Prefabricated frame structure system and construction method for large-span multi-story industrial plants

Abstract

This invention provides a prefabricated frame structure system and construction method for large-span, multi-story industrial plants. The system includes a foundation, prestressed composite beams, precast columns, precast floor slabs, and precast wall panels. The precast columns are installed on the foundation and consist of precast column segments and post-cast sections. Each precast column segment has a corbel at its upper end. The prestressed composite beams include precast prestressed beams and post-cast beams. The precast prestressed beams are supported at both ends on the column corbels and connected to the post-cast sections. Side corbels are provided on the sides of the precast prestressed beams. The two ends of the precast floor slabs are supported between the side corbels of the precast prestressed beams. The post-cast beams are cast above the precast prestressed beams, with both ends integrally cast with the post-cast sections of the precast columns. The two sides of the beams are connected to the precast floor slabs or precast wall panels. This invention improves the beam-column joint connection method, optimizes the stress characteristics of the beam-column joints, improves construction efficiency, saves construction time, and enhances the seismic performance and overall stability of the structure.

Description

Technical Field

[0001] This invention relates to the field of building industrial plant technology, and in particular to a prefabricated frame structure system for large-span multi-story industrial plants and its construction method. Background Technology

[0002] With the acceleration of urbanization, the contradiction between the supply and demand of industrial land is becoming increasingly prominent. The traditional single-story factory building model is difficult to meet the needs of industrial upgrading. Many places face the problem of "land resource shortage" and "inefficient land use" coexisting. Multi-story and high-rise factory buildings have become an important way to promote industrial upgrading. The new industrialization of construction has led to an increasing demand for prefabricated multi-story industrial buildings, especially those that can meet the requirements of large span, multi-story, and highly industrialized industrial buildings. The construction of high-rise factories expands the space for industrial development, helps the manufacturing industry transform towards high-end and intelligent manufacturing, focuses on "precision, small and light" (low energy consumption, low emissions, low noise, low vibration) industries, such as optoelectronic information, biomedicine, and new energy, and promotes the development of advanced manufacturing clusters. This places higher demands on new structural systems that can meet the requirements of large span, multi-story, and highly industrialized industrial buildings.

[0003] Currently, prefabricated concrete structures mainly include prefabricated concrete frame structures, prefabricated concrete shear wall structures, and prefabricated concrete frame-shear wall structures. Among them, prefabricated concrete frame structures are easy to standardize in design and industrialize in terms of major components such as beams and columns, and are widely used in residential and industrial buildings, showing significant advantages in promotion. However, due to different seismic fortification standards and building codes abroad, their structural designs generally do not fully consider the seismic resistance requirements of high-intensity earthquake zones, limiting the direct applicability of related foreign technologies in my country. Since the 1950s, my country has successively carried out relevant research and application of prefabricated concrete frame structures and established several prefabricated concrete frame structure systems. Typical prefabricated concrete frame structure systems include the "Runtai System" and the "Shigou System." However, the application of existing prefabricated frame structures such as the "Runtai System" and the "Shigou System" in these building types has certain limitations and is difficult to meet the comprehensive performance requirements of new buildings.

[0004] The "Runtai System" primarily uses ordinary steel bars for the reinforcement of precast concrete beams without incorporating prestressing technology, resulting in low beam stiffness. When used in large-span industrial plant structures, concrete cracking is prone to occur in the mid-span region of the beams under self-weight, which can further reduce structural stiffness and thus affect the overall load-bearing capacity of the structure.

[0005] While the "World Structure System" enhances stiffness through prestressed concrete beams, initially meeting some large-span application requirements, its beams and columns are connected by additional U-shaped reinforcing bars lapped with steel strands in the beam keyways and integrally cast. Under seismic loads, the lapped reinforcement areas at the beam ends are prone to bending failure, failing to fully utilize the advantages of high-strength materials. Furthermore, the keyways interfere with concrete pouring quality control during construction, affecting the anchorage effect of the bottom reinforcement, posing significant risks to the structure's seismic performance. In particular, it is prone to failure modes where the bottom reinforcement is pulled out during earthquakes, failing to meet seismic design requirements.

