Modularized fully-fabricated steel-concrete combined open-web sandwich plate structure

Abstract

The invention relates to the technical field of sandwich plates, in particular to a modularized full-assembly type steel-concrete combined hollow sandwich plate structure. Aiming at the problems of low assembly degree and insufficient modeling adaptability of the traditional steel-concrete combined open-web sandwich plate, the invention provides the following technical scheme: the steel-concrete combined open-web sandwich plate comprises at least one assembly module, and the assembly module comprises a concrete layer and at least three groups of assembly units; each assembly unit comprises an upper rib and a lower rib parallel to the upper rib, two sets of shear keys are fixedly connected between the upper rib and the lower rib, and the shear keys are located at the two ends of the upper rib and the two ends of the lower rib; and the plurality of groups of connecting holes are formed in the upper rib, the lower rib and the shear keys. The modeling adaptability is enhanced, the construction efficiency and precision are improved, and the requirements for high prefabrication rate, wet-free operation and adaptation to complex modeling are met.

Description

Technical Field

[0001] The present invention relates to the technical field of sandwich panels, and in particular to a modular fully assembled steel-concrete composite hollow sandwich panel structure. Background Art

[0002] As a structural form that combines the high strength of steel and the good durability of concrete, steel-concrete composite hollow sandwich panels have been widely used in large-span construction projects (such as large venues, convention and exhibition centers) and urban overpass projects due to their excellent three-dimensional spatial stress performance, effectively meeting the needs of modern architecture for large spans, lightweight and economy.

[0003] However, traditional structures generally employ a construction model of "prefabricated steel frame + cast-in-place concrete panels" or "partially prefabricated panels + post-cast joints," heavily relying on on-site wet work. To ensure synergistic load-bearing between steel and concrete, post-cast joints are required at the structural joints. This not only hinders further increases in the prefabrication rate of the structure, but also significantly prolongs the overall construction period due to the curing cycle of the post-cast joint concrete, contradicting the modern construction project's requirements for efficient construction and rapid delivery.

[0004] Moreover, in actual engineering, with the continuous innovation of architectural design concepts, higher requirements are placed on the complexity of structural modeling (such as curved surfaces and special-shaped contours). However, traditional construction processes are difficult to accurately control the molding quality of curved structures and cannot meet the precision requirements of complex models. At the same time, when discrete prefabricated components are used for assembly, a large number of special-shaped nodes will be formed at special locations such as structural boundaries and arches. The installation tolerance control of these nodes is extremely difficult, which not only increases the complexity of construction, but also seriously affects construction efficiency. In view of this, the present invention proposes a modular fully assembled steel-concrete composite hollow sandwich plate structure. Summary of the Invention

[0005] The purpose of the present invention is to address the problems of low assembly degree and insufficient shape adaptability of traditional steel-concrete composite hollow sandwich panels in the background technology, and to propose a modular fully assembled steel-concrete composite hollow sandwich panel structure.

[0006] The technical solution of the present invention is: a modular fully assembled steel-concrete composite hollow sandwich plate structure, comprising at least one assembly module, the assembly module comprising a concrete layer and at least three groups of assembly units, each of the assembly units comprising an upper rib and a lower rib arranged parallel thereto, two groups of shear keys fixedly connected between the upper rib and the lower rib, the shear keys being located at both ends of the upper rib and the lower rib; and multiple groups of connection holes being opened on the upper rib, the lower rib and the shear keys.

[0007] Optionally, the assembly module is a rectangular module, which is a rectangular structure composed of four assembly units, and multiple rectangular modules are spliced ​​together to form a rectangular plane.

[0008] Optionally, the assembly module is a regular hexagonal module, which is a regular hexagonal structure formed by six assembly units, and multiple regular hexagonal modules are spliced ​​to form a three-dimensional symmetrical honeycomb plane; the regular hexagonal module is cut along the diagonal to form a 1 / 2 regular hexagonal module, and the regular hexagonal module is divided into six equal parts to form a 1 / 6 regular hexagonal module.

[0009] Optionally, a plurality of the regular hexagonal modules are combined with a plurality of 1 / 2 regular hexagonal modules to form an equiangular scalene hexagonal plane.

