel plate through pre-pierced bolts. The stiffness of the steel shell-concrete composite orthotropic bridge deck is 60 times that of the steel top plate of the traditional steel orthotropic bridge deck, solving the fatigue problem of the weld between the stiffener and the steel top plate of the steel orthotropic bridge deck, and at the same time avoiding the problem that the traditional composite bridge deck is prone to cracking under negative bending moment and the stiffness drops significantly, giving full play to the performance of the steel shell and concrete, and solving the problem of excessive weight of the traditional steel-concrete composite bridge deck.

[0006] To achieve the above object, according to one aspect of the present invention, a steel-concrete composite orthotropic bridge deck structure is proposed, which includes a plurality of steel-concrete composite orthotropic bridge deck units. Each steel-concrete composite orthotropic bridge deck unit includes: a steel shell structure, infilled concrete provided in the steel shell structure, longitudinal and transverse stiffeners provided at the bottom of the steel shell structure, and a plate end connection structure connecting adjacent steel-concrete composite orthotropic bridge deck units. Among them, the steel shell structure includes upper steel plates, lower steel plates arranged in parallel, and a plurality of core bar steels arranged in parallel. A plurality of perforated T-shaped ribs arranged parallel to the longitudinal direction of the bridge deck are provided between the upper steel plate and the lower steel plate. The core bar steels are arranged through the perforated T-shaped ribs. The steel shell structure also includes a plurality of shear stud assemblies for anchoring the upper steel plate and the lower steel plate to the infilled concrete. The web of the perforated T-shaped rib of the T-shaped stiffener is welded to the upper steel plate, and the flange plate is riveted to the lower steel plate, so that the upper steel plate and the lower steel plate attached with the shear stud assemblies are connected into a steel shell structure that can share forces in a narrow space. The reinforced concrete tenons formed by the perforated T-shaped ribs and the core bar steels and the shear stud assemblies anchor the upper steel plate and the lower steel plate to the infilled concrete, so that the steel shell structure and the infilled concrete are combined into a steel-concrete composite plate with coordinated deformation and common force sharing.

[0007] As a further preference, a web circular hole for accommodating the core bar steel to pass through is provided on the web of the perforated T-shaped rib, and the panel of the perforated T-shaped rib is fixedly connected to the lower steel plate through a first rivet.

[0008] As a further preference, the spacing of the perforated T-shaped ribs in the transverse direction of the bridge is 600 - 800 mm. The vertical position of the web circular hole is in the middle of the web of the perforated T-shaped rib, and the longitudinal spacing between adjacent web circular holes is 100 - 300 mm.

[0009] As a further preference, the shear stud assembly includes upper steel plate shear studs fixedly connected to the upper steel plate and lower steel plate shear studs fixedly connected to the lower steel plate. The longitudinal and transverse spacings of the upper steel plate shear studs are both 120 - 220 mm. The arrangement spacing of the lower steel plate shear studs is the same as that of the upper steel plate shear studs, but the upper steel plate shear studs and the lower steel plate shear studs are arranged in a longitudinal staggered and empty manner, and the longitudinal staggered spacing range is 60 - 110 mm.

[0010] As a further preference, the total thickness of the steel shell structure is 8 - 12 cm, and the thicknesses of the upper steel plate and the lower steel plate are not greater than 1 / 8 of the thickness of the steel shell structure.

[0011] As a further preference, the infilled concrete adopts ordinary concrete, high-performance concrete, fiber concrete or ultra-high-performance concrete according to the force requirements of the steel-concrete composite orthotropic bridge deck.

[0012] As a further preference, the plate end connection structure includes an intermediate insertion plate assembly and an intermediate connection plate arranged on the same horizontal plane. The intermediate insertion plate assembly is used to connect the specified number of the core bar reinforcements at the two transverse ends of the steel shell structure, and the intermediate connection plate is used to connect two adjacent intermediate insertion plate assemblies. In this way, the connection between the intermediate insertion plate and the infilled concrete is enhanced, enabling the intermediate insertion plate and the infilled concrete to form an integral working unit. At the same time, the intermediate insertion plate connects the infilled concretes of adjacent steel shell-concrete composite orthotropic bridge deck structures, converting the connection between concretes into the connection of steel plates and eliminating the weak link of concrete connection.

[0013] As a further preference, the intermediate insertion plate assembly includes a first intermediate insertion plate, a second intermediate insertion plate, and a third intermediate insertion plate arranged in sequence from the transverse center of the steel shell structure towards both ends. Among them, one end of the third intermediate insertion plate is connected to the core bar reinforcement, and the other end is connected to the intermediate connection plate.

[0014] As a further preference, a plurality of insertion plate round holes are provided on each of the first intermediate insertion plate, the second intermediate insertion plate, and the third intermediate insertion plate.

[0015] As a further preference, the plate end connection structure further includes a weld connecting two adjacent upper steel plates and a bottom connection plate connecting two adjacent lower steel plates. The bottom connection plate is fixedly connected to the lower steel plate by second rivets.

[0016] As a further preference, the plate end connection structure further includes an end variable cross-section T-shaped rib. The end variable cross-section T-shaped rib is provided at both ends of the open-hole T-shaped rib and is integrally formed with the open-hole T-shaped rib. The end variable cross-section T-shaped rib is arranged between the upper steel plate and the lower steel plate, and its end is provided with an arc-shaped variable cross-section, so that a cavity is formed between the upper steel plate, the bottom connection plate, and the end variable cross-section T-shaped rib. Reinforced concrete is filled in the cavity to form an internal support constraint.

[0017] As a further preference, the longitudinal and transverse stiffeners include a plurality of transverse stiffening components arranged in parallel along the transverse direction and a plurality of longitudinal stiffening components arranged in parallel along the longitudinal direction;

[0018] As a further preference, the distance between adjacent transverse stiffening components is 2000 - 4000 mm; the distance between adjacent longitudinal T-shaped stiffeners is 900 - 1800 mm.

[0019] And combinations of any of the above embodiments. According to another aspect of the present invention, a manufacturing method of a steel shell-concrete composite orthotropic bridge deck structure is further provided, including the following steps:

[0020] Step 1: Weld the perforated T-shaped ribs to the lower surface of the upper steel plate. Weld the perforated T-shaped ribs and the shear studs of the upper steel plate together on the lower surface of the upper steel plate. Pass the core bar through the perforated T-shaped ribs, and fix both ends of the core bar to the outermost perforated T-shaped ribs with bolts.

[0021] Weld the longitudinal and transverse stiffeners to the lower surface of the lower steel plate.

[0022] Drill rivet holes at the positions corresponding to the rivet holes of the T-shaped stiffeners and the positions corresponding to the openings of the bottom connecting plate on the lower steel plate. At the same time, weld the shear studs of the lower steel plate to the upper surface of the lower steel plate. Pre-penetrate pop rivets into the openings at the longitudinal ends of the lower steel plate.

[0023] Place the upper surface of the lower steel plate on the flange plate of the perforated T-shaped ribs welded to the upper steel plate, and rivet the perforated T-shaped ribs and the lower steel plate through the first rivet parts to complete the rigid connection between the upper steel plate and the lower steel plate. The steel shell structure and the longitudinal and transverse stiffeners together form a steel structure component.

[0024] Step 2: Place the steel structure component obliquely with the side having longitudinal and transverse stiffeners facing up. Inject the concrete mixture into the space between two adjacent perforated T-shaped ribs at a specified flow rate. Before injecting the concrete mixture between two adjacent perforated T-shaped ribs, first shape the concrete mixture into a thin-layer flowing concrete with a thickness not greater than the distance between the lower edge of the core bar and the top surface of the upper steel plate. At this time, an exhaust channel is formed between the upper edge of the core bar and the top surface of the lower steel plate. Then, apply a vibration force to the thin-layer flowing concrete to gradually transform the disordered flow state of the thin-layer flowing concrete into an ideal flow state of uniform and stable flow along the inclined slope direction, and flow into the space between two adjacent perforated T-shaped ribs, keeping the exhaust channel unobstructed.