[0006] Therefore, there is an urgent need for a new type of prefabricated frame structure system to overcome the limitations of existing prefabricated concrete frame structures in the application of large-span, multi-story industrial plants, especially to meet the application requirements of modern industrial plants in terms of multi-story, large-span, and good seismic resistance. Summary of the Invention

[0007] The purpose of this invention is to provide a prefabricated frame structure system for large-span, multi-story industrial plants and its construction method. This system aims to improve construction efficiency, save construction time, and enhance the seismic performance and overall stability of the structure, thereby solving the technical problems of existing prefabricated prestressed concrete frame plant systems, such as small span, insufficient load-bearing capacity, complex node connections, insufficient structural integrity and seismic performance, and low assembly rate.

[0008] To achieve the above objectives, the present invention adopts the following technical solution:

[0009] A prefabricated frame structure system for a large-span, multi-story industrial plant includes a foundation, prestressed composite beams, precast columns, precast floor slabs, and precast wall panels. The bottom of the precast columns is installed on the foundation. Each precast column includes several precast column segments and a cast-in-place precast column section between adjacent precast column segments. Each precast column segment is provided with a column corbel at its upper end.

[0010] The prestressed composite beam includes a precast prestressed beam and a post-cast beam. The two ends of the precast prestressed beam are supported on the column corbels and connected to the post-cast section of the precast column. The side of the precast prestressed beam is provided with side corbels. The two ends of the precast floor slab are supported between the side corbels of the two oppositely arranged precast prestressed beams. The post-cast beam is cast above the precast prestressed beam and is integrally cast with the post-cast section of the precast column at both ends. The two sides of the post-cast beam are connected to the precast floor slab or precast wall panel.

[0011] Furthermore, the precast prestressed beam is made of high-strength concrete, with prestressed steel bars arranged at the bottom of the beam. The prestressed steel bars are anchored at the beam ends and do not extend into the post-cast section of the precast column. The bottom of the beam is also equipped with lower layer main reinforcement bars, which extend beyond the precast prestressed beam to form beam-column anchoring reinforcement bars, that is, they extend into the post-cast section of the precast column and are bent up for anchoring. The precast prestressed beam is provided with several stirrups, the top of which is exposed outside the top of the precast prestressed beam. The sides of the precast prestressed beam are also provided with several waist reinforcement bars.

[0012] Furthermore, the precast column segment is made of high-strength concrete, and the main reinforcement bars inside the precast column segment extend beyond the upper end of the precast column segment to form the post-cast section connecting reinforcement bars. A corresponding reinforcement sleeve is provided at the lower end of the precast column segment.

[0013] Furthermore, the post-cast section of the precast column includes post-cast section connecting steel bars and post-cast concrete of the precast column, wherein the end of the post-cast section connecting steel bars is connected to the steel bar sleeve at the lower end of the adjacent precast column segment.

[0014] Furthermore, the precast floor slab is selected from one of the cross-sectional types of hollow slab, trough slab or closely spaced ribbed slab, and is made of high-strength concrete. The transverse steel bars of the precast floor slab extend beyond the transverse ends of the precast floor slab to form beam-slab connecting steel bars.

[0015] Furthermore, the upper inner side of the precast wall panel is provided with a shear keyway, and the inner side of the precast wall panel is also provided with wall beam connecting steel bars at the shear keyway position; the lower inner side of the precast wall panel is also pre-embedded with a limiting connector, one end of which is pre-embedded in the precast wall panel and the other end extends to the inner side of the precast wall panel; the top of the precast wall panel is also pre-embedded with a reinforcing bar, and the bottom of the precast wall panel is also formed with a hole matching the reinforcing bar.

[0016] Furthermore, the post-cast beam is divided into a first post-cast beam and a second post-cast beam;

[0017] The first post-cast beam is located between adjacent precast floor slabs and includes upper beam reinforcement and post-cast concrete. The upper beam reinforcement is connected to the exposed stirrups and beam-slab connecting reinforcement at the top of the precast prestressed beam. The post-cast concrete is poured on top of the precast prestressed beam and wraps the upper beam reinforcement, exposed stirrups, and beam-slab connecting reinforcement.