[0010] Optionally, a plurality of the regular hexagonal modules are combined with a plurality of 1 / 2 regular hexagonal modules and a plurality of 1 / 6 regular hexagonal modules to form a regular triangle plane.

[0011] Optionally, in the rectangular module, the length of the upper rib in one group of oppositely arranged assembly units is greater than the length of the lower rib, forming a one-way arched rectangular module, and multiple one-way arched rectangular modules are spliced ​​to form a one-way arched surface.

[0012] Optionally, the upper ribs and the lower ribs are both made of angle steel or C-shaped steel, and the shear keys are made of angle steel or steel plates.

[0013] Optionally, it also includes multiple groups of shear rivets fixedly connected to the side of the upper rib away from the lower rib, and a steel mesh is set at the position of the multiple groups of shear rivets. The steel mesh uses multiple groups of staggered steel bars. At the same time, the staggered parts of the steel bars and the contact positions between the steel bars and the shear rivets are all tied with wire. The concrete layer is poured at the steel mesh position, and the effective anchoring depth of the shear rivets penetrating into the concrete layer is ≥50mm.

[0014] Optionally, the middle positions of the multiple groups of shear keys are fixedly connected with stiffening ribs, and the stiffening ribs are perpendicular to the shear keys.

[0015] Optionally, a solid web is fixedly connected between the upper rib and the lower rib in the support area, and both ends of the solid web are fixedly connected to shear keys.

[0016] In summary, this application includes at least one of the following beneficial technical effects:

[0017] The present invention adopts a modular design. The upper ribs, lower ribs, shear keys and other components are prefabricated and welded in the factory to form the module body. The concrete layer is also poured and cured in the factory. The only fastening on site is through connection holes and bolts. There is no need for on-site wet work and post-casting strips, which greatly improves the prefabrication rate.

[0018] Furthermore, shear rivets are used to form a reliable mechanical anchor with the concrete layer, and high-strength bolts are used to achieve a fully dry connection between modules, which can immediately bear loads, effectively shortening the construction period and meeting the high requirements of "fully dry connection and immediate load bearing";

[0019] Furthermore, through a variety of modular forms, a variety of plane shapes can be formed to adapt to conventional areas, straight boundaries and sharp-angle boundaries. The modules are prefabricated in the factory to ensure accuracy, and there are fewer special-shaped nodes during on-site assembly, making installation tolerances easy to control, thereby improving adaptability to complex shapes and construction efficiency.

[0020] In summary, the present invention enhances the adaptability of shapes and improves construction efficiency and precision, meeting the requirements of high prefabrication rate, wet-free operation and adaptability to complex shapes. BRIEF DESCRIPTION OF THE DRAWINGS

[0021] Figure 1 It is a structural schematic diagram of a modular fully assembled steel-concrete composite hollow sandwich plate structure;

[0022] Figure 2 It is a schematic diagram of a rectangular module structure with a solid web;

[0023] Figure 3 It is a schematic diagram of rectangular structure assembly;

[0024] Figure 4 It is a schematic diagram of the hexagonal module structure;

[0025] Figure 5 It is a schematic diagram of the hexagonal module structure with solid webs;

[0026] Figure 6 This is a schematic diagram of the 1 / 2 hexagonal module structure;

[0027] Figure 7 This is a schematic diagram of the 1 / 6 hexagonal module structure;

[0028] Figure 8 It is a schematic diagram of the hexagonal structure assembly;

[0029] Figure 9 It is a schematic diagram of the assembly of special-shaped structures;

[0030] Figure 10 This is a schematic diagram of a one-way arched rectangular module structure;

[0031] Figure 11 Schematic diagram of the arch structure assembly;

[0032] Reference numerals:

[0033] 1. Upper rib; 2. Lower rib; 3. Shear key; 4. Connection hole; 5. Shear rivet; 6. Steel mesh; 7. Concrete layer; 8. Stiffening rib; 9. Solid web. DETAILED DESCRIPTION

[0034] The technical solution of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only part of the embodiments of the present invention, rather than all the embodiments.

[0035] The components of the embodiments of the present invention generally described and shown in the drawings herein may be arranged and designed in a variety of different configurations. Therefore, the following detailed description of the embodiments of the invention provided in the drawings is not intended to limit the scope of the claimed invention, but merely represents selected embodiments of the invention.