[0025] Step 3: After the thin-layer flowing concrete flows into the space between two adjacent perforated T-shaped ribs in the ideal flow state, continue to apply a vibration force to the thin-layer flowing concrete along the inclined direction to make the flow rate of the concrete mixture equal in each section until the concrete mixture reaches the bottom of the steel shell structure and fills the space between the lower edge of the core bar and the top surface of the upper steel plate.

[0026] Step 4: When the concrete mixture flows to the bottom of the steel shell structure, gradually accumulate and backfill the exhaust channel. As the height of the concrete mixture increases by a specified height from bottom to top, adjust the frequency of the vibration force in the corresponding section, vibrate for a specified time length, and then stop the output of the vibration force in the corresponding section to discharge the internal air bubbles until the concrete mixture fills the entire exhaust channel. Then, cure the concrete mixture to obtain a steel shell concrete composite orthotropic bridge deck unit.

[0027] Step 5: Connect adjacent steel shell concrete composite orthotropic bridge deck units using a plate end connection structure to complete the fabrication of the steel shell concrete composite orthotropic bridge deck structure.

[0028] As a further preference, step one specifically includes the following steps:

[0029] Weld the perforated T-shaped ribs and the upper steel plate shear studs to the lower surface of the upper steel plate together;

[0030] Pass the core bar through the web round hole, and fix both ends of the core bar to the outermost perforated T-shaped rib with bolts. The core bar is located at the center of the web round hole;

[0031] Weld the intermediate insert plate to the core bar;

[0032] At the positions corresponding to the rivet holes on the lower steel plate and the positions corresponding to the openings on the bottom connecting plate, drill rivet holes. At the same time, weld the second shear studs to the upper surface of the lower steel plate, and pre-penetrate the second rivets into the openings at the longitudinal ends of the lower steel plate to ensure the riveting in the longitudinal connection area;

[0033] Weld the transverse stiffening assembly and the longitudinal stiffening assembly to the lower surface of the lower steel plate;

[0034] Pass the first rivets through the rivet holes and temporarily fix them. Turn the lower steel plate upside down, and pass the rivets through the rivet holes. Complete the rigid connection between the upper steel plate and the lower steel plate through riveting. The steel shell structure and the longitudinal and transverse stiffening ribs jointly form a steel structure assembly.

[0035] As a further preference, in step two and step three, the application method of the exciting force includes:

[0036] Arrange a plurality of vibrators with adjustable frequencies along the transverse bridge and longitudinal bridge directions. Among them, the multi-vibrators in the transverse bridge direction vibrate synchronously, and the multi-vibrators in the longitudinal bridge direction vibrate in a coordinated manner with variable frequencies in different zones. Gradually reduce the vibrator frequency from the bottom to the top, so that the vibrator frequency resonates with the flowing concrete mixture, to stimulate the thixotropic property of the flowing concrete, overcome the resistance of the first shear studs, make the flow velocity of the concrete mixture equal in each section, realize the coordination of the vibration frequency and the flow velocity, and the concrete mixture can flow downward continuously, evenly and stably.

[0037] As a further preference, step five specifically includes the following steps:

[0038] Weld the upper steel plate and the intermediate connecting plate of the adjacent bridge deck plate end connecting assemblies in sequence;

[0039] Adopt cold drawn rivets to connect the bottom connecting plate to complete the connection between the steel structures of the bridge deck;

[0040] Adopt reinforced concrete to pour into the cavity surrounded by the upper steel plate, the intermediate connecting plate and the bottom connecting plate as the support boundary for the out-of-plane deformation of the steel plate.

[0041] Connect the longitudinal and transverse stiffening ribs of the adjacent bridge decks.

[0042] Generally speaking, compared with the prior art, the above technical solution conceived by the present invention mainly has the following technical advantages:

[0043] 1. In the present invention, the upper steel plate of the above steel shell structure bears the tensile stress of the negative bending moment, and the lower steel plate of the steel shell structure bears the tensile stress of the positive bending moment. The filled concrete and the steel shell are stressed in coordination, avoiding the problems that the traditional composite bridge deck is prone to cracking under the action of negative bending moment and the stiffness drops significantly.

[0044] 2. In the steel-concrete composite plate of the present invention, the filled concrete anchors the upper and lower steel plates of the steel shell structure, avoiding the elastic buckling of the upper and lower steel plates. The upper and lower steel plates of the steel shell structure can both reach the yield stress, giving full play to the material performance of the steel shell structure. The thickness of the upper and lower steel plates is not greater than 1 / 8 of the total thickness of the composite plate, saving steel compared with the traditional orthotropic bridge deck; the upper and lower steel plates restrain the concrete, improving the crack resistance strength and crack restraint ability of the concrete, effectively improving the concrete structural performance, and the thickness can be only 1 / 3 - 1 / 4 of the concrete layer of the traditional steel-concrete composite bridge deck, solving the problem of the excessive weight of the traditional steel-concrete composite bridge deck.

[0045] 3. In the present invention, the steel shell and the filled concrete are coordinated in deformation, and the cross-section stress satisfies the plane section assumption. The steel shell-concrete orthotropic composite bridge deck has a large stiffness. The bending stiffness of the 80-mm-thick steel shell-concrete orthotropic composite bridge deck is equivalent to that of a 70-mm-thick steel plate, and the stiffness is 60 times that of the steel top plate of the traditional steel orthotropic bridge deck, greatly improving the stiffness of the top plate. At the same time, without U-rib stiffening, the improvement of its own stiffness and the simplification of the stiffening rib structure solve the fatigue problem of the weld between the stiffening rib and the steel top plate of the steel orthotropic bridge deck.

[0046] 4. The structure of the upper steel plate of the steel shell structure of the present invention with open holes for T-shaped ribs reserved with anchor bolt holes, pre-pierced bolts connected to the lower steel plate, and the manufacturing method of the steel shell structure components of the steel shell-concrete orthotropic composite bridge deck solve the problem of connecting the upper and lower steel plates in a narrow space.

[0047] 5. The pouring method of the filled concrete of the present invention, through the inclined steel shell structure, the concrete can flow naturally. At the same time, through the reasonable arrangement of vibrators, resonance is formed with the filled concrete, giving full play to its thixotropic performance, significantly enhancing the fluidity of the concrete, and solving the problem of concrete pouring in a narrow space.

[0048] 6. The connection structure of adjacent composite plate units provided by the present invention converts the connection of concrete into the connection of steel plates, not only solving the problem of connecting concrete in a narrow space, but also making the connection strength between the filled concretes higher than that of the filled concrete itself, eliminating the weak link of concrete connection.

[0049] 7. All the steel shell structure components of the present invention and the pouring of the filled concrete are carried out in the factory, with a high degree of mechanization, less manual input, and easy environmental protection control.

