Factory prefabricated steel shell concrete combination section and construction method

Abstract

The factory prefabricated steel shell concrete combination section comprises an inner wall plate and an outer wall plate, an annular structure is formed between the inner wall plate and the outer wall plate, and transverse stiffening ribs and longitudinal stiffening ribs are arranged on the opposite sides of the annular structure of the inner wall plate and the outer wall plate. Concrete is poured in the annular structure of the inner wall plate to form an annular concrete section, two positioning shear keys are arranged on the top face and the bottom face of the annular concrete section, and two slurry passing holes are formed in each annular opening face. The inner wall plates and the outer wall plates of the steel shell section concrete are welded through bridge site ring opening steel structures, and ring opening concrete pouring is conducted between the steel shell section concrete. The optimal combination of a steel structure and a concrete structure is advantageously reflected, the problems that in the prior art, a steel shell concrete tower is complex in design, and the bridge site construction period is too long can be solved, and construction is convenient.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of bridge construction, in particular to a factory-precast steel shell concrete combined section and a construction method thereof. BACKGROUND

[0002] The steel shell concrete tower cooperates with the steel shell and the internal filled concrete, the steel shell provides tensile and shear capacity, the concrete bears the compressive load, significantly improves the overall bearing capacity and stiffness of the tower body, and is especially suitable for high-rise and large-span structures. The steel shell can be used as a permanent formwork, eliminating the traditional formwork setting process, and after the concrete is poured, it forms an integral whole with the steel shell, shortening the construction period, and the factory-precast steel shell section is assembled on site and poured with concrete simultaneously, which is suitable for complex construction environment. Compared with the all-steel structure, the steel shell concrete tower saves the amount of steel and reduces the cost, and the local damage can be quickly repaired by repairing the steel shell or grouting the concrete, and the maintenance cost in the whole life cycle is lower than that of the pure concrete structure.

[0003] When the steel shell section of the conventional steel shell concrete tower is precast in the factory, the steel shell is not poured with concrete, and the dense stiffening ribs and angle steels are arranged between the inner and outer walls of the steel shell to improve the overall rigidity and avoid deformation during hoisting; a large number of reinforcing bars are arranged to improve the concrete bonding force, and the concrete is poured after the steel shell section is hoisted and welded at the bridge site. The construction period of the scheme is relatively long, and the construction quality also has room for improvement. Therefore, a factory-precast steel shell concrete structure is designed, which not only improves the overall rigidity of the section by replacing the dense angle steels with concrete, but also greatly shortens the construction period at the bridge site. Therefore, the structure form and manufacturing method become a major problem to be solved. SUMMARY

[0004] The present application proposes a factory-precast steel shell concrete combined section and a construction method thereof, which more optimally combines steel structure and concrete structure, and can solve the technical problems of complex design of the steel shell concrete tower and long construction period at the bridge site in the prior art.

[0005] To achieve the above-mentioned purposes, the technical scheme of the present application is as follows: A construction method of a factory-precast steel shell concrete combined section, characterized in that it comprises the following steps: S1. Making a panel: positioning the panel on a flat bed jigsaw, and arranging horizontal stiffening ribs and vertical stiffening ribs on one side surface of the panel; S2. Steel shell segment: around the special tire frame positioning the panel to form a ring-shaped inner wall plate, the outer wall plate is positioned along the ring-shaped panel to form a ring-shaped outer wall plate, the inner wall plate and the outer wall plate are arranged with one side of the transverse stiffening rib and the vertical stiffening rib, the inner wall plate and the outer wall plate are equidistant, the welding and flaw detection of the fusion angle weld between the panels in the inner wall plate and the outer wall plate are completed in turn, the height of the inner wall plate is not more than 300mm lower than the height of the outer wall plate, a widened groove is formed in the inner wall plate as a bridge position wide embedded section along the ring direction; S3. Steel shell segment concrete: the steel shell segment made in step S2 is placed on the horizontal tire frame, the central axis of the steel shell segment is horizontal, the concrete pouring formwork is laid at both ends of the steel shell segment, the concrete pouring formwork is uniformly provided with a plurality of circular holes and shear key positioning grooves along the ring direction, anchor pipes are installed in the circular holes for fixing steel pipes, so that after pouring the ring-shaped concrete segment between the inner wall plate and the outer wall plate, the concrete reserved hole penetrating the upper and lower ring faces is formed in the ring-shaped concrete segment, and the recess for accommodating the shear key and the shear key are formed at both ends of the ring-shaped concrete segment; S4. Steel shell segment concrete segment pre-assembly: using vertical continuous matching pre-assembly, after pre-assembly is completed, matching parts and identification mark lines are installed; S5. Steel shell segment concrete segment bridge position hoisting and positioning: steel shell segment concrete hoisting and positioning is carried out, the preliminary rapid positioning of the steel shell segment concrete is carried out through the shear key position, the positioning accuracy is measured by using a total station, after the data is qualified, the matching parts are fixed, and the size of the identification mark line is rechecked to be consistent with the identification mark line in S4; S6. Steel shell segment concrete segment bridge position ring opening steel structure welding: a single butt groove is opened on the outer wall plate towards the outer side of the steel shell, a ceramic lining is pasted on the back of the inner wall plate close to the outer wall plate, butt fusion welding of the outer wall plate is carried out, after the outer wall plate is welded, a single butt groove is opened on the inner wall plate towards the center side of the steel shell, a steel lining is arranged on the back of the inner wall plate close to the outer wall plate, and butt fusion welding of the embedded section of the inner wall plate is carried out; S7, steel shell segment concrete segment bridge position ring opening concrete pouring: 2-3 steel shell segment concrete segments are used to pour the ring opening concrete through the reserved grouting hole.