[0036] Based on the embodiments of the present invention, all other embodiments obtained by ordinary technicians in this field without making any creative work shall fall within the scope of protection of the present invention.

[0037] In the description of the present invention, it should be noted that the terms "center," "upper," "lower," "left," "right," "vertical," "horizontal," "inner," and "outer," etc., indicating orientations or positional relationships, are based on the orientations or positional relationships shown in the accompanying drawings and are intended solely to facilitate and simplify the description of the present invention. They are not intended to indicate or imply that the devices or components referred to must have, be constructed, or operate in a specific orientation, and therefore should not be construed as limitations on the present invention. Furthermore, the terms "first," "second," and "third" are used for descriptive purposes only and should not be construed as indicating or implying relative importance.

[0038] In the description of the present invention, it should be noted that, unless otherwise expressly specified or limited, the terms "mounted," "connected," and "connected" should be understood in a broad sense. For example, they may refer to fixed, detachable, or integral connections; mechanical or electrical connections; direct or indirect connections through an intermediate medium; and internal communication between two components. Those skilled in the art will understand the specific meanings of the above terms in the present invention based on the specific circumstances.

[0039] Example 1

[0040] like Figures 1 to 3 As shown, the present invention proposes a modular, fully assembled steel-concrete composite hollow sandwich panel structure, comprising at least one assembly module, multiple of which can be assembled into a specific shape. The assembly module includes a concrete layer 7 and at least three sets of assembly units. Each assembly unit includes an upper rib 1 and a lower rib 2 arranged parallel thereto. Both the upper rib 1 and the lower rib 2 are made of angle steel or C-shaped steel.

[0041] In this embodiment, the assembly module is a rectangular module. The rectangular module is a rectangular structure composed of four assembly units. Multiple rectangular modules are spliced ​​together to form a rectangular plane. Two sets of shear keys 3 are fixedly connected between the upper rib 1 and the lower rib 2. The shear keys 3 are located at both ends of the upper rib 1 and the lower rib 2. The shear keys 3 are perpendicular to the upper rib 1 and the lower rib 2. The shear keys 3 are made of angle steel or steel plate to transmit interlayer shear force. The upper rib 1, the lower rib 2, and the shear keys 3 are welded to form the main body of the rectangular module. After the multiple rectangular modules are spliced ​​together, the upper rib 1 and the lower rib 2 are arranged horizontally along the four sides of the rectangular module to form a grid-like load-bearing base.

[0042] Furthermore, the sandwich panel structure further includes a plurality of connection holes 4 provided on the upper rib 1, the lower rib 2 and the shear key 3. The plurality of connection holes 4 are distributed in an equidistant array to facilitate the connection of two adjacent modules through fasteners.

[0043] Specifically, the sandwich panel structure includes multiple sets of shear rivets 5 fixedly connected to the side of the upper rib 1 away from the lower rib 2. The multiple sets of shear rivets 5 are arranged in an array with equal intervals along the edge of the upper rib 1. The shear rivets 5 are cylindrical head welded in a straight or plum blossom pattern and fixed to the side of the upper rib 1 away from the lower rib 2 by full penetration welding. The effective anchoring depth of the shear rivets 5 in the concrete layer 7 is ≥50 mm, forming a mechanical anchoring connection between the concrete layer 7 and the upper rib 1.

[0044] Furthermore, the sandwich panel structure includes a steel mesh 6 positioned at the locations of the multiple sets of shear rivets 5. The concrete layer 7 is poured at the locations of the steel mesh 6. The steel mesh 6 uses multiple sets of staggered steel bars. Wire is used to tie the steel bars at the intersections and at the points where the steel bars contact the shear rivets 5. The wire ties secure the position of the steel mesh 6 and do not affect the position of the steel mesh 6 during the pouring of the concrete layer 7. After the concrete layer 7 solidifies, the steel mesh 6 increases the strength of the concrete layer 7.