[0050] 8. When the present invention is installed, the T-shaped steel transverse ribs on the lower steel plate are riveted or bolted to the steel beam to complete the connection with the steel beam; the adjacent upper steel plates are welded, and the bottom connection steel plates are connected by bolts or cold-drawn rivets to complete the connection between the bridge decks. All connections are mechanical connections; during maintenance, only the mechanical connections between the bridge deck and the steel beam and between the bridge decks need to be released, and the damaged components can be replaced. The modular installation and disassembly of the bridge deck are realized, and the construction efficiency and maintenance efficiency are improved. BRIEF DESCRIPTION OF THE DRAWINGS

[0051] Figure 1 is a schematic structural diagram of a steel shell concrete composite orthotropic bridge deck structure according to an embodiment of the present invention;

[0052] Figure 2 is a schematic structural diagram of the steel shell structure according to an embodiment of the present invention;

[0053] Figure 3 is a schematic structural diagram of the longitudinal and transverse stiffeners according to an embodiment of the present invention;

[0054] Figure 4 is a schematic installation process diagram of a steel shell concrete composite orthotropic bridge deck structure according to an embodiment of the present invention;

[0055] Figure 5 is a cross-sectional view in the transverse bridge direction of a steel shell concrete composite orthotropic bridge deck structure according to an embodiment of the present invention;

[0056] Figure 6 is a schematic structural diagram of the plate end connection structure according to an embodiment of the present invention;

[0057] Figure 7 is a front structural schematic diagram of the concrete pouring device according to an embodiment of the present invention;

[0058] Figure 8 is a back structural schematic diagram of the concrete pouring device according to an embodiment of the present invention;

[0059] Figure 9 is a longitudinal sectional view of the concrete pouring device according to an embodiment of the present invention.

[0060] In all the drawings, the same reference numerals represent the same technical features, specifically:

[0061] 100 - Steel shell structure, 101 - Upper steel plate, 102 - Lower steel plate, 102 - 2 - Rivet hole, 103 - Open - hole T - shaped rib, 103 - 1 - Web of open - hole T - shaped rib, 103 - 2 - Circular hole in the web, 103 - 3 - Flange plate, 103 - 4 - First rivet hole, 104 - Shear stud assembly, 104 - 1 - First shear stud, 104 - 2 - Second shear stud, 105 - Core bar, 106 - First rivet,

[0062] 200 - Vertical and horizontal stiffeners, 201 - Horizontal stiffening assembly, 201 - 1 - Horizontal stiffening web, 201 - 2 - Horizontal stiffening panel, 202 - Vertical stiffening assembly, 202 - 1 - Vertical stiffening web, 202 - 2 - Vertical stiffening panel,

[0063] 300 - Infilled concrete,

[0064] 400 - Plate - end connection structure, 401 - End - variable - section T - shaped rib, 402 - Intermediate plate assembly, 402 - 1 - First intermediate plate, 402 - 2 - Second intermediate plate, 402 - 3 - Third intermediate plate, 403 - Intermediate connecting plate, 404 - Bottom connecting steel plate, 405 - Openings in the bottom connecting plate, 406 - Weld seam, 407 - Second rivet, 408 - Reinforced concrete, 409 - Circular hole in the plate,

[0065] 500 - Concrete pouring device, 501 - Hopper, 502 - Shaping and feeding section, 503 - Regulating valve plate, 504 - Transition section, 504 - 1 - Transparent top plate of the transition section, 504 - 2 - Steel bottom plate of the transition section, 505 - External vibration unit, 505 - 1 - Bracket, 505 - 2 - Vibrator, 506 - Concrete mixture, 507 - Exhaust passage, 508 - Support base. Detailed implementation manners

[0066] In order to make the objectives, technical solutions and advantages of the present invention clearer and more understandable, the present invention will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present invention and are not used to limit the present invention. In addition, the technical features involved in the various embodiments of the present invention described below can be combined with each other as long as they do not conflict with each other.

[0067] As Figures 1 to 6As shown in the figure, a steel shell-concrete composite orthotropic bridge deck structure provided by an embodiment of the present invention includes a plurality of steel shell-concrete composite orthotropic bridge deck units. Each steel shell-concrete composite orthotropic bridge deck unit includes: a steel shell structure 100, an in-filled concrete 300 provided inside the steel shell structure 100, longitudinal and transverse stiffeners 200 provided at the bottom of the steel shell structure 100, and a plate end connection structure 400 connecting adjacent steel shell-concrete composite orthotropic bridge deck units. Among them, the steel shell structure 100 includes an upper steel plate 101, a lower steel plate 102 arranged in parallel, and a plurality of core bar steels 105 arranged in parallel. A plurality of perforated T-shaped ribs 103 arranged parallel to the longitudinal direction of the bridge deck are provided between the upper steel plate 101 and the lower steel plate 102. The core bar steels 105 are arranged through the perforated T-shaped ribs 103. The steel shell structure 100 further includes a plurality of shear stud assemblies 104 for anchoring the upper steel plate 101 and the lower steel plate 102 to the in-filled concrete 300. The perforated T-shaped rib web 103-1 of the T-shaped stiffener 103 is welded to the upper steel plate 101, and the flange plate 103-3 is riveted to the lower steel plate 102, so that the upper steel plate 101 and the lower steel plate 102 attached with the shear stud assemblies 104 are connected into a steel shell structure 100 that can jointly bear force in a narrow space. The reinforced concrete tenon formed by the perforated T-shaped ribs 103 and the core bar steels 105 and the shear stud assemblies 104 anchor the upper steel plate 101 and the lower steel plate 102 to the in-filled concrete 300, so that the steel shell structure 100 and the in-filled concrete 300 are combined into a steel shell-concrete composite plate with coordinated deformation and joint force. In this embodiment, the upper and lower steel plates attached with shear studs are connected into a steel shell structure assembly that can jointly bear force in a narrow space; the reinforced concrete tenon formed by the perforated T-shaped ribs and the core bar steels and the shear studs anchor the upper and lower steel plates to the in-filled concrete. The T-shaped stiffeners reduce the free plate widths of the upper and lower steel plates and jointly form a strong constraint on the upper and lower steel plates with the shear studs, ensuring that the upper and lower steel plates do not undergo elastic buckling before tensile and compressive yielding, and enabling the material properties of the upper and lower steel plates in the structure to be fully exerted; the steel shell structure strongly constrains the in-filled concrete through a closed space, reinforced concrete tenons and shear studs, improves its crack resistance and crack constraint ability, effectively improves the performance of the concrete structure, and combines the steel shell structure assembly with the in-filled concrete into a steel shell-concrete composite plate with coordinated deformation and joint force.

[0068] Based on the above embodiment, in a preferred embodiment of the present invention, the steel shell structure 100 further includes a plurality of shear stud assemblies 104 for anchoring the upper steel plate 101 and the lower steel plate 102 to the in-filled concrete 300. The shear stud assemblies 104 are used to bear part of the shear force between the upper steel plate 101, the lower steel plate 102, and the in-filled concrete 300.

[0069] Based on the above-mentioned embodiments or a combination of multiple embodiments, in a preferred embodiment of the present invention, the perforated T-shaped rib 103 includes a perforated T-shaped rib web 103-1 and a perforated T-shaped rib flange plate that are integrally formed. A web circular hole 103-2 for accommodating the core bar 105 to pass through is provided on the perforated T-shaped rib web 103-1. The perforated T-shaped rib panel and the lower steel plate 102 are fixedly connected by a first rivet 106.

[0070] Based on the above-mentioned embodiments or a combination of multiple embodiments, in a preferred embodiment of the present invention, both ends of the core bar 105 are fixed to the perforated T-shaped rib web 103-1 at the transverse end of the bridge deck by bolts.

[0071] That is, in the present invention, the internal filling concrete 300 is densely poured into the steel shell structure 100. The perforated T-shaped rib 103, the core bar 105 and the internal filling concrete 300 jointly form a reinforced concrete tenon 301, which is used to ensure that the steel shell structure 100 and the internal filling concrete 300 cooperate to bear external loads. The shear studs 104 anchor the upper steel plate 101 and the lower steel plate 102 into the internal filling concrete 300 and bear part of the shear force between the upper and lower steel plates and the internal filling concrete 300. The perforated T-shaped rib 103 reduces the free plate width of the upper and lower steel plates. The internal filling concrete 300 strongly restrains the perforated T-shaped rib 103 to prevent it from buckling, and jointly forms a strong restraint on the upper and lower steel plates with the shear studs 104, ensuring that the upper and lower steel plates do not undergo elastic buckling before tensile and compressive yielding, and enabling the material properties of the upper and lower steel plates in the structure to be fully exerted. The steel shell structure 100 strongly restrains the internal filling concrete 300 through the closed space, the reinforced concrete tenon 301 and the shear studs 104, improves its crack resistance and crack restraint ability, and effectively improves the performance of the concrete structure. The steel shell structure 100 and the internal filling concrete 300 form a steel shell-concrete composite slab with coordinated deformation and common force bearing, enabling the material properties of steel and concrete to be fully exerted and effectively improving the structural stiffness and strength.