[0018] The second post-cast beam is located between the precast floor slab and the precast wall panel, and includes the upper layer of reinforcing steel bars and the post-cast concrete. The upper layer of reinforcing steel bars are connected to the exposed stirrups, wall beam connecting steel bars, and beam slab connecting steel bars. The post-cast concrete is poured on top of the precast prestressed beam, wrapping the upper layer of reinforcing steel bars, exposed stirrups, wall beam connecting steel bars, and beam slab connecting steel bars, and forming shear keys in the shear keyway.

[0019] Furthermore, an L-shaped anchor plate is installed along the length of the upper surface of the second post-cast beam. The upper end of the L-shaped anchor plate has a pre-reserved mounting groove for a limiting connector. After the limiting connector is inserted into the mounting groove, it is fixedly connected to the L-shaped anchor plate by bolts. Secondly, this invention provides a construction method for a prefabricated frame structure system for large-span multi-story industrial plants, comprising the following steps:

[0020] Step 1: Install the foundation;

[0021] Step two: Install precast column segments above the foundation;

[0022] Step 3: Install precast prestressed beams on the column brackets between adjacent precast column segments;

[0023] Step 4: Install precast floor slabs between the side corbels of two relatively positioned precast prestressed beams;

[0024] Step 5: Install precast wall panels on the outside of the precast prestressed beam;

[0025] Step 6: Concrete is poured integrally between adjacent precast column segments and above the precast prestressed beams to form the post-cast sections and post-cast beams of the precast columns. The post-cast beams are connected with the precast prestressed beams to form prestressed composite beams. The post-cast beams are connected with the precast floor slabs and precast wall panels to form a whole; thus forming the first-floor frame structure.

[0026] Step 7: Continue installing precast column segments above the first-layer frame structure, repeating steps 3 to 6 to form the second-layer frame structure, and so on to form a multi-layer frame structure.

[0027] Compared with existing technologies, the core innovation of this invention lies in its systematic reconstruction of beam-column joint structures and floor slab connection methods for the special stress conditions of large-span, multi-story industrial buildings. This invention has the following characteristics and beneficial effects:

[0028] (1) Beam-column joint connection structure: a targeted innovation based on actual working conditions;

[0029] Unlike the conventional practice of extending all beam reinforcement into the joint, this invention optimizes the reinforcement and connection of beam-column joints based on the characteristic that the beam ends of large-span multi-story frame beams are in a state of negative bending moment for a long time: the precast prestressed beams are placed on the column corbels and do not enter the core area of ​​the joint; the straight prestressed tendons at the bottom of the beams are cut off at the ends and do not extend into the beam-column joints; while the main reinforcement of the lower layer of the beams extends into and is anchored in the core area of ​​the joints, and the longitudinal reinforcement of the post-cast beams also extends into and is anchored in the core area of ​​the joints.

[0030] Non-obvious stress logic: By having the top reinforcement of the prestressed composite beam pass through the beam-column joint to bear the negative bending moment, while only the bottom reinforcement (i.e. the lower layer of reinforcement) is configured and bent into the beam-column joint, the reinforcement density in the beam-column joint area is systematically reduced; it significantly improves the concrete pouring quality and seismic reliability of the beam-column joint area.

[0031] The essential difference from the "world structure system" is that it abandons the method of anchoring by lap splicing steel strands at the beam ends and innovatively uses ribbed prestressed steel bars with better plasticity and bonding performance for anchoring. This synergistic replacement of materials and structure brings about a non-obvious improvement in crack resistance and load-bearing capacity, overcoming the inherent defects of the existing system in failing to fully utilize the performance of high-strength materials.

[0032] (2) Floor system: It is an unconventional integration and application of conventional materials;

[0033] It is known that large spans can be achieved by using one-time molding non-overlapping precast floor slabs, but this invention integrates them into a prestressed composite beam frame system and produces a synergistic effect, resulting in a non-obvious overall effect.

[0034] An innovative combination of non-overlapping precast floor slabs and prestressed composite beams: The end reinforcement bars of the non-overlapping precast floor slabs are connected to the post-cast concrete of the main beams with the overlapping reinforcement bars to form an assembled monolithic floor system. This combination is not a simple replacement. While ensuring the integrity, it utilizes the high rigidity of the non-overlapping precast floor slabs to work together with the precast prestressed beams, significantly improving the performance of the floor system under large loads.