[0006] The inner support in step 2 adopts a profile with a cross section not less than 60 mm, each panel of the inner wall plate is supported by a plurality of pairs of inner supports, the lower end of each pair of inner supports is anchored on a special jig frame, and the upper end of each pair of inner supports is separately anchored on two support points of the supported panel higher than the center of gravity of the inner wall plate, forming a spade support, and the support point one is arranged on the panel at a position not less than 500-800 mm away from the weld.

[0007] The panels of each face of the inner wall plate or the outer wall plate in step S1 are connected by a fusion angle weld, both of which adopt a single-sided welding double-sided forming welding process, and the welding deformation of the panel is controlled by a constraint tool, first, the vertical fusion angle weld of the inner wall plate is sequentially welded, and then the vertical fusion angle weld of the outer wall plate is sequentially welded.

[0008] The prefabricated steel shell concrete combined section is characterized in that it comprises a plurality of steel shell section concretes connected in the axial direction, each steel shell section concrete comprises an inner wall plate and an outer wall plate, the inner wall plate and the outer wall plate form an annular structure, the opposite sides of the inner wall plate and the outer wall plate are provided with transverse stiffening ribs and longitudinal stiffening ribs, the upper and lower sides of the inner wall plate are provided with wide patch sections along the circumferential direction, the annular structure is internally poured with concrete to form an annular concrete section, the top surface and the bottom surface of the annular concrete section are respectively provided with a plurality of grooves accommodating shear keys, positioning shear keys and grout holes along the circumferential direction at intervals, each steel shell section concrete is connected by mortise and tenon through the grooves and the positioning shear keys, the inner wall plates and the outer wall plates of each steel shell section concrete are welded by bridge ring steel structure, and annular concrete pouring is performed between each steel shell section concrete.

[0009] The height of the inner wall plate is 300 mm lower than the height of the outer wall plate.

[0010] The thickness of the annular structure is 8 mm.

[0011] The shear key has a length not less than 500 mm, a width not less than 300 mm, and a height not less than 500 mm.

[0012] The diameter of the grout hole is 200 mm.

[0013] The factory prefabricated steel shell concrete combined structure is adopted in the application, which more favorably reflects the optimal combination of the steel structure and the concrete structure, can improve the overall rigidity of the segment by replacing the dense angle steel with the concrete, and can effectively ensure the dense weld quality in the narrow space of the factory prefabricated steel shell concrete combined structure and improve the overall manufacturing precision of the factory prefabricated steel shell concrete combined structure. BRIEF DESCRIPTION OF DRAWINGS

[0014] Figure 1 is a three-dimensional schematic view of the factory prefabricated steel shell concrete combined segment in the application; Figure 2 is a three-dimensional view of the factory steel structure of the combined segment in the application; Figure 3 is a plan view of the factory steel structure of the combined segment in the application; Figure 4 is a three-dimensional view of the factory prefabricated concrete of the combined segment in the application; Figure 5 is a plan view of the factory prefabricated concrete of the combined segment in the application; Figure 6 is a sectional view of the factory prefabricated concrete of the combined segment in the application; Figure 7 is a three-dimensional view of the bridge site installation of the bridge site steel shell concrete combined structure in the application; Figure 8 is a schematic view of the installation sequence of the bridge site steel shell concrete combined structure in the application, and the arrow direction in the drawing indicates the welding direction of the welder. DETAILED DESCRIPTION

[0015] The technical solutions of the application will be described clearly and completely below in combination with the embodiments of the application. Obviously, the described embodiments are only some of the embodiments of the application, but not all the embodiments. Based on the embodiments in the application, all the other embodiments obtained by those skilled in the art without creative labor fall within the protection scope of the application.