[0072] Based on the above-mentioned embodiments or a combination of multiple embodiments, in a preferred embodiment of the present invention, the spacing of the perforated T-shaped ribs 103 in the transverse bridge direction is 600 - 800 mm. The vertical position of the web circular hole 103-2 is in the middle of the perforated T-shaped rib web 103-1, and the longitudinal spacing between adjacent web circular holes 103-2 is 100 - 300 mm. The opening shape of the web circular hole 103-2 is circular, and the core bar 105 passing through the web circular hole 103-2 forms a reinforced concrete tenon 301 with the concrete in the hole.

[0073] Based on the above embodiments or a combination of multiple embodiments, in a preferred embodiment of the present invention, the shear stud assembly 104 includes an upper steel plate shear stud 104-1 fixedly connected to the upper steel plate 101 and a lower steel plate shear stud 104-2 fixedly connected to the lower steel plate 102. The longitudinal and transverse spacings of the upper steel plate shear stud 104-1 are both 120 - 220 mm. The layout spacing of the lower steel plate shear stud 104-2 is the same as that of the upper steel plate shear stud 104-1, but the upper steel plate shear stud 104-1 and the lower steel plate shear stud 104-2 are arranged staggeredly in the longitudinal direction with a void in between, and the longitudinal stagger spacing ranges from 60 - 110 mm. Specifically, the longitudinal and transverse spacings of the upper steel plate shear stud 104-1 are both 120 - 220 mm, the layout spacing of the lower steel plate shear stud 104-2 is the same as that of the upper steel plate shear stud 104-1, but the upper steel plate shear stud 104-1 and the lower steel plate shear stud 104-2 are arranged staggeredly in the longitudinal direction with a void in between.

[0074] Based on the above embodiments or a combination of multiple embodiments, in a preferred embodiment of the present invention, the total thickness of the steel shell structure 100 is 8 - 12 cm, and the thicknesses of the upper steel plate 101 and the lower steel plate 102 are not greater than 1 / 8 of the thickness of the steel shell structure 100.

[0075] Based on the above embodiments or a combination of multiple embodiments, in a preferred embodiment of the present invention, the infilled concrete 300 is ordinary concrete, high-performance concrete, fiber concrete, or ultra-high-performance concrete according to the force-bearing requirements of the steel shell-concrete composite orthotropic bridge deck.

[0076] Based on the above embodiments or a combination of multiple embodiments, in a preferred embodiment of the present invention, the plate end connection structure 400 includes an intermediate insertion plate assembly 402 and an intermediate connection plate 403 disposed on the same horizontal plane. The intermediate insertion plate assembly 402 is used to connect a specified number of the core bar reinforcements 105 at the transverse two ends of the steel shell structure 100, and the intermediate connection plate 403 is used to connect two adjacent intermediate insertion plate assemblies 402. In this way, the connection between the intermediate insertion plate 402 and the infilled concrete 300 is enhanced, so that the intermediate insertion plate 402 and the infilled concrete 300 form an integral working unit. At the same time, the intermediate insertion plate 402 connects the infilled concrete 300 of adjacent steel shell-concrete composite orthotropic bridge deck structures, converting the connection between concretes into the connection of steel plates, eliminating the weak link of concrete connection. The intermediate insertion plate assembly 402 includes a first intermediate insertion plate 402-1, a second intermediate insertion plate 402-2, and a third intermediate insertion plate 402-3 arranged in sequence from the transverse center of the steel shell structure 100 towards both ends. Among them, one end of the third intermediate insertion plate 402-3 is connected to the core bar reinforcement 105, and the other end is connected to the intermediate connection plate 403. That is, in this embodiment, the intermediate insertion plate assembly 402 is divided into the first intermediate insertion plate 402-1, the second intermediate insertion plate 402-2, and the third intermediate insertion plate 402-3 and welded to the core bar reinforcement 105. Round holes 409 are provided in the middle of the first intermediate insertion plate 402-1, the second intermediate insertion plate 402-2, and the third intermediate insertion plate 402-3, forming concrete tenons with the concrete flowing into them, further enhancing the connection between the intermediate insertion plate 402 and the infilled concrete 300, so that the intermediate insertion plate assembly 402 and the infilled concrete 300 form an integral working unit. The intermediate insertion plate assemblies 402 of adjacent steel shell-concrete composite plates are welded and connected through the intermediate connection plate 403, so that the intermediate insertion plate assembly 402 connects the infilled concrete 300 of adjacent steel shell-concrete composite plates, converting the connection between concretes into the connection of steel plates, eliminating the weak link of concrete connection; the upper steel plates 101 of adjacent steel shell-concrete composite plates are connected through welds 406; the lower steel plates 102 of adjacent steel shell-concrete composite plates are connected to the bottom connection plate 404 through pre-pierced bolts; after the above connections are completed, the cavity formed among the upper steel plate 101, the bottom connection plate 404, and the end variable cross-section T-shaped rib 401 is filled with reinforced concrete 408 to form an internal support constraint.

[0077] Based on the above embodiments or a combination of multiple embodiments, in a preferred embodiment of the present invention, the plate end connection structure 400 further includes a weld 406 connecting two adjacent upper steel plates 101 and a bottom connection plate 404 connecting two adjacent lower steel plates 102. The bottom connection plate 404 is fixedly connected to the lower steel plate 102 through second rivets 407.

[0078] Based on the above-mentioned embodiment or a combination of multiple embodiments, in a preferred embodiment of the present invention, the plate end connection structure 400 further includes an end variable cross-section T-shaped rib 401, which is arranged at both ends of the open-hole T-shaped rib 103 and integrally formed with the open-hole T-shaped rib 103. The end variable cross-section T-shaped rib 401 is arranged between the upper steel plate 101 and the lower steel plate 102, and its end is provided with an arc-shaped variable cross-section, so that a cavity is formed among the upper steel plate 101, the bottom connection steel plate 404, and the end variable cross-section T-shaped rib 401, and reinforced concrete 408 is filled in the cavity to form internal support constraints.

[0079] Based on the above-mentioned embodiment or a combination of multiple embodiments, in a preferred embodiment of the present invention, the longitudinal and transverse stiffeners 200 include multiple transverse stiffening components 201 arranged in parallel along the transverse direction and multiple longitudinal stiffening components 202 arranged in parallel along the longitudinal direction. The distance between adjacent transverse stiffening components 201 is 2000 - 4000 mm; the distance between adjacent longitudinal T-shaped stiffeners 201 is 900 - 1800 mm. In this embodiment, the bottom surface of the steel shell-concrete composite plate is welded to the webs (201-1, 202-1) of the longitudinal and transverse T-shaped stiffening components. The longitudinal and transverse stiffeners (201, 202) further enhance the stiffness of the steel shell-concrete composite plate. Since the heights and stiffnesses of the longitudinal and transverse stiffeners (201, 202) can be set respectively, the steel shell-concrete composite plate strengthened by them has different stiffnesses along the longitudinal and transverse directions, thus forming a steel shell-concrete composite orthotropic bridge deck structure.

[0080] As Figure 7 , Figure 8 and Figure 9 shown, according to another aspect of the present invention, a manufacturing method of a steel shell-concrete composite orthotropic bridge deck structure with strong mutual constraints between steel and concrete is also provided, including the following steps:

[0081] Step 1, preparation of steel structure components.

