A production method of corrugated steel-concrete beam suitable for heavy industrial buildings

Abstract

The application discloses a corrugated plate steel reinforced concrete beam suitable for heavy industrial buildings and a production method thereof, and belongs to the technical field of building structures.The corrugated plate steel reinforced concrete beam comprises wing plates, an intermediate web and a tie steel mesh; the intermediate web comprises a corrugated web and straight webs welded at both ends of the corrugated web, and web holes for joint connection are arranged on the straight webs; the intermediate web connects two parallel wing plates to form an I-shaped steel beam, the tie steel mesh is fixed between the wing plates, one tie steel mesh is arranged on each side of the intermediate web, and concrete is cast on both sides of the intermediate web; the corrugated web in the application enables the whole intermediate web to have out-of-plane buckling resistance, and thus the stiffness of the steel reinforced concrete beam is improved under the premise that the steel consumption basically remains unchanged.

Description

Technical Field

[0001] This invention relates to the field of construction, and more particularly to a corrugated steel-concrete composite beam suitable for heavy industrial buildings and its production method. Background Technology

[0002] In traditional construction, most work must be completed on-site. Long construction periods, severe environmental pollution, large material storage areas, and labor shortages have become barriers to the progress of the construction industry. While prefabricated buildings offer significant advantages in construction, some problems remain, such as the reliability of vertical joints in PC structures, cracking and leakage in steel and composite structure enclosure walls, and generally high costs, leading to lower satisfaction among owners and users. Steel structures, while offering reliable joint construction and easily guaranteed construction quality, suffer from poor sound insulation, low stiffness, poor comfort, and the need for additional fireproofing and corrosion protection. Steel-concrete composite structures combine the advantages of both traditional and steel structures, with most of the main body covered in concrete and featuring the same connection joints as steel structures. In steel-concrete composite beams (referred to as steel-concrete beams), the H-beams primarily bear bending moments. The best way to improve bending capacity is to increase the web height and decrease the web thickness; however, the web is prone to buckling under shear forces, and deformation during transportation and installation is difficult to control. To improve the shear capacity and stiffness of structural members, it is generally necessary to increase the thickness of the web or add stiffening ribs to improve the stability of the web. This increases both the amount of steel used in the member and the amount of construction work. Summary of the Invention

[0003] The technical problem to be solved by the present invention is to provide a novel corrugated steel-concrete beam to increase the stiffness of the steel-concrete beam and control the amount of steel used in the components and the amount of construction work, and at the same time to provide a corresponding production method to improve the production efficiency of the novel corrugated steel-concrete beam.

[0004] To solve the above-mentioned technical problems, the technical solution adopted by the present invention is: a corrugated steel-concrete beam suitable for heavy industrial buildings, comprising a flange, a central web and a reinforcing steel mesh;

[0005] The intermediate web includes a corrugated web and a straight web welded to both ends of the corrugated web, and the straight web is provided with web holes for node connection.

[0006] The intermediate web plate connects two parallel flanges to form an I-shaped steel beam. The tie steel mesh is fixed between the flanges. A tie steel mesh is set on each side of the intermediate web plate. Concrete is poured on both sides of the intermediate web plate.

[0007] The wavy web enables the entire intermediate web to have out-of-plane buckling resistance, thereby improving the stiffness of the steel-concrete beam while keeping the amount of steel used basically unchanged.

[0008] Since the intermediate web of this invention mainly adopts a corrugated web, the waves of the corrugated web encroach on part of the beam width, resulting in insufficient welding length between the traditional C-shaped tie bars and the flange. To overcome this problem, the tie bar mesh includes straight vertical tie bars, horizontal crack-resistant bars, and horizontal connecting bars. All vertical tie bars are parallel to each other and welded to the horizontal crack-resistant bars. Two horizontal connecting bars are welded to both ends of the vertical tie bars respectively. The tie bar mesh is welded to the flange through the horizontal connecting bars.

[0009] Furthermore, the corrugated web and the straight web are welded together by full penetration. The thickness of the corrugated web is 2-6 mm. The wave height and wave pitch of the corrugated web can be determined according to the actual processing capacity. Generally, a wave height of ±20 mm and a wave pitch of 155 mm are recommended. The length of the straight web is not less than one beam height.