[0045] Furthermore, stiffening ribs 8 are welded in the middle of multiple groups of shear keys 3. The stiffening ribs 8 are perpendicular to the shear keys 3. The stiffening ribs 8 are made of steel plates and are vertically welded to the middle of the shear keys 3 to enhance the local stiffness of the shear keys 3.

[0046] Finally, a solid web 9 is fixedly connected between the upper rib 1 and the lower rib 2 in the support area, and both ends of the solid web 9 are fixedly connected to the shear key 3. The solid web 9 is connected to the upper rib 1, lower rib 2, and shear key 3 via double-sided fillet welds, forming a rigid node area to resist shear stress concentration at the support.

[0047] In this embodiment, when prefabricating the rectangular module, a special jig is first used to position and weld the upper rib 1, lower rib 2, shear key 3, and stiffening rib 8. The weld quality meets the first-level standard of GB50205-2020. After welding, a connection hole 4 is opened, and the welding position of the shear rivet 5 is marked on the side of the upper rib 1 away from the lower rib 2. An automated rivet welding machine is used to complete the welding of the shear rivet 5 to ensure a reliable interface connection. When applied to large-span scenarios with a span of ≥7.5m (see Figure 2 ), a solid web 9 is added where the upper and lower ribs 1 and 2 connect to the supports. This web 9 extends from the top of the lower rib 2 to the bottom of the upper rib 1 and is connected to the upper and lower ribs 1, 2, and shear keys 3 via double-sided fillet welds, forming a rigid joint area to resist shear stress concentration at the supports. Next, the forming mold for the concrete layer 7 is set up, and the rebar is tied to form a steel mesh 6. The concrete layer 7 is poured and cured to 100% of the design strength. Finally, the connection holes 4 are precision-checked, and the concrete is packaged, numbered, and transported to the construction site.

[0048] During on-site assembly, adjacent modules are butted together through connection holes 4 on upper rib 1, lower rib 2, and shear key 3. High-strength bolts are used to secure the modules in the order of "lower rib 2 → shear key 3 → upper rib 1." After assembly, pressure grouting is performed using a specialized sealant, such as micro-expansion high-strength mortar. A waterproof coating is then applied to the surface to achieve a waterproof seal and a smooth appearance.

[0049] Example 2

[0050] like Figures 4 to 9 As shown, based on the first embodiment, in this embodiment, the assembly module is a regular hexagonal module, and the regular hexagonal module is a regular hexagonal structure formed by six assembly units. Multiple regular hexagonal modules are spliced ​​to form a three-dimensional symmetrical honeycomb plane. The 1 / 2 regular hexagonal module formed by cutting the regular hexagonal module along the diagonal line (such as Figure 6 As shown), the 1 / 6 regular hexagonal module formed by dividing the regular hexagonal module into six equal parts (as shown Figure 7 The upper rib 1, lower rib 2, and shear key 3 are welded to form a regular hexagonal module body. The upper rib 1 and lower rib 2 in the regular hexagonal module are arranged in a regular hexagonal shape. After multiple regular hexagonal modules are spliced ​​together, the upper rib 1 and lower rib 2 are arranged horizontally along the four sides of the regular hexagonal module to form a regular hexagonal plane grid load-bearing base.

[0051] Furthermore, multiple regular hexagonal modules are combined with multiple 1 / 2 regular hexagonal modules to form an equiangular scalene hexagonal plane (such as Figure 8 Multiple regular hexagonal modules are combined with multiple 1 / 2 regular hexagonal modules and multiple 1 / 6 regular hexagonal modules to form a regular triangle plane (as shown). Figure 9 shown).

[0052] In this embodiment, when prefabricating the regular hexagonal module, the 1 / 2 regular hexagonal module and the 1 / 6 regular hexagonal module, a special jig is first used to position and weld the upper rib 1, the lower rib 2, the shear key 3 and the stiffening rib 8. The weld quality meets the first-level standard of GB50205-2020. After welding, a three-dimensional coordinate measuring machine is used to detect the position deviation of the intersection of each rib ≤ 0.5mm. Then, a connecting hole 4 is opened, and the welding position of the shear rivet 5 is marked on the side of the upper rib 1 away from the lower rib 2. An automatic rivet welding machine is used to complete the welding of the shear rivet 5 to ensure reliable interface connection. When applied to large-span scenarios (please refer to Figure 5 ), a solid web 9 is added where the upper and lower ribs 1 and 2 connect to the supports. This web 9 extends from the top of the lower rib 2 to the bottom of the upper rib 1 and is connected to the upper and lower ribs 1, 2, and shear keys 3 via double-sided fillet welds, forming a rigid joint area to resist shear stress concentration at the supports. Next, the forming mold for the concrete layer 7 is set up, and the rebar is tied to form a steel mesh 6. The concrete layer 7 is poured and cured to 100% of the design strength. Finally, the connection holes 4 are precision-checked, and the concrete is packaged, numbered, and transported to the construction site.