[0082] Weld the perforated T-shaped rib 103 to the lower surface of the upper steel plate 101, weld the perforated T-shaped rib 103 and the upper steel plate shear stud 104-1 together to the lower surface of the upper steel plate 101, pass the core bar 105 through the perforated T-shaped rib 103, and fix both ends of the core bar 105 to the outermost perforated T-shaped rib 103 with bolts; weld the longitudinal and transverse stiffeners 200 to the lower surface of the lower steel plate 102; weld the shear stud assemblies 104 to the lower surface of the upper steel plate 101 and the upper surface of the lower steel plate 102 respectively; place the upper surface of the lower steel plate 102 on the flange plate of the upper steel plate 101 welded with the perforated T-shaped rib 103, and rivet the perforated T-shaped rib 103 and the lower steel plate 102 through the first rivet 106 to complete the rigid connection between the upper steel plate 101 and the lower steel plate 102. The steel shell structure 100 and the longitudinal and transverse stiffeners 200 together form a steel structure assembly.

[0083] Specifically:

[0084] (11) Weld the perforated T-shaped rib 103 and the upper steel plate shear stud 104-1 together to the lower surface of the upper steel plate 101;

[0085] (12) Pass the core bar 105 through the web round hole 103-2, fix both ends of the core bar 105 to the outermost perforated T-shaped rib 103 with bolts, and the core bar 105 is located at the center of the web round hole 103-2;

[0086] (13) Weld the intermediate insert plate 402 to the core bar 105;

[0087] (14) At the positions corresponding to the first rivet holes 103-4 on the lower steel plate 102 and the openings of the bottom connecting plate 405, drill rivet holes. At the same time, weld the second shear stud 104-2 to the upper surface of the lower steel plate 102, and pre-penetrate the second rivet 407 into the openings at the longitudinal ends of the lower steel plate 102 to ensure the riveting in the longitudinal connection area;

[0088] (15) Weld the transverse stiffening assembly 201 and the longitudinal stiffening assembly 202 to the lower surface of the lower steel plate 102;

[0089] (16) Pass the first rivet 106 through the first rivet hole 103-4 and temporarily fix it, turn the lower steel plate 102 upside down, and pass the rivet 106 through the second rivet hole 102-1. Complete the rigid connection between the upper steel plate 101 and the lower steel plate 102 through riveting. The steel shell structure 100 and the longitudinal and transverse stiffeners 200 together form a steel structure assembly.

[0090] Step 2: Pouring the concrete filled inside. Place the steel structure component in an inclined position, with the side having longitudinal and transverse stiffeners 200 facing upward, and the core bar 105 parallel to the horizontal plane. Inject the concrete mixture 506 between two adjacent perforated T-shaped ribs 103 at a specified flow rate. Before injecting the concrete mixture 506 between two adjacent perforated T-shaped ribs 103, first shape the concrete mixture 506 into a thin-layer flowing concrete with a thickness not greater than the distance between the lower edge of the core bar 105 and the top surface of the upper steel plate 101. At this time, an exhaust channel 507 is formed between the upper edge of the core bar 105 and the top surface of the lower steel plate 102. Then, apply a vibration force to the thin-layer flowing concrete so that the thin-layer flowing concrete gradually transforms from a disordered flow state to an ideal flow state of uniform and stable flow along the inclined slope direction and flows into the space between two adjacent perforated T-shaped ribs 103, keeping the exhaust channel 507 unobstructed. After the thin-layer flowing concrete flows into the space between two adjacent perforated T-shaped ribs 103 in the ideal flow state, continue to apply a vibration force to the thin-layer flowing concrete along the inclined direction so that the flow rates of the concrete mixture 506 in each section are equal until the concrete mixture 506 reaches the bottom of the steel shell structure 100 and fills the space between the lower edge of the core bar 105 and the top surface of the upper steel plate 101. When the concrete mixture 506 flows to the bottom of the steel shell structure 100, it gradually accumulates and backfills the exhaust channel 507. As the height of the concrete mixture 506 increases by a specified height from bottom to top, increase the frequency of the vibration force in the corresponding section, vibrate for a specified time length, and then stop the output of the vibration force in the corresponding section to discharge the internal air bubbles until the concrete mixture 506 fills the entire exhaust channel 507. Then, cure the concrete mixture 506 to obtain a steel shell-concrete composite orthotropic bridge deck unit.

[0091] Specifically, this step includes:

[0092] (21) Place the steel structure component on an inclined support, with the upper steel plate at the bottom and the T-shaped stiffeners at the top. Connect a feeding hopper 501, a shaping feeding section 502, a transition section 504, and the steel structure component in sequence from top to bottom. After the concrete mixture 506 enters the feeding hopper 501, control the flow rate through the regulating valve plate 503, flow through the shaping feeding section 502, shape the concrete mixture 506 entering the feeding hopper in batches into a thin-layer flowing concrete with a thickness not greater than the distance between the lower edge of the core bar 105 and the top surface of the upper steel plate 101, and flow into the transition section 504 naturally along the inclined slope.

[0093] (22) High-frequency vibration units are arranged in the transition section. After the concrete mixture 506 enters the transition section 504, under the combined action of gravity and the exciting force of the external vibration unit 505, it overcomes the resistance of the upper steel plate shear studs 104-1 and continues to flow, and gradually transforms the thin-layer flowing concrete from a disordered flow state into an ideal flow state of uniform and stable flow along the inclined slope direction, and keeps the exhaust channel 507 between the concrete mixture 506 and the bottom steel plate 102 unobstructed;

[0094] (23) The concrete mixture enters the inside of the steel shell structure 100 in an ideal flow state. Vibration units 505 are arranged at the bottom of the upper steel plate 101. The arrangement method of the external vibration unit 505 is: synchronous multi-vibration units horizontally and coordinated variable-frequency vibration longitudinally in zones. Gradually reduce the frequency of the external vibration unit 505 from the bottom to the top to resonate with the flowing concrete mixture, stimulate the thixotropic properties of the flowing concrete, overcome the resistance of the upper steel plate shear studs 104-1, make the flow velocity of the concrete mixture 506 equal in each section, realize the coordination of vibration frequency and flow velocity, and the concrete mixture 506 can continuously flow downward evenly and stably until the concrete mixture 506 reaches the bottom of the steel shell structure 100 and fills the space between the lower edge of the core bar 105 and the top surface of the upper steel plate 101. During this process, all external vibration units 505 remain in the open state;

[0095] (24) The concrete mixture 506 flows to the bottom of the steel shell structure 100 and gradually accumulates to backfill the exhaust channel 507. As the liquid level height of the concrete mixture rises by 1 m from bottom to top, the frequency of the external vibration unit 505 in the corresponding section is adjusted to high frequency, and it automatically stops after vibrating for 30 s. Use the high-frequency exciting force to discharge the internal air bubbles to achieve the effect of dense exhaust. As the material surface rises, gradually close the external vibration units 505 from bottom to top;

[0096] (25) Continuously keep the regulating valve 503 open, so that the liquid level of the concrete mixture 506 is gradually backfilled until the transition section 504 is filled. Close all external vibration units 505, remove the transition section 504, pour out the internal concrete mixture to avoid all defects accumulated at the end of the bridge deck, and retain all the concrete mixture 506 in the steel shell structure components; The transition section 504 can be reused after being washed after the production of the steel shell-concrete orthotropic composite bridge deck unit is completed.

[0097] (26) When the concrete age meets the strength requirements for hoisting and demolition, lift the completed cast steel shell-concrete orthotropic composite bridge deck from the casting gantry and enter the curing process.