[0010] The present invention also provides a method for producing corrugated steel-concrete composite beams suitable for heavy industrial buildings, comprising the following steps:

[0011] Step 1: Weld straight web plates to both ends of the corrugated web plate to form the intermediate web plate, and weld the intermediate web plate to the flange plate to form an I-beam.

[0012] Step 2: Processing the pouring auxiliary tools, which include a support assembly, a support column, and a composite template. The support assembly includes a base plate and a support beam. The base plate is provided with a locking assembly and fixing holes. The support column is installed in the locking assembly, and the support beam is installed on the base plate. The composite template is semi-circular. The straight edge of the composite template is provided with two wing plate grooves aligned with the wing plate and multiple rebar grooves aligned with the horizontal anti-crack bars and horizontal connecting bars.

[0013] Step 3: Fix the support components to the web holes of the flat web through fixing holes and bolts. A support component is set on both sides of each flat web. Insert the wing plate groove of the composite template into the wing plate and fix the composite template to the base plate.

[0014] Step 4: Weld vertical tie bars, horizontal crack-resistant bars, and horizontal connecting bars to form a tie bar mesh;

[0015] Step 5: Transport the processed and assembled I-beams and pouring auxiliary tools to the pouring site. The integrated formwork at the bottom of the I-beams supports the I-beams at both ends. The support columns further support the I-beams to ensure that the straight web of the I-beams remains horizontal.

[0016] Step 6: Dismantle the upper integrated formwork on the I-beam, place the tie steel mesh on the support beam of the support component, and then weld the horizontal connecting bars of the tie steel mesh to the flange.

[0017] Step 7: Reinsert the removed formwork. The formwork and the flange form together form an upward-facing pouring cavity, with the reinforcing mesh inside the cavity.

[0018] Step 8: Pour concrete into the casting cavity;

[0019] Step 9: After the poured concrete has solidified and reached 70% of its design strength, remove the support columns; then push the steel-concrete beam to roll so that the surface of the middle web that has not been poured with concrete faces upward; then reinstall the support columns for auxiliary support.

[0020] Step 10: Repeat steps 6-8 to pour concrete on the other side of the intermediate web.

[0021] Step 11: After the concrete has solidified, disassemble the pouring aids.

[0022] In traditional reinforced concrete beam casting processes, if the beam is cast on both sides, it must be flipped using a hoist after one side is poured. This requires the casting site to be equipped with large hoisting equipment or a road for crane access, limiting the production efficiency of reinforced concrete beams. The production method of this invention installs semi-circular integrated templates at both ends of the I-beam, enabling the beam to roll. Production units can use manpower or a small winch to drive the beam to roll 180°, making the casting operation more convenient and flexible.

[0023] Specifically, the locking assembly includes a tapered tube, a locking nut, and a steel ball. The tapered tube is fixed on the base plate, and the outer surface of the tapered tube is threaded. The locking nut is threadedly connected to the tapered tube. The support column passes through the tapered tube and the locking nut. The steel ball is located in the gap between the support column and the tapered tube. A pressure ring is provided inside the locking nut, which presses down on the steel ball. After loosening the locking nut, the pressure ring does not apply pressure to the steel ball, allowing it to move freely in the gap between the support column and the tapered tube. At this point, the steel ball does not exert any restraint on the support column, which can then move freely within the tapered tube. This allows workers to easily adjust the position of the support column so that it can provide adequate support for the I-beam, ensuring that the middle web of the I-beam is horizontal. Once the support column is adjusted to the appropriate position, the worker tightens the locking nut. The pressure ring then presses the steel ball tightly into the wedge-shaped gap between the support column and the tapered tube, locking the support column in place. This wedge-shaped gap provides a self-locking capability between the steel ball and the support column. The greater the axial force on the support column, the stronger the locking effect of the steel ball.

[0024] Furthermore, the base plate is provided with guide posts, the surface of which is threaded and fitted with support nuts. The support beam is provided with guide holes, the guide posts are inserted into the guide holes, and the support beam rests on the support nuts. The height of the support beam can be adjusted by rotating the support nuts. Adjusting the height of the support beam can adjust the position of the tie-bar mesh within the I-beam. The support beam is used to temporarily support the tie-bar mesh, making it convenient for workers to weld the tie-bar mesh to the I-beam.