[0035] Unconventional construction and performance advantages: This integration not only reduces joints and on-site errors, but its more important non-obvious effect is that the combination of the hollow slab, trough slab and other cross-sectional forms of the precast floor slab with the prestressed beams forms a lightweight and high-strength horizontal stress system, thereby achieving the construction conditions of "few supports and no formwork". This innovation in the overall construction method is not an inevitable result of using non-overlapping precast floor slabs.

[0036] (3) Construction methods and system integration: fundamentally improved efficiency;

[0037] An unconventional construction process: By forming a self-stabilizing construction system where "main beams are supported by column corbels and floor slabs are supported by side corbels of the main beams," it becomes possible to "eliminate the need for full-span scaffolding and formwork." This effect is a direct product of systematic innovation in component form, node design, and installation sequence, and cannot be achieved by improving a single component.

[0038] The high assembly rate is achieved by setting up post-cast zones only in key parts (beam-column joints, beam-slab junctions), which significantly improves the assembly rate. The less obvious aspect is that, with such a high assembly rate, the overall integrity and seismic performance of the unconventional prefabricated system are still guaranteed through the above-mentioned targeted node and connection structures.

[0039] In summary, this invention can improve construction efficiency, save construction time, and enhance the seismic performance and overall stability of structures. Attached Figure Description

[0040] The present invention will now be described in further detail with reference to the accompanying drawings.

[0041] Figure 1 This is a structural schematic diagram of the prefabricated frame structure system for large-span multi-story industrial plants, an example of the present invention.

[0042] Figure 2 This is a schematic diagram of a prefabricated column segment as an example of the present invention;

[0043] Figure 3 This is a schematic diagram of a precast prestressed beam, an example of the present invention.

[0044] Figure 4 This is a schematic diagram of a precast floor slab, an example of the present invention;

[0045] Figure 5 This is a schematic diagram of the beam-column joint connection structure of an example of the present invention;

[0046] Figure 6 This is a schematic diagram of the beam-slab joint connection structure of an example of the present invention;

[0047] Figure 7 This is a schematic diagram of the wall-beam node connection structure of an example of the present invention;

[0048] Figure 8 This is a schematic diagram of the connection structure between the main beam and the secondary beam in an example of the present invention.

[0049] In the diagram: 1-Foundation; 2-Precast column segment; 21-Column corbel; 22-Column main reinforcement; 23-Reinforcement sleeve; 24-Post-cast section connecting reinforcement; 3-Prestressed composite beam; 31-Beam stirrups; 32-Beam upper layer reinforcement; 33-Beam web reinforcement; 34-Beam lower layer main reinforcement; 35-Prestressed reinforcement; 36-Edge corbel; 37-Temporary steel corbel; 4-Precast floor slab; 41-Floor slab transverse main reinforcement; 42-Floor slab longitudinal main reinforcement; 5-Precast wall panel; 51-Wall beam connecting reinforcement; 52-Shear keyway; 53-Limiting connector; 54-L-shaped anchor plate; 55-Dowel bar; 6-Precast secondary beam; 61-Secondary beam main reinforcement; 62-Secondary beam stirrups. Detailed Implementation

[0050] The specific embodiments of the present invention will now be described in more detail with reference to the accompanying drawings. The advantages and features of the present invention will become clearer from the following description. It should be noted that the accompanying drawings are in a non-simplified form and use non-precise proportions, and are only used to facilitate and clarify the illustration of the embodiments of the present invention.

[0051] Example 1;

[0052] Please refer to Figures 1 to 7 This embodiment is a prefabricated frame structure system for a large-span multi-story industrial plant, including a foundation 1, prestressed composite beams 3, precast concrete columns, precast floor slabs 4, and precast wall panels 5; the bottom of the precast columns is installed on the foundation 2, and the precast columns include several precast column segments 2 and precast column post-cast sections provided between adjacent precast column segments 2, and each precast column segment 2 is provided with a column corbel 21 at its upper end;

[0053] The prestressed composite beam 3 includes a precast prestressed beam and a post-cast beam. The two ends of the precast prestressed beam are supported on column corbels 21 and connected to the post-cast section of the precast column. Side corbels 36 are provided on the sides of the precast prestressed beam. The two ends of the precast floor slab 4 are supported between the side corbels 36 of the two opposing precast prestressed beams. The post-cast beam is cast above the precast prestressed beam, with both ends integrally cast with the post-cast section of the precast column. The two sides of the post-cast beam are connected to the precast floor slab 4 or precast wall panel 5. The precast floor slab 4 is a one-piece molded non-composite precast concrete slab.