[0098] Step 3: Connection of adjacent steel shell - concrete orthotropic composite bridge deck units. The plate - end connection structure 400 is used to connect adjacent steel shell - concrete composite orthotropic bridge deck units, completing the fabrication of the steel shell - concrete composite orthotropic bridge deck structure. Specifically:

[0099] (31) Weld the upper steel plate 101 and the intermediate connecting plate 403 of the adjacent bridge deck plate - end connection components in sequence;

[0100] (32) Use cold - drawn rivets to connect the bottom connecting plate 404 to complete the connection between the steel structures of the bridge deck;

[0101] (33) Pour reinforced concrete 408 into the cavity formed by the upper steel plate 101, the intermediate connecting plate 403, and the bottom connecting plate 404 as the support boundary for the out - of - plane deformation of the steel plate.

[0102] (34) Connect the longitudinal and transverse stiffeners of adjacent bridge decks.

[0103] Thus, the connection of the bridge deck units is completed, and the fabrication of the bridge deck is completed.

[0104] Based on the above - mentioned embodiment or a combination of multiple embodiments, according to another aspect of the present invention, there is also provided a concrete pouring device 500 for fabricating a steel shell - concrete composite orthotropic bridge deck structure, which includes:

[0105] A support base with an inclined top surface;

[0106] A plurality of external vibration units 505 arranged along the inclined surface and fixedly provided on the support base. The plurality of external vibration units 505 are arranged in parallel in the horizontal direction. Each external vibration unit 505 includes a jig 505 - 1 provided on the support base and a plurality of vibrators 505 - 2 provided at the bottom of the jig 505 - 1. The plurality of vibrators 505 - 2 are arranged at intervals in the transverse direction of the jig 505 - 1;

[0107] A transition section 504 provided at the top of the support base and connected to the top surface of the jig 505 - 1. The transition section 504 includes a shell with a hollow structure inside. The top surface of the shell is a transition section transparent top plate 504 - 1 for observing the flow state of the internal concrete mixture 506 in real - time. A shear stud assembly 104 and a core bar 105 that are the same as and corresponding to the internal structure of the steel shell structure 100 are provided inside the hollow structure of the shell;

[0108] A feeding hopper 501 provided at the top of the transition section 504. A regulating valve plate 503 is provided at the bottom of the feeding hopper 501;

[0109] A shaping feeding section 502 provided between the feeding hopper 501 and the transition section 504.

[0110] In the above embodiments, the transition section 504 has the same structure as the steel shell structure 100. The difference is that the steel shell structure 100 is composed of an upper steel plate and a lower steel plate to form a shell structure, while the transition section 504 is composed of a transition section transparent top plate 504-1 and a transition section bottom plate 504-2 to form a shell structure, and the internal structures of the shell structures are the same. Moreover, the top and bottom ends of this transition section are respectively connected to the shaping and blanking section of the blanking hopper and the steel shell structure by means of a quick-release device. Inside the transition section, the same slurry blockers as in the steel shell structure are provided, namely shear studs and core bar reinforcements; outside the transition section, the same external vibration unit layout method as at the bottom of the steel shell structure is adopted. The top surface of the transition section is sealed with a transition section transparent top plate for real-time observation of the flow state of the internal concrete mixture.

[0111] Based on the above embodiments or a combination of multiple embodiments, a plurality of vibrators (505-2) of the concrete pouring device 500 are arranged in the transverse bridge and longitudinal bridge directions. Among them, the multi-vibrators 505-2 in the transverse bridge direction vibrate synchronously, and the multi-vibrators 505-2 in the longitudinal bridge direction vibrate in a zone-varying frequency coordination manner. The frequency of the vibrators 505-2 gradually decreases from the bottom to the top, so that the frequency of the vibrators 505-2 resonates with the flowing concrete mixture to stimulate the thixotropic property of the flowing concrete, overcome the resistance of the first shear stud 104-1, make the flow velocity of the concrete mixture 506 equal in each section, realize the coordination of the vibration frequency and the flow velocity, and the concrete mixture 506 can flow downward continuously, evenly and stably.

[0112] Based on the above embodiments or a combination of multiple embodiments, according to another aspect of the present invention, a working method of a concrete pouring device 500 for manufacturing a steel shell-concrete composite orthotropic bridge deck structure is further provided.

[0113] It includes the following steps:

[0114] Step 1: The concrete mixture 506 placed in the blanking hopper 501 flows into the shaping and blanking section 502 at a specified flow velocity. The vibrator 505-2 at the bottom of the shaping and blanking section 502 applies an exciting force to the concrete mixture 506 to shape the concrete mixture 506 into a specified thickness. Specifically, the steel structure components are placed on the inclined brackets, with the upper steel plate at the bottom and the T-shaped stiffener at the top. The blanking hopper 501, the shaping and blanking section 502, the transition section 504 and the steel structure components are connected in sequence from top to bottom. After the concrete mixture 506 enters the blanking hopper 501, the flow rate is controlled by the regulating valve plate 503, flows through the shaping and blanking section 502, and the concrete mixture 506 entering the blanking hopper in batches is shaped into a thin-layer flowing concrete with a thickness not greater than the distance between the lower edge of the core bar reinforcement 105 and the top surface of the upper steel plate 101, and naturally flows into the transition section 504 along the inclined slope.

[0115] Step 2: The concrete mixture 506 with a specified thickness enters the transition section 504. The vibrator 505-2 at the bottom of the transition section 504 applies an exciting force to the concrete mixture 506. Under the combined action of gravity and the exciting force, the concrete mixture 506 with a specified thickness gradually transforms from a disordered flow state to an ideal flow state of uniform and stable flow along the inclined slope direction. During this process, the exhaust channel 507 is kept unobstructed. Specifically, high-frequency vibration units are arranged in the transition section. After the concrete mixture 506 enters the transition section 504, under the combined action of gravity and the exciting force of the external vibration unit 505, it continues to flow by overcoming the resistance of the shear studs 104-1, and the thin-layer flowing concrete gradually transforms from a disordered flow state to an ideal flow state of uniform and stable flow along the inclined slope direction, and the exhaust channel 507 between the concrete mixture 506 and the bottom steel plate 102 is kept unobstructed.

[0116] Step 3: The concrete mixture 506 in the ideal flow state flows into the steel shell structure 100 provided at the bottom end of the transition section 504. The vibrator 505-2 on the bottom surface of the steel shell structure 100 applies an exciting force to the concrete mixture 506 along the inclined direction, so that the flow velocities of the concrete mixture 506 in each section of the steel shell structure 100 are equal until the concrete mixture 506 reaches the bottom of the steel shell structure 100 and fills the space between the lower edge of the core bar 105 and the top surface of the upper steel plate 101. Specifically, the concrete mixture enters the steel shell structure 100 in the ideal flow state. External vibration units 505 are arranged at the bottom of the upper steel plate 101. The arrangement method of the external vibration units 505 is as follows: multiple vibration units in the transverse direction are synchronized, and the vibration frequencies in the longitudinal direction are changed in different zones and coordinated. The frequency of the external vibration units 505 gradually decreases from the bottom to the top, so as to resonate with the flowing concrete mixture, stimulate the thixotropic properties of the flowing concrete, overcome the resistance of the shear studs 104-1 on the upper steel plate, make the flow velocities of the concrete mixture 506 in each section equal, and achieve the coordination of the vibration frequency and the flow velocity. The concrete mixture 506 can continuously flow downward evenly and stably until the concrete mixture 506 reaches the bottom of the steel shell structure 100 and fills the space between the lower edge of the core bar 105 and the top surface of the upper steel plate 101. During this process, all the external vibration units 505 remain in the open state.