[0025] Furthermore, the substrate is provided with studs, and the outer surface of the composite template is provided with a tongue plate with connecting holes. The composite template is fixed to the substrate by the tongue plate and the studs.

[0026] Furthermore, in step 7, wooden strips are used to fill the rebar grooves of the composite formwork.

[0027] Beneficial effects: (1) The corrugated steel-concrete beam of the present invention adopts a corrugated web in the middle web, which enables the entire middle web to have out-of-plane buckling resistance, thereby improving the stiffness of the steel-concrete beam under the premise of basically unchanged steel consumption, making the steel-concrete beam more suitable for heavy industrial buildings. (2) The corrugated steel-concrete beam of the present invention is equipped with horizontal connecting bars in the tie steel mesh, which can meet the welding requirements of the tie steel mesh and adapt to the special shape of the corrugated web. (3) The production method of the corrugated steel-concrete beam of the present invention uses a semi-circular integrated template as the side template of the casting cavity, which can meet the casting requirements and enable the steel-concrete beam to have the ability to roll, making it convenient for the production unit to carry out double-sided casting and improving production efficiency. (4) The production method of the corrugated steel-concrete beam of the present invention uses a tapered tube, locking nut and steel ball to realize the translation and locking of the support column, ensuring that the steel-concrete beam can roll and control its own posture, and ensuring that the middle web of the I-beam accepts concrete casting in a horizontal posture. Attached Figure Description

[0028] Figure 1 This is a three-dimensional view of the corrugated steel-concrete beam of Example 1.

[0029] Figure 2 yes Figure 1 A 3D view of a central I-beam steel beam.

[0030] Figure 3 This is a three-dimensional view of the steel mesh tie in Example 1.

[0031] Figure 4 This is a construction status diagram of the corrugated steel-concrete beam in Example 1.

[0032] Figure 5 This is an exploded view of the pouring auxiliary tool in Example 1.

[0033] Figure 6 This is a diagram showing the state of the pouring auxiliary tools after installation in Example 1.

[0034] Figure 7 yes Figure 6 Side view.

[0035] Figure 8 yes Figure 7 AA cross-section view.

[0036] Figure 9 yes Figure 8 Enlarged view of A.

[0037] Figure 10 This is a production process diagram of the corrugated steel-concrete beam in Example 1 (Part 1).

[0038] Figure 11 This is a production process diagram of the corrugated steel-concrete beam in Example 1 (Part 2).

[0039] Figure 12 This is a production process diagram of the corrugated steel-concrete beam in Example 1 (Part 3).

[0040] Among them: 100, wing plate; 200, intermediate web plate; 210, wavy web plate; 220, straight web plate; 221, web plate hole; 300, tie bar mesh; 310, vertical tie bar; 320, horizontal anti-crack bar; 330, horizontal connecting bar; 400, structural column; 500, corbel; 600, casting auxiliary tool; 610, support component; 611, base plate; 611-1, fixing hole; 611-2, guide post; 611-3, stud; 611-4, tapered tube; 611-5, locking nut; 611-6, steel ball; 611-7, pressure bead ring; 612, support beam; 620, support column; 630, composite formwork; 631, wing plate groove; 632, rebar groove; 633, tongue plate. Detailed Implementation

[0041] The present invention will be further described in detail below with reference to specific embodiments. Example 1

[0042] like Figures 1 to 4 As shown, the corrugated steel-concrete beam suitable for heavy industrial buildings in this embodiment includes a flange 100, a central web 200, and a reinforcing steel mesh 300.

[0043] like Figure 2As shown, the intermediate web 200 includes a corrugated web 210 and a straight web 220 welded to both ends of the corrugated web 210. The straight web 220 has web holes 221 for node connections. The intermediate web 200 connects two parallel flanges 100 to form an I-beam. A tie-bar mesh 300 is fixed between the flanges 100. A tie-bar mesh 300 is provided on each side of the intermediate web 200. Concrete is poured on both sides of the intermediate web 200. For easy observation, Figure 1 Concrete is not shown.