[0053] During on-site assembly, adjacent modules are butted together using connection holes 4 provided on the upper rib 1, lower rib 2, and shear key 3. High-strength bolts are used to secure the modules in the order "lower rib 2 → shear key 3 → upper rib 1." Regular hexagonal modules, 1 / 2 regular hexagonal modules, and 1 / 6 regular hexagonal modules are joined at a 120° angle to form three-dimensional symmetrical honeycomb, regular triangle, and scalene hexagonal planes, respectively suitable for conventional area splicing, straight-line boundary transitions, and acute-angle boundary adaptation. After assembly, pressure grouting is performed using a specialized caulking agent, such as micro-expansion high-strength mortar, and the surface is coated with a waterproof coating to achieve a waterproof seal and a smooth appearance.

[0054] Example 3

[0055] like Figure 10 and Figure 11 As shown, based on the above-mentioned embodiment 1, in the rectangular module, the length of the upper rib 1 in one group of oppositely arranged assembly units is greater than the length of the lower rib 2, forming a one-way arched rectangular module, and multiple one-way arched rectangular modules are spliced ​​to form a one-way arched surface. The upper rib 1, the lower rib 2 and the shear key 3 are welded to form the main body of the one-way arched rectangular module. In the one-way arched rectangular module, the length of the upper rib 1 is equal to the length of the lower rib 2, and the upper rib 1 can be formed into an arc shape through CNC bending. At the same time, the width of the upper rib 1 is greater than the width of the lower rib 2. The shear key 3 is vertically welded between the upper rib 1 and the lower rib 2 using a steel plate. The shear key 3 is perpendicular to the tangent plane of the arched surface. The shear key 3 forms an angle of 90° to 105° with the lower rib 2, transmitting the interlayer shear force and supporting the arch shape. After multiple one-way arched rectangular modules are spliced, the upper rib 1 and the lower rib 2 are horizontally arranged along the four sides of the one-way arched rectangular module to form an arched grid force base.

[0056] In this embodiment, when the one-way arched rectangular module is prefabricated, a special jig is first used to position and weld the upper rib 1, the lower rib 2, the shear key 3 and the stiffening rib 8. The rib 1 in the arching direction is formed by CNC bending or directly spliced ​​with a straight profile, and the weld quality meets the GB50205-2020 Level 1 standard. After welding is completed, a connection hole 4 is opened, and the welding position of the shear rivet 5 is marked on the side of the upper rib 1 away from the lower rib 2. An automatic rivet welding machine is used to complete the welding of the shear rivet 5 to ensure a reliable interface connection. When applied to a large-span scenario with a span of ≥7.5m, a solid web 9 is required to be added at the connection position between the upper rib 1 and the lower rib 2 and the support. The height of the solid web 9 extends from the lower rib 2 to the bottom of the upper rib 1, and is connected to the upper rib 1, the lower rib 2 and the shear key 3 by double-sided fillet welding to form a rigid node area to resist the shear stress concentration at the support. After that, the forming mold of the concrete layer 7 is supported and the steel bars are tied to form the steel mesh 6. The concrete layer 7 is poured and cured to 100% of the design strength. Finally, the connection holes 4 are precision-checked, and the parts are numbered, packed, and transported to the construction site.

[0057] During on-site assembly, adjacent modules are butted together using connection holes 4 provided on the upper rib 1, lower rib 2, and shear key 3. High-strength bolts are used to secure the modules in the order of "lower rib 2 → shear key 3 → upper rib 1." Calibration of the arch height is performed using a total station or laser measurement equipment to ensure that the curved surface meets design requirements after assembly. After assembly, pressure grouting is performed using a specialized caulking agent, such as micro-expansive high-strength mortar. A waterproof coating is then applied to the surface to achieve a waterproof seal and a smooth appearance.