[0016] As Figures 1-8As shown, a factory prefabricated steel shell concrete combined section includes a plurality of axially connected steel shell section concretes, each steel shell section concrete including a steel shell structure, the steel shell structure comprising an inner wall plate 1 and an outer wall plate 2, forming an 8cm thick annular structure between the inner wall plate 1 and the outer wall plate 2, the inner wall plate 1 and the outer wall plate 2 being provided with vertical stiffening ribs 8 and horizontal stiffening ribs 9 on opposite sides, the upper and lower sides of the inner wall plate 1 being provided with wide patch segments 5 along the circumferential direction, and the annular concrete segment 4 being poured inside the annular structure to form a ring-shaped concrete segment 4, the upper and lower ring opening surfaces of the ring-shaped concrete segment 4 being provided with grooves accommodating shear keys 6, shear keys 6 and grout holes 7, respectively, the grout holes 7 penetrating the upper and lower ring opening surfaces, each steel shell section concrete being connected by mortise and tenon connection through the grooves and positioning shear keys, and the inner wall plates and the outer wall plates of each steel shell section concrete being welded by bridge ring opening steel structure, and the annular concrete pouring between each steel shell section concrete being performed.

[0017] Further, the height of the inner wall plate 1 is set to be lower than the height of the outer wall plate 2 by 300mm, forming a widened groove along the circumferential direction as a bridge wide patch segment, and a bevel is arranged in the groove to facilitate the implementation of fusion welding, which can ensure the welding quality.

[0018] A new construction method of a factory prefabricated steel shell concrete combined section, comprising the following steps: S1, panel making: First, position and assemble the panels of each side of the inner wall plate 1 or the outer wall plate 2 on the flat jig frame, set the vertical stiffening ribs 8 and the horizontal stiffening ribs 9, and use a gantry double-arm welding robot to complete the welding of the fillet welds between the panels of each side of the inner wall plate 1 or the outer wall plate 2 and the stiffening ribs.

[0019] S2, steel shell section making: first, position the panels of each side of the inner wall plate 1 on the special jig frame by inner support, with the side facing away from the outer wall plate 2, then position the panels of each side of the outer wall plate 2 on the outer periphery of the inner wall plate 1 to form the outer wall plate 2, and perform external support on the outer wall plate 2, install horizontal stiffening ribs, and ensure the distance between the inner and outer wall plates, complete the welding and inspection of the fusion corner welds between the inner and outer wall plates, the height of the inner wall plate is not more than 300mm lower than the height of the outer wall plate, and a widened groove along the circumferential direction is formed on the inner wall plate as a bridge wide patch segment.

[0020] Further, the special jig frame requires sufficient carrying capacity, the top surface of the jig frame is provided with horizontal supports, the elevation can be adjusted, and the outer contour size can be adjusted according to the steel shell section.

[0021] Further, the inner support adopts a section not less than 60mm profile, each panel of the inner wall plate 1 is supported by multiple pairs of inner supports, the lower end of each pair of inner supports is anchored on the special jig frame, and the upper end of each pair of inner supports is anchored on two support points of the supported panel higher than the gravity center of the inner wall plate, forming an eight-shaped support, and the support point one is arranged on the panel at a position not less than 500-800mm away from the weld.

[0022] The outer support adopts a section not less than 60mm profile, and each panel of the outer wall plate 2 is arranged with not less than 2 outer supports on the side away from the inner wall plate, the lower end of the outer support is anchored on the jig frame, and the upper end of the outer support is anchored on the support point two of the supported panel, the support point two is arranged on the panel at a position not less than 500-800mm away from the weld and about 1000mm away from the top surface of the panel, and the extension length of the outer support is adjusted according to the angle of the outer wall plate relative to the ground.

[0023] Further, the panels of each face of the inner wall plate 1 or the outer wall plate 2 are connected by penetration corner welds, and both adopt single-sided welding and double-sided forming welding process, and the welding deformation of the panel is controlled by a constraint tool. First, the vertical penetration corner welds of the inner wall plate are sequentially welded, and then the vertical penetration corner welds of the outer wall plate are sequentially welded.