[0117] Step 4: The concrete mixture 506 flows to the bottom of the steel shell structure 100 and gradually accumulates to backfill the exhaust channel 507. As the height of the concrete mixture 506 increases by a specified height from bottom to top, the frequency of the vibration force in the corresponding section is adjusted upward. After vibrating for a specified time length, the output of the vibration force in the corresponding section is stopped to discharge the internal air bubbles until the concrete mixture 506 fills the transition section 504, and then the vibrator 505-2 is turned off. Specifically, the concrete mixture 506 flows to the bottom of the steel shell structure 100 and gradually accumulates to backfill the exhaust channel 507. As the liquid level height of the concrete mixture increases by 1 m from bottom to top, the frequency of the external vibration unit 505 in the corresponding section is adjusted to a high frequency. After vibrating for 30 s, it automatically stops, and the internal air bubbles are discharged with the high-frequency vibration force to achieve the effect of dense exhaust. As the material surface rises, the external vibration units 505 are gradually turned off from bottom to top; continuously keep the regulating valve 503 open to gradually backfill the liquid level of the concrete mixture 506 until it fills the transition section 504. Then, all the external vibration units 505 are turned off, the transition section 504 is removed, and the internal concrete mixture is poured out to avoid all the defects accumulated at the end of the bridge deck, and all the concrete mixture 506 in the steel shell structure assembly is retained; the transition section 504 can be reused after being rinsed after the production of the steel shell-concrete orthotropic composite bridge deck unit.

[0118] In this embodiment, the stiffness of the steel shell-concrete composite orthotropic bridge deck is 60 times that of the steel top plate of the traditional steel orthotropic bridge deck, which solves the fatigue problem of the weld between the stiffening rib and the steel top plate of the steel orthotropic bridge deck. At the same time, it avoids the problem that the traditional composite bridge deck is prone to cracking under negative bending moment and the stiffness drops significantly, gives full play to the performance of the steel shell and concrete, and solves the problem of excessive weight of the traditional steel-concrete composite bridge deck.

[0119] It is easy for those skilled in the art to understand that the above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent replacements, and improvements made within the spirit and principle of the present invention shall be included within the protection scope of the present invention.

Claims

1. A steel shell-concrete composite orthotropic bridge deck structure, characterized in that: The invention comprises a plurality of steel shell-concrete composite orthotropic bridge deck units, each of which comprises: a steel shell structure (100), an inner filling concrete (300) arranged in the steel shell structure (100), longitudinal and transverse stiffening ribs (200) arranged at the bottom of the steel shell structure (100), and a plate end connection structure (400) connecting adjacent steel shell-concrete composite orthotropic bridge deck units, wherein the steel shell structure (100) comprises an upper steel plate (101) and a lower steel plate (102) arranged in parallel, and a plurality of mandrel steel bars (105) arranged in parallel, a plurality of open hole T-shaped ribs (103) arranged in parallel along the longitudinal direction of the bridge deck are arranged between the upper steel plate (101) and the lower steel plate (102), and the mandrel steel bars (105) are arranged through the open hole T-shaped ribs (103), and the steel shell structure (100) further comprises a plurality of A shear bolt assembly (104) is provided for anchoring the upper steel plate (101) and the lower steel plate (102) in the inner filling concrete (300), the perforated T-shaped rib web plate (103-1) of the perforated T-shaped rib (103) is welded to the upper steel plate (101), and the flange plate (103-3) is riveted to the lower steel plate (102), so that the upper steel plate (101) and the lower steel plate (102) attached with the shear bolt assembly (104) can be fixed in a narrow space. The steel plates (102) are connected to form a steel shell structure (100) capable of bearing stress together. The reinforced concrete tenon and shear bolt assembly (104) formed by the perforated T-shaped ribs (103) and the core rod steel bars (105) anchor the upper steel plate (101) and the lower steel plate (102) in the inner filling concrete (300), so that the steel shell structure (100) and the inner filling concrete (300) are combined to form a steel shell-concrete composite plate with coordinated deformation and joint stress. The plate end connection structure (400) comprises an intermediate plug plate assembly (402) and an intermediate connecting plate (403) arranged on the same horizontal plane. The intermediate plug plate assembly (402) is used to connect the designated core rod steel bars (105) at the two transverse ends of the steel shell structure (100), and the intermediate connecting plate (403) is used to connect two adjacent intermediate plug plate assemblies (402). In this way, the connection between the intermediate plug plate assembly (402) and the inner filling concrete (300) is strengthened, so that the intermediate plug plate assembly (402) and the inner filling concrete (300) form a whole that works together. At the same time, the intermediate plug plate assembly (402) connects the inner filling concrete (300) of the adjacent steel shell-concrete composite orthotropic bridge deck structure, converts the connection between the concrete into a connection between the steel plates, and eliminates the weak link of the concrete connection.

2. The steel shell-concrete composite orthotropic bridge deck structure according to claim 1, characterized in that: The perforated T-shaped rib web (103-1) is provided with a web circular hole (103-2) for accommodating the core rod steel bar (105) to pass through, and the perforated T-shaped rib panel is fixedly connected to the lower steel plate (102) by a first rivet (106).

3. The steel shell-concrete composite orthotropic bridge deck structure according to claim 2, characterized in that: The spacing of the perforated T-shaped ribs (103) along the transverse direction is 600-800 mm, the vertical position of the web circular holes (103-2) is in the middle of the perforated T-shaped rib web (103-1), and the longitudinal spacing of adjacent web circular holes (103-2) is 100-300 mm.

4. The steel shell-concrete composite orthotropic bridge deck structure according to claim 1, characterized in that: The shear bolt assembly (104) comprises an upper steel plate shear bolt (104-1) fixedly connected to the upper steel plate (101) and a lower steel plate shear bolt (104-2) fixedly connected to the lower steel plate (102), the longitudinal and transverse spacings of the upper steel plate shear bolt (104-1) are both 120 to 220 mm, the arrangement spacing of the lower steel plate shear bolt (104-2) is the same as that of the upper steel plate shear bolt (104-1), but the upper steel plate shear bolt (104-1) and the lower steel plate shear bolt (104-2) are arranged in a longitudinal staggered manner, and the longitudinal staggered spacing ranges from 60 to 110 mm.

5. The steel shell-concrete composite orthotropic bridge deck structure according to claim 1, characterized in that: The total thickness of the steel shell structure (100) is 8 to 12 cm, and the thickness of the upper steel plate (101) and the lower steel plate (102) is no more than 1 / 8 of the thickness of the steel shell structure (100).

6. The steel shell-concrete composite orthotropic bridge deck structure according to claim 1, characterized in that: The inner filling concrete (300) is made of ordinary concrete, high performance concrete, fiber concrete or ultra-high performance concrete according to the stress requirements of the steel shell-concrete composite orthotropic bridge deck.

7. The steel shell-concrete composite orthotropic bridge deck structure according to claim 1, characterized in that: The intermediate plug plate assembly (402) comprises a first intermediate plug plate (402-1), a second intermediate plug plate (402-2) and a third intermediate plug plate (402-3) which are arranged in sequence from the transverse center of the steel shell structure (100) to both ends, wherein one end of the third intermediate plug plate (402-3) is connected to the mandrel steel bar (105), and the other end is connected to the intermediate connecting plate (403).

8. The steel shell-concrete composite orthotropic bridge deck structure according to claim 7, characterized in that: The first intermediate plug board (402-1), the second intermediate plug board (402-2) and the third intermediate plug board (402-3) are each provided with a plurality of plug board circular holes (409).

9. The steel shell-concrete composite orthotropic bridge deck structure according to claim 1, characterized in that: The plate end connection structure (400) further includes a weld (406) connecting two adjacent upper steel plates (101) and a bottom connecting steel plate (404) connecting two adjacent lower steel plates (102), wherein the bottom connecting steel plate (404) is fixedly connected to the lower steel plate (102) via a second rivet (407).