[0044] like Figure 3 As shown, the tie bar mesh 300 includes straight vertical tie bars 310, horizontal crack-resistant bars 320 and horizontal connecting bars 330. All vertical tie bars 310 are parallel to each other and welded to the horizontal crack-resistant bars 320. The density of the arrangement of the vertical tie bars 310 is determined according to the needs. Two horizontal connecting bars 330 are welded to both ends of the vertical tie bars 310 respectively. The tie bar mesh 300 is welded to the flange 100 through the horizontal connecting bars 330.

[0045] In this embodiment, the corrugated web 210 and the straight web 220 are welded together by full penetration. The thickness of the corrugated web 210 is 2-6 mm, the wave height of the corrugated web 210 is ±20 mm, the wave pitch is 155 mm, and the length of the straight web 220 is not less than one beam height.

[0046] The state of the corrugated plate after concrete pouring in this embodiment is as follows: Figure 4 As shown, the concrete poured on both sides of the intermediate web 200 should not exceed the web hole 221 on the straight web 220; during construction, the precast corrugated steel-concrete beam is hoisted to the designated height, and the two ends of the corrugated steel-concrete beam are aligned with the brackets 500 reserved on the structural column 400. Then, high-strength bolts and steel plates are used to connect the corrugated steel-concrete beam to the brackets 500, and finally, concrete is poured in the connection area.

[0047] In this embodiment, the corrugated steel-concrete beams are prefabricated in the factory. During the production process, it is necessary to use, for example... Figure 5 The pouring auxiliary tool 600 shown includes a support assembly 610, a support column 620, and a composite template 630. The support assembly 610 includes a base plate 611 and a support beam 612. The base plate 611 is provided with a locking assembly, fixing holes 611-1, guide posts 611-2, and studs 611-3, as shown. Figure 8 and Figure 9As shown, the locking assembly includes a tapered tube 611-4, a locking nut 611-5, and a steel ball 611-6. The tapered tube 611-4 is fixed to the base plate 611, and its outer surface is threaded. The locking nut 611-5 is threadedly connected to the tapered tube 611-4. A support post 620 passes through the tapered tube 611-4 and the locking nut 611-5. The steel ball 611-6 is located in the gap between the support post 620 and the tapered tube 611-4. A pressure ring 611-7 is provided inside the locking nut 611-5, which presses down on the steel ball 611-6. After the locking nut 611-5 is loosened, the pressure ring 611-7 does not apply pressure to the steel ball 611-6, allowing the steel ball 611-6 to remain in the gap between the support post 620 and the tapered tube 611-4. The steel ball 611-6 moves freely, and at this point, it does not constrain the support column 620. The support column 620 can move freely within the tapered tube 611-4, allowing workers to easily adjust its position so that it can provide reasonable support for the I-beam and ensure that the middle web 200 of the I-beam is horizontal. Once the support column 620 is adjusted to the appropriate position, the worker tightens the locking nut 611-5, and the pressure ring 611-7 presses the steel ball 611-6 tightly into the wedge-shaped gap between the support column 620 and the tapered tube 611-4, locking the support column 620. This wedge-shaped gap gives the steel ball 611-6 and the support column 620 a self-locking capability. The greater the axial force on the support column 620, the stronger the locking effect of the steel ball 611-6 on the support column 620. The guide post 611-2 has threads on its surface and is fitted with a support nut. The support beam 612 has guide holes. The guide post 611-2 is inserted into the guide holes, and the support beam 612 rests on the support nut. The height of the support beam 612 can be adjusted by rotating the support nut. The composite template 630 is semi-circular. The straight edge of the composite template 630 has two wing plate grooves 631 aligned with the wing plate 100 and multiple steel bar grooves 632 aligned with the horizontal anti-crack reinforcement 320 and the horizontal connecting reinforcement 330. The outer surface of the composite template 630 has a tongue plate 633 with connecting holes. The composite template 630 is fixed to the base plate 611 by the tongue plate 633 and the stud 611-3.