[0024] S3, steel shell segment concrete prefabrication: placing the steel shell segment made in step S2 on a horizontal jig frame, making the central axis of the steel shell segment horizontal, laying concrete pouring formwork at both ends of the steel shell segment, pouring the annular concrete segment 4 between the inner and outer wall plates, and performing concrete curing work after pouring.

[0025] Further, a shear key positioning groove is arranged on the concrete pouring formwork, so as to form a groove accommodating the shear key 6 on the upper annular mouth surface of the annular concrete segment 4, and the shear key 6 is formed on the upper annular mouth surface of the annular concrete segment 4, so that the shear key can be poured synchronously when pouring concrete.

[0026] Preferably, the shear key 6 and the shear key positioning groove have a specification not less than 300mm (width) x 500mm (height) x 500mm (length), and are matched with each other in a mortise and tenon structure, facilitating bridge installation and playing a role of guide block.

[0027] Further, a plurality of φ200mm round holes are uniformly arranged along the annular direction of the concrete pouring formwork, an anchor pipe is installed in the round hole for fixing a steel pipe, so as to form a concrete reserved grouting hole penetrating the upper and lower annular mouth surfaces in the annular concrete segment 4, and the steel pipe is required to protrude from the anchor pipe by 20mm, facilitating construction.

[0028] S4, steel shell segment concrete segment pre-assembly: adopting vertical continuous matching pre-assembly, installing matching parts and marking lines after completing the pre-assembly assembly.

[0029] Preferably, the matching piece contains a base, a stiffening plate and an adjusting plate, and the base is designed with four bolt holes. The installation time of the matching piece is after the pre-assembly is completed and the measurement is qualified.

[0030] S5, steel shell segment concrete segment bridge position hoisting positioning: adopt the tower crane suitable for the tonnage of the project to hoist and position the steel shell segment concrete, first preliminarily and quickly position the steel shell segment concrete through the shear key 6, use the total station instrument to measure the positioning accuracy, and after the data is qualified, fix the matching piece, review the size of the mark line and the size of the design mark line, and keep them consistent.

[0031] Further, two bolts and two impact nails are symmetrically installed to fix the matching piece, so as to ensure the correct position of the beam segment and safe fixation.

[0032] S6, steel shell segment concrete segment bridge position ring opening steel structure welding: adopt welding robot to perform butt fusion welding of the outer wall plate, and after the welding of the outer wall plate is completed, weld the butt fusion of the inner wall plate patch 5.

[0033] Further, the steel shell inner wall plate 1 is provided with a 300mm wide patch 5 along the ring direction, first complete the welding of the ring joint of the outer wall plate 2, open a single butt joint groove towards the outer side of the steel shell, and paste a ceramic lining on the back of the outer wall plate close to the inner wall plate for welding. Then weld the circumferential joint of the inner wall plate, open a single butt joint groove towards the center side of the steel shell, and set a steel lining on the back due to the inability to enter.

[0034] S7, steel shell segment concrete segment bridge position ring opening concrete 10 pouring: according to the design requirements, 2-3 steel shell segment concrete segments are poured together through the reserved φ200mm grout hole 7 to pour the ring opening concrete.

[0035] Although the specific embodiments of the present disclosure are described above in combination with the drawings, it is not a limitation on the protection scope of the present disclosure, and those skilled in the art should understand that various modifications or changes made on the basis of the technical solutions of the present disclosure without creative labor are still within the protection scope of the present disclosure.