[0054] See Figure 1 As shown, the floor includes: precast column segments 2, prestressed composite beams 3, and precast floor slabs 4. The precast column segments 2 are constructed on or below the foundation 1. The foundation 1 is a cast-in-place independent column foundation with pre-installed reinforcing bars. The precast column segments 2 and the foundation 1 are connected by grout anchors to form a rigid column base node. The column reinforcement of the upper and lower precast column segments 2 is connected by grouting through steel bar sleeves. The ends of the prestressed composite beams 3 rest on column corbels 21, and the ends of the precast floor slabs 4 are set on the side corbels 36 of the prestressed composite beams. The side corbels 36 of the prestressed composite beams are located on the sides of the prestressed composite beams.

[0055] See Figure 2 As shown, the precast concrete column is assembled from multi-layer precast column segments 2 made of high-strength concrete, with the splicing points being the post-cast sections of the precast column; see also Figure 3 , 5 As shown, the prestressed composite beam 3 includes beam stirrups 31, upper layer reinforcement 32, beam web reinforcement 33, lower layer main reinforcement 34, and prestressed reinforcement 35; see also Figure 4 , 6As shown, the precast floor slab 4 can be a hollow slab, a channel slab, or a ribbed slab, made of high-strength concrete, with transverse reinforcement at both ends, including transverse reinforcement 41 and longitudinal reinforcement 42. The precast wall panel 5 is a lightweight, insulated, and integrally formed wall panel with exterior decoration, including wall beam connecting reinforcement 51, shear keyway 52, and limiting connector 53. The precast column segment 2, prestressed composite beam 3, precast floor slab 4, and precast wall panel 5 can all be produced in the prefabrication plant and reliably connected by cast-in-place concrete on site.

[0056] See Figure 5 As shown, the prestressed composite beam 3 is supported at both ends on the column corbels 21 of the precast column segment 2 after the structure has stabilized. The prestressed composite beam 3 and the precast column segment 2 are connected by reinforcement bars in the post-cast concrete joint area to form a prefabricated integral frame. The lower layer main reinforcement 34 of the prestressed composite beam 3 extends into the core area of ​​the joint (post-cast section of the precast column) and is bent up for anchorage. The prestressed steel bars 35 at the bottom of the prestressed composite beam 3 are cut off at the beam end and do not extend into the core area of ​​the joint, that is, they are not inserted into the post-cast section of the precast column.

[0057] See Figure 5 As shown, the precast column segment 2 has main reinforcing bars 22 arranged inside. A column corbel 21 is provided at the upper end of the precast column segment 2, and a reinforcing bar sleeve 23 is installed at the lower end of the precast column segment 2, with the reinforcing bar sleeve 23 fixedly connected to the lower end of the main reinforcing bars 22. The main reinforcing bars 22 of the lower precast column segment 2 extend beyond the precast column segment 2, forming the post-cast section connecting reinforcing bars 24. The end of the post-cast section connecting reinforcing bars 24 is fixedly connected to the reinforcing bar sleeve 23 at the lower end of the adjacent precast column segment 2. The post-cast section of the precast column includes the post-cast section connecting reinforcing bars 24 and the post-cast concrete of the precast column, and also includes post-cast section stirrups (not shown in the figure). See also... Figure 6 As shown, the precast floor slab 4 is supported at both ends on the side corbels 36 of the prestressed composite beam 3. The end reinforcement of the precast floor slab 4 is connected to the reinforcement of the composite part of the post-cast concrete of the prestressed composite beam 3 to form a prefabricated integral floor slab, that is, the transverse reinforcement 41 of the floor slab is inserted into the post-cast beam for anchorage.