[0048] The production steps of the corrugated steel-concrete beam in this embodiment include:

[0049] Step 1: As Figure 2 As shown, straight web plates 220 are welded to both ends of the corrugated web plate 210 to form an intermediate web plate 200, and the intermediate web plate 200 is welded to the flange plate 100 to form an I-shaped steel beam.

[0050] Step 2: Processing as follows Figure 5 The pouring auxiliary tool 600 shown;

[0051] Step 3: As Figure 10As shown, the support assembly 610 is fixed to the web hole 221 of the straight web 220 through the fixing hole 611-1 and bolts. Support assemblies 610 are provided on both sides of each straight web 220. The wing plate groove 631 of the composite template 630 is inserted into the wing plate 100, and the composite template 630 is fixed to the base plate 611. For easier observation, Figure 10 The bolt inside the fixing hole 611-1 is not shown.

[0052] Step 4: As Figure 3 As shown, vertical tie bars 310, horizontal crack-resistant bars 320, and horizontal connecting bars 330 are welded to form a tie steel mesh 300; steps 1 to 2020 are shown in the figure. Figure 4 Completed within the steel structure fabrication workshop;

[0053] Step 5: [The following text appears to be a separate, unrelated section:] ... Figure 10 The processed and assembled I-beams and pouring auxiliary tools 600 are transported to the pouring site. The integrated formwork 630, located under the I-beams, supports the I-beams at both ends. The support columns 620 further support the I-beams to ensure that the straight webs 220 of the I-beams remain horizontal.

[0054] Step 6: As Figure 11 As shown, dismantle the upper-level integrated formwork 630 on the I-beam, and then... Figure 12 As shown, the tie steel mesh 300 is placed on the support beam 612 of the support assembly 610, and then the worker welds the horizontal connecting bar 330 of the tie steel mesh 300 to the flange 100.

[0055] Step 7: As Figure 6 and Figure 7 As shown, the disassembled integrated formwork 630 is reinserted, and the integrated formwork 630 is reconnected and fixed to the base plate 611. The integrated formwork 630 and the wing plate 100 form an upward-facing pouring cavity, and the reinforcing mesh 300 is located inside the pouring cavity; as shown. Figure 8 As shown, the composite formwork 630 at this time also has some steel bar grooves 632 that may cause concrete leakage. Wooden strips should be used to fill the steel bar grooves 632 of the composite formwork 630.

[0056] Step 8: Pour concrete into the casting cavity;

[0057] Step 9: After the poured concrete has solidified and reached 70% of its design strength, loosen the screws as follows: Figure 8 and Figure 9As shown, the locking nut 611-5 and the pressure ring 611-7 do not apply pressure to the steel ball 611-6. The steel ball 611-6 can move freely in the gap between the support column 620 and the tapered tube 611-4. At this time, the steel ball 611-6 does not exert any constraint on the support column 620, and the support column 620 can move freely within the tapered tube 611-4. Without the constraint of the support column 620, as... Figure 6 The reinforced concrete beam can roll freely; workers manually or using a small mobile winch push the beam to roll so that the surface of the intermediate web 200 without poured concrete faces upwards; after the intermediate web 200 is adjusted to a horizontal position, adjustments are made as follows: Figure 8 and Figure 9 The support column 620 shown touches the ground and the locking nut 611-5 is tightened;

[0058] Step 10: Repeat steps 6-8 to pour concrete on the other side of the intermediate web 200.

[0059] Step 11: After the concrete has solidified, disassemble the pouring auxiliary tool 600.