Claims

1. A method of construction of a factory prefabricated steel shell concrete composite segment, characterised in that, Includes the following steps: S1. Fabrication of the panel: Position the panel on the flat jig, and set transverse stiffening ribs and vertical stiffening ribs on one side surface of the panel; S2. Fabrication of steel shell segments: The panel is positioned around a special jig to form an annular inner wall plate. The panel is positioned circumferentially around the inner wall plate to form an annular outer wall plate. The panels of the inner and outer wall plates are provided with transverse stiffening ribs and vertical stiffening ribs on one side facing each other. The inner and outer wall plates are equally spaced. Welding and flaw detection of the penetration corner welds between each panel in the inner and outer wall plates are completed in sequence. The height of the inner wall plate is no more than 300mm lower than the height of the outer wall plate. A widened groove is formed along the circumferential direction in the inner wall plate as a bridge position wide interlocking segment. S3. Concrete preparation of steel shell segments: Place the steel shell segments prepared in step S2 on a horizontal jig, making the central axis of the steel shell segments horizontal. Lay concrete pouring templates at both ends of the steel shell segments. The concrete pouring templates are evenly provided with multiple round holes and shear key positioning grooves along the circumferential direction. Anchor pipes are installed in the round holes to fix the steel pipes so that after the annular concrete segment is poured between the inner wall panel and the outer wall panel, a concrete reserved hole is formed in the annular concrete segment that penetrates the upper and lower annular openings. Grooves for accommodating shear keys and shear keys are respectively formed on the annular buckle surfaces at both ends of the annular concrete segment. S4. Pre-assembly of steel shell segment concrete segment: Vertical continuous matching pre-assembly is adopted. After the pre-assembly is completed, the matching parts and marking lines are installed. S5. Steel shell segment concrete segment hoisting and positioning: The steel shell segment concrete is hoisted and positioned. First, the steel shell segment concrete is initially and quickly positioned by the shear key position. The positioning accuracy is measured by a total station. After the data is qualified, the matching parts are fixed and the size of the marker line is checked to be consistent with the marking line in S4. S6. Steel shell segment concrete segment bridge site ring steel structure welding: The outer wall panel is opened with a single-sided bevel facing the outside of the steel shell. A ceramic gasket is attached to the back of the outer wall panel near the inner wall panel. The outer wall panel is then welded with full penetration. After the outer wall panel is welded, the inner wall panel is opened with a single-sided bevel facing the center of the steel shell. A steel gasket is placed on the back of the inner wall panel near the outer wall panel. The inner wall panel is then welded with full penetration. S7. Steel shell segment concrete segment bridge site ring concrete pouring: 2-3 steel shell segment concrete segments are poured together through the reserved grouting holes for ring concrete pouring.

2. The construction method according to claim 1, characterized in that, In step 2, the inner support uses profiles with a cross-section of not less than 60mm. Each panel of the inner wall is supported by multiple pairs of inner supports. The lower ends of each pair of inner supports are anchored together on a special jig, and the upper ends of each pair of inner supports are separately anchored on two support points one above the center of gravity of the inner wall panel, forming a figure-eight brace. Support point one is set on the panel at a distance of not less than 500-800mm from the weld. The outer support uses profiles with a cross-section of not less than 60mm. Each panel of the outer wall is arranged with no less than two outer supports on the side facing away from the inner wall panel. The lower ends of the outer supports are anchored on the jig, and the upper ends of the outer supports are anchored on support point two of the supported panel. Support point two is set on the panel at a distance of not less than 500-800mm from the weld and 1000mm from the top surface of the panel.

3. The construction method according to claim 1, characterized in that, In step S1, the panels on each side of the inner or outer wall panel are connected by a penetration fillet weld. The welding process is a single-sided welding with double-sided forming. The welding deformation of the control panel is controlled by the constraint tooling. First, the vertical penetration fillet welds of the inner wall panel are welded in sequence, and then the vertical penetration fillet welds of the outer wall panel are welded in sequence.

4. The precast concrete composite segment of claim 1, wherein The structure comprises multiple axially connected steel shell concrete segments. Each steel shell concrete segment includes an inner wall panel and an outer wall panel, forming a ring structure. Transverse stiffening ribs and longitudinal stiffening ribs are provided on opposite sides of the inner and outer wall panels. Wide interlocking sections are provided on the upper and lower sides of the inner wall panel along the circumferential direction. Concrete is poured inside the ring structure to form a ring concrete segment. Multiple grooves for accommodating shear keys, positioning shear keys, and grout passage holes are provided at intervals along the circumferential direction on the top and bottom surfaces of the ring concrete segment. The steel shell concrete segments are connected by tenon and mortise joints through the grooves and positioning shear keys. The inner wall panels and outer wall panels of the steel shell concrete segments are welded together through a bridge-position ring steel structure. Ring concrete is poured between the steel shell concrete segments.

5. The factory-prefabricated steel-shell concrete composite section according to claim 4, characterized in that, The height of the inner wall panel is 300mm lower than that of the outer wall panel.

6. The factory-prefabricated steel-shell concrete composite section according to claim 4, characterized in that, The thickness of the ring structure is 8cm.

7. The factory-prefabricated steel-shell concrete composite section according to claim 4, characterized in that, The shear key specifications are as follows: length not less than 500mm, width not less than 300mm, and height not less than 500mm.

8. The factory-prefabricated steel-shell concrete composite section according to claim 4, characterized in that, The diameter of the slurry passage hole is 200 mm.

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