[0058] See Figure 7 As shown, a shear keyway 52 is provided on the upper inner side of the precast wall panel 5, and a wall beam connecting steel bar 51 is also provided on the inner side of the precast wall panel 5 at the position of the shear keyway 54; a limiting connector 53 is also pre-embedded on the lower inner side of the precast wall panel 5, one end of the limiting connector 53 is pre-embedded in the precast wall panel 5, and the other end extends to the inner side of the precast wall panel 5; a dowel bar 55 is also installed at the bottom of the precast wall panel 5, and a dowel hole matching the dowel bar 55 is also formed on the top of the precast wall panel 5 (not shown in the figure).

[0059] See Figure 7As shown, the precast wall panel 5 and the prestressed composite beam 3 are connected by a wet connection. The wet connection method means that the precast wall panel 5 is anchored to the beam connecting steel bar 51 extending from the wall beam and to the upper layer steel bar 32 of the prestressed composite beam 3, as well as to the beam connecting steel bar extending from the end of the precast floor slab 4. That is, it is anchored to the protruding end of the transverse steel bar 41 of the floor slab, and concrete is poured in place in this area, with out-of-plane limiting connectors installed. The precast wall panel 5 is constructed simultaneously with the main structure.

[0060] See Figure 7 As shown, the out-of-plane limiting connector includes a limiting connector 53 and an L-shaped anchor plate 54. Before concrete pouring, the L-shaped anchor plate 54 is first placed on the surface of the post-cast beam. The L-shaped anchor plate 54 is divided into two parts: a flat plate and a vertical plate. The two are perpendicular to each other, and their corners match the wall corners. The flat plate is pre-embedded in the post-cast beam with anchor bars and connected to the wall beam connecting steel bars 51 or the transverse main steel bars 41 of the floor slab. The upper surface of the flat plate is flush with the upper surface of the precast floor slab 4. The vertical plate is arranged vertically, and an installation groove for the limiting connector 53 is formed on the vertical plate. When the limiting connector 53 is inserted into the installation groove, it is fixedly connected to the L-shaped anchor plate with a nut. The end of the limiting connector 53 is threaded. For easy distinction, the post-cast concrete section between adjacent precast floor slabs 4 and above the prestressed composite beam 3 is referred to as the first post-cast beam (e.g., Figure 6 The post-cast portion), located between the precast floor slab 4 and the precast wall panel 5, and above the prestressed composite beam 3, is referred to as the second post-cast beam (e.g., the post-cast concrete strip overlapping part). Figure 7 The first post-cast beam includes the upper layer of reinforcing bars 32 and the post-cast concrete. The upper layer of reinforcing bars 32 are connected to the exposed beam stirrups 31 and beam-slab connecting reinforcing bars (the protruding bars of the transverse main reinforcing bars 41 of the floor slab) at the top of the precast prestressed beam. The post-cast concrete is poured on top of the precast prestressed beam, wrapping the upper layer of reinforcing bars 32, the exposed beam stirrups 31, and the beam-slab connecting reinforcing bars. The second post-cast beam includes the upper layer of reinforcing bars 32 and the post-cast concrete. The upper layer of reinforcing bars 32 are connected to the exposed beam stirrups 31, wall-beam connecting reinforcing bars 51, and beam-slab connecting reinforcing bars (the protruding bars of the transverse main reinforcing bars 41 of the floor slab). The post-cast concrete is poured on top of the precast prestressed beam, wrapping the upper layer of reinforcing bars 32, the exposed beam stirrups 31, wall-beam connecting reinforcing bars 51, and beam-slab connecting reinforcing bars, and forming a shear key in the shear keyway 52.

[0061] The difference between the first and second post-cast beams lies in the fact that the first post-cast beam requires side corbels 36 on both sides for the precast floor slabs 4 on both sides to support it, while the second post-cast beam only has side corbels 36 on one side for the precast floor slab 4 on that side, and the other side connects to the precast wall panel 5. Furthermore, the outer surface of the second post-cast beam also forms a shear key, which matches the shear keyway 52 provided on the precast wall panel 5. The exposed wall beam connecting steel bars 51 of the precast wall panel 5 serve as part of the stirrups of the second post-cast beam. Of course, longitudinal steel bars are also required inside the second post-cast beam as main reinforcement. Therefore, the wall beam connecting steel bars 51 in the precast wall panel 5 need to be set along the width direction of the precast wall panel 5. Adjacent precast wall panels 5 are connected by a socket joint; a socket hole is provided at the bottom of the lower precast wall panel 5, and a reinforcing bar 55 is provided at the top of the upper precast wall panel 5. The socket joint is completed by inserting the reinforcing bar 55 into the socket hole. Then, a limiting connector 53 is installed on the inner side of the bottom of the precast wall panel 5 to connect with the second post-cast beam.