[0060] Although embodiments of the present invention have been described in the specification, these embodiments are merely illustrative and should not be construed as limiting the scope of protection of the present invention. Various omissions, substitutions, and modifications made without departing from the spirit of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for producing corrugated steel-concrete composite beams suitable for heavy industrial buildings, characterized in that: The corrugated steel-concrete beam suitable for heavy industrial buildings includes flanges, a central web, and a reinforcing steel mesh. The intermediate web includes a corrugated web and a straight web welded to both ends of the corrugated web, and the straight web is provided with web holes for node connection. The intermediate web plate connects two parallel flanges to form an I-beam. The tie steel mesh is fixed between the flanges. A tie steel mesh is set on each side of the intermediate web plate. Concrete is poured on both sides of the intermediate web plate. The tie reinforcement mesh includes straight vertical tie bars, horizontal crack-resistant bars and horizontal connecting bars. All vertical tie bars are parallel to each other and welded to the horizontal crack-resistant bars. Two horizontal connecting bars are welded to both ends of the vertical tie bars respectively. The tie reinforcement mesh is welded to the flange through the horizontal connecting bars. The production method of the corrugated steel-concrete beams suitable for heavy industrial buildings includes the following steps: Step 1: Weld straight web plates to both ends of the corrugated web plate to form the intermediate web plate, and weld the intermediate web plate to the flange plate to form an I-beam. Step 2: Processing the pouring auxiliary tools, which include a support assembly, a support column, and a composite template. The support assembly includes a base plate and a support beam. The base plate is provided with a locking assembly and fixing holes. The support column is installed in the locking assembly, and the support beam is installed on the base plate. The composite template is semi-circular. The straight edge of the composite template is provided with two wing plate grooves aligned with the wing plate and multiple rebar grooves aligned with the horizontal anti-crack bars and horizontal connecting bars. Step 3: Fix the support components to the web holes of the flat web through fixing holes and bolts. A support component is set on both sides of each flat web. Insert the wing plate groove of the composite template into the wing plate and fix the composite template to the base plate. Step 4: Weld vertical tie bars, horizontal crack-resistant bars, and horizontal connecting bars to form a tie bar mesh; Step 5: Transport the processed and assembled I-beams and pouring auxiliary tools to the pouring site. The integrated formwork at the bottom of the I-beams supports the I-beams at both ends. The support columns further support the I-beams to ensure that the straight web of the I-beams remains horizontal. Step 6: Dismantle the upper integrated formwork on the I-beam, place the tie steel mesh on the support beam of the support component, and then weld the horizontal connecting bars of the tie steel mesh to the flange. Step 7: Reinsert the removed formwork. The formwork and the flange form together form an upward-facing pouring cavity, with the reinforcing mesh inside the cavity. Step 8: Pour concrete into the casting cavity; Step 9: After the poured concrete has solidified and reached 70% of its design strength, remove the support columns; then push the steel-concrete beam to roll so that the surface of the middle web that has not been poured with concrete faces upward; then reinstall the support columns for auxiliary support. Step 10: Repeat steps 6-8 to pour concrete on the other side of the intermediate web. Step 11: After the concrete has solidified, disassemble the pouring aids.

2. The method for producing corrugated steel-concrete composite beams suitable for heavy industrial buildings according to claim 1, characterized in that: The wavy web and the straight web are welded together by full penetration welding.

3. The method for producing corrugated steel-concrete composite beams suitable for heavy industrial buildings according to claim 2, characterized in that: The thickness of the wavy web is 2-6 mm.

4. The method for producing corrugated steel-concrete composite beams suitable for heavy industrial buildings according to claim 3, characterized in that: The length of the straight web is not less than one beam height.

5. The method for producing corrugated steel-concrete composite beams suitable for heavy industrial buildings according to claim 1, characterized in that: The locking assembly includes a tapered tube, a locking nut, and a steel ball. The tapered tube is fixed on the base plate, and the outer surface of the tapered tube is threaded. The locking nut is threadedly connected to the tapered tube. The support column passes through the tapered tube and the locking nut. The steel ball is located in the gap between the support column and the tapered tube. A pressure ring is provided inside the locking nut, which presses down on the steel ball.

6. The method for producing corrugated steel-concrete composite beams suitable for heavy industrial buildings according to claim 5, characterized in that: The substrate is provided with guide posts, the surface of the guide posts is provided with threads and a support nut is installed, the support beam is provided with guide holes, the guide posts are inserted into the guide holes, and the support beam rests on the support nut.

7. The method for producing corrugated steel-concrete composite beams suitable for heavy industrial buildings according to claim 6, characterized in that: The substrate is provided with studs, and the outer surface of the composite template is provided with a tongue plate with connecting holes. The composite template is fixed to the substrate by the tongue plate and the studs.

8. The method for producing corrugated steel-concrete composite beams suitable for heavy industrial buildings according to claim 7, characterized in that: In step 7, wooden strips are used to fill the rebar grooves of the composite formwork.

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