[0058] The above specific embodiments are merely several optional embodiments of the present invention. Based on the technical solutions of the present invention and the relevant inspirations of the above embodiments, those skilled in the art may make various alternative improvements and combinations to the above specific embodiments.

Claims

1. A modular fully assembled steel-concrete composite hollow sandwich plate structure, characterized in that: include: At least one assembly module, the assembly module comprising a concrete layer (7) and at least three groups of assembly units, each of the assembly units comprising an upper rib (1) and a lower rib (2) arranged parallel thereto, two groups of shear keys (3) being fixedly connected between the upper rib (1) and the lower rib (2), the shear keys (3) being located at both ends of the upper rib (1) and the lower rib (2); Multiple groups of connection holes (4) are provided on the upper rib (1), the lower rib (2) and the shear key (3).

2. A modular fully assembled steel-concrete composite hollow sandwich plate structure according to claim 1, characterized in that: The assembly module is a rectangular module, which is a rectangular structure composed of four assembly units. Multiple rectangular modules are spliced ​​together to form a rectangular plane.

3. A modular fully assembled steel-concrete composite hollow sandwich plate structure according to claim 1, characterized in that: The assembly module is a regular hexagonal module, which is a regular hexagonal structure formed by six assembly units. Multiple regular hexagonal modules are spliced ​​to form a three-dimensional symmetrical honeycomb plane; the regular hexagonal module is cut along the diagonal to form a 1 / 2 regular hexagonal module, and the regular hexagonal module is divided into six equal parts to form a 1 / 6 regular hexagonal module.

4. A modular fully assembled steel-concrete composite hollow sandwich plate structure according to claim 3, characterized in that: A plurality of the regular hexagonal modules are combined with a plurality of 1 / 2 regular hexagonal modules to form an equiangular scalene hexagonal plane.

5. The modular fully assembled steel-concrete composite hollow sandwich plate structure according to claim 3, characterized in that: A plurality of the regular hexagonal modules are combined with a plurality of 1 / 2 regular hexagonal modules and a plurality of 1 / 6 regular hexagonal modules to form a regular triangle plane.

6. The modular fully assembled steel-concrete composite hollow sandwich plate structure according to claim 2, characterized in that: In the rectangular module, the length of the upper rib (1) in one group of oppositely arranged assembly units is greater than the length of the lower rib (2), forming a one-way arched rectangular module, and multiple one-way arched rectangular modules are spliced ​​to form a one-way arched surface.

7. A modular fully assembled steel-concrete composite hollow sandwich plate structure according to any one of claims 1 to 6, characterized in that: The upper rib (1) and the lower rib (2) are both made of angle steel or C-shaped steel, and the shear key (3) is made of angle steel or steel plate.

8. The modular fully assembled steel-concrete composite hollow sandwich plate structure according to claim 7, characterized in that: The invention also includes a plurality of groups of shear rivets (5) fixedly connected to the side of the upper rib (1) away from the lower rib (2), and a steel mesh (6) is provided at the positions of the plurality of groups of shear rivets (5). The steel mesh (6) uses a plurality of groups of staggered steel bars, and the staggered positions of the steel bars and the contact positions between the steel bars and the shear rivets (5) are all tied with iron wires. The concrete layer (7) is poured at the position of the steel mesh (6), and the effective anchoring depth of the shear rivets (5) deep into the concrete layer (7) is ≥50 mm.

9. The modular fully assembled steel-concrete composite hollow sandwich plate structure according to claim 8, characterized in that: The middle positions of the multiple groups of shear keys (3) are all fixedly connected with stiffening ribs (8), and the stiffening ribs (8) are perpendicular to the shear keys (3).

10. The modular fully assembled steel-concrete composite hollow sandwich plate structure according to claim 9, characterized in that: A solid web (9) is also fixedly connected between the upper rib (1) and the lower rib (2) in the support area, and both ends of the solid web (9) are fixedly connected to the shear keys (3).

Images