10. The steel shell-concrete composite orthotropic bridge deck structure according to claim 1, characterized in that: The plate end connection structure (400) further comprises an end variable-section T-shaped rib (401), which is arranged at both ends of the perforated T-shaped rib (103) and is formed integrally with the perforated T-shaped rib (103). The end variable-section T-shaped rib (401) is arranged between the upper steel plate (101) and the lower steel plate (102), and an arc-shaped variable section is arranged at its end, so that a cavity is formed between the upper steel plate (101), the bottom connecting steel plate (404), and the end variable-section T-shaped rib (401), and the cavity is filled with reinforced concrete (408) to form an internal support constraint.

11. The steel shell-concrete composite orthotropic bridge deck structure according to claim 10, characterized in that: The longitudinal and transverse stiffening ribs (200) include a plurality of transverse stiffening components (201) arranged in parallel in the transverse direction and a plurality of longitudinal stiffening components (202) arranged in parallel in the longitudinal direction; The spacing between adjacent transverse stiffening assemblies (201) is 2000-4000 mm; the spacing between adjacent longitudinal stiffening assemblies (202) is 900-1800 mm.

12. A method for manufacturing a steel shell-concrete composite orthotropic bridge deck structure, characterized in that: The following steps are involved: Step 1: Weld the perforated T-shaped rib (103) to the lower surface of the upper steel plate (101), weld the perforated T-shaped rib (103) and the upper steel plate shear nail (104-1) to the lower surface of the upper steel plate (101), pass the mandrel steel bar (105) through the perforated T-shaped rib (103), and fix the two ends of the mandrel steel bar (105) to the outermost perforated T-shaped rib (103) with bolts; Welding longitudinal and transverse stiffening ribs (200) to the lower surface of the lower steel plate (102); A second rivet hole (102-1) is drilled at a position of the lower steel plate (102) corresponding to the first rivet hole (103-4) of the T-shaped stiffening rib and at a position corresponding to the opening (405) of the bottom connecting plate, and at the same time, a lower steel plate shear nail (104-2) is welded to the upper surface of the lower steel plate (102); a second rivet (407) is pre-inserted into the opening (102-2) at the longitudinal end of the lower steel plate (102); The upper surface of the lower steel plate (102) is buckled onto the flange plate welded to the perforated T-shaped rib (103) of the upper steel plate (101), and the perforated T-shaped rib (103) is riveted to the lower steel plate (102) by a first rivet (106) to complete the rigid connection between the upper steel plate (101) and the lower steel plate (102), and the steel shell structure (100) and the longitudinal and transverse stiffening ribs (200) together form a steel structure assembly; Step 2, the steel structure assembly is placed at an angle, with the side provided with the longitudinal and transverse stiffening ribs (200) on the top, and a concrete mixture (506) is injected into the space between two adjacent perforated T-shaped ribs (103) at a specified flow rate. Before the concrete mixture (506) is injected into the space between two adjacent perforated T-shaped ribs (103), the concrete mixture (506) is first shaped into a thin layer of fluid concrete having a thickness not greater than the distance between the lower edge of the core rod steel bar (105) and the top surface of the upper steel plate (101). At this time, an exhaust channel (507) is formed between the upper edge of the core rod steel bar (105) and the top surface of the lower steel plate (102). Then, an exciting force is applied to the thin layer of fluid concrete, so that the thin layer of fluid concrete is gradually transformed from a chaotic flow state to an ideal flow state of uniform and stable flow along the inclined slope direction, and flows into the space between two adjacent perforated T-shaped ribs (103), and the exhaust channel (507) is kept unobstructed; Step 3, after the thin layer of fluid concrete flows into between two adjacent open hole T-shaped ribs (103) from an ideal flow state, an exciting force is continuously applied to the thin layer of fluid concrete in an inclined direction so that the flow velocity of the concrete mixture (506) in each section is equal, until the concrete mixture (506) reaches the bottom of the steel shell structure (100) and fills the space between the lower edge of the core rod steel bar (105) and the top surface of the upper steel plate (101); Step 4: The concrete mixture (506) flows to the bottom of the steel shell structure (100), and gradually accumulates to fill the exhaust channel (507). From bottom to top, as the height of the concrete mixture (506) increases by a specified height, the frequency of the exciting force of the corresponding section is increased, and the output of the exciting force of the corresponding section is stopped after the specified length of vibration, so as to discharge the internal bubbles until the concrete mixture (506) fills the entire exhaust channel (507), and then the concrete mixture (506) is cured to obtain a steel shell-concrete composite orthotropic bridge deck unit; Step 5: Adjacent steel shell-concrete composite orthotropic bridge deck units are connected using a plate end connection structure (400) to complete the fabrication of the steel shell-concrete composite orthotropic bridge deck structure.

13. The method for manufacturing a steel shell-concrete composite orthotropic bridge deck structure according to claim 12, characterized in that: The step 1 specifically includes the following steps: (11) welding the perforated T-shaped rib (103) and the upper steel plate shear pin (104-1) to the lower surface of the upper steel plate (101); (12) passing the mandrel steel bar (105) through the web circular hole (103-2), fixing both ends of the mandrel steel bar (105) to the outermost opening T-shaped rib (103) with bolts, and positioning the mandrel steel bar (105) at the center of the web circular hole (103-2); (13) welding the middle plug plate assembly (402) and the mandrel steel bar (105); (14) Drill rivet holes at positions corresponding to the first rivet holes (103-4) of the lower steel plate (102) and at positions corresponding to the openings (405) of the bottom connecting plate, weld the second shear nails (104-2) to the upper surface of the lower steel plate (102), and pre-insert the second rivet (407) into the openings at the longitudinal ends of the lower steel plate (102) to ensure riveting of the longitudinal connecting area; (15) Welding the transverse stiffening assembly (201) and the longitudinal stiffening assembly (202) to the lower surface of the lower steel plate (102); (16) The first rivet (106) is passed through the first rivet hole (103-4) and temporarily fixed, the lower steel plate (102) is turned upside down, and the second rivet hole (102-1) is inserted into the first rivet (106), and the rigid connection between the upper steel plate (101) and the lower steel plate (102) is completed by riveting. The steel shell structure (100) and the longitudinal and transverse stiffening ribs (200) together form a steel structure component.

14. The method for manufacturing a steel shell-concrete composite orthotropic bridge deck structure according to claim 12, characterized in that: In step 2 and step 3, the exciting force is applied in the following manner: A plurality of frequency-adjustable vibrators (505-2) are arranged along the transverse bridge and longitudinal bridge directions, wherein the multiple vibrators (505-2) in the transverse bridge direction are synchronized, and the vibrators (505-2) in the longitudinal bridge direction are vibrated in a coordinated manner with variable frequencies in different sections, and the frequency of the vibrator (505-2) is gradually reduced from the bottom to the top, so that the frequency of the vibrator (505-2) resonates with the fluid concrete mixture to stimulate the thixotropic properties of the fluid concrete, overcome the resistance of the first shear nail (104-1), and make the flow velocity of the concrete mixture (506) equal in each section, so as to achieve coordination between the vibration frequency and the flow velocity, and the concrete mixture (506) can continue to flow downward evenly and stably.

15. The method for manufacturing a steel shell-concrete composite orthotropic bridge deck structure according to claim 13, characterized in that: The step five specifically includes the following steps: (51) sequentially welding the upper steel plates (101) and the middle connecting plates (403) of the adjacent bridge deck plate end connecting assemblies; (52) The bottom connecting steel plate (404) is connected by cold riveting to complete the connection between the bridge deck steel structures; (53) using reinforced concrete (408) to pour the cavity surrounded by the upper steel plate (101), the middle connecting plate (403) and the bottom connecting steel plate (404) as a supporting boundary for the out-of-plane deformation of the steel plate; (54) Connect the longitudinal and transverse stiffening ribs of adjacent bridge decks.

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