[0062] Furthermore, precast wall panel 5 is a composite wall panel with integrated load-bearing, thermal insulation, and decorative functions. Precast wall panel 5 employs a three-layer composite sandwich structure, consisting of an inner leaf panel, an insulation sandwich layer, and an outer leaf panel. Both the inner and outer leaf panels utilize lightweight aggregate concrete, with expanded clay aggregate as the coarse aggregate, supplemented by cement, silica fume, fly ash, and other binding materials. A steel reinforcement framework is installed between the inner and outer leaf panels to enhance bending resistance. Junction boxes, hoisting anchors, etc., are pre-embedded during the pouring stage to ensure convenient installation.

[0063] Furthermore, the out-of-plane limiting connector is a connecting component used in prefabricated buildings between the external precast wall 5 and the main structure (such as precast beams and slabs). Its main function is to limit the displacement of the precast wall panel 5 outside the plane (i.e., perpendicular to the wall surface), preventing excessive deformation or detachment of the precast wall panel 5 due to wind loads, earthquakes, etc., while allowing the precast wall panel 5 to have a certain deformation capacity in the plane to adapt to the thermal expansion and contraction, creep, and earthquakes of the structure. The out-of-plane limiting connector is L-shaped and adopts a split design. It is installed at the corner where the precast wall panel 5 and the prestressed composite beam 3 are located. One end is connected to the external precast wall panel 5 through embedded parts or bolts, and the other end is anchored to the post-cast concrete of the prestressed composite beam 3 through bolts or anchor bars. The limiting connector 53 is prefabricated as an integral part of the precast wall panel 5. The bolts or anchor bars at the other end of the L-shaped anchor plate 54 are embedded in the designated position before the post-cast concrete of the prestressed composite beam 3 is poured, and then poured together with the post-cast concrete to form a whole.

[0064] The prestressed composite beam 3 is supported on the column corbel 21 of the precast segment column 2 after the structure has stabilized. The prestressed composite beam 3 and the precast segment column 2 are connected by reinforcement bars in the post-cast concrete joint area to form a prefabricated integral frame.

[0065] The precast floor slab 4 is supported on the corbel 36 on the side of the prestressed composite beam 3. The transverse reinforcing bars at both ends of the precast floor slab are connected to the reinforcing bars of the composite part of the post-cast concrete of the prestressed composite beam 3 to form a prefabricated monolithic floor system.

[0066] The precast wall panel 4 is connected to the main structure by line support and edge beams. The precast wall panel 4 is connected to the prestressed composite beam 3 and the precast floor slab 4 by the reinforcement bars in the post-cast concrete to form an assembled integral structure.

[0067] This embodiment also provides a construction method for a prefabricated frame structure system for large-span, multi-story industrial plants. The construction steps are as follows:

[0068] (1) Producing precast components in the factory: producing precast column segments 2, precast prestressed beams, precast floor slabs 4, and precast wall panels 5; wherein the precast column segments 2 are equipped with column corbels 21, and the precast prestressed beams are equipped with side corbels 36.

[0069] (2) Construction foundation 1: Independent column foundation with pre-reserved reinforcing bars;

[0070] (3) Install the precast column segment 2 and connect it to the foundation 1 using grout anchors; install column stabilizing brackets on the precast column segment 2 to make the precast column segment 2 and its frame structure more stable;

[0071] (4) Install precast prestressed beams on the column brackets 21 of adjacent precast column segments 2;

[0072] (5) The precast floor slab 4 is supported on the side brackets 36 of two precast prestressed beams that are arranged opposite each other;

[0073] (6) Install precast wall panels 5 on the outside of the precast prestressed beam;

[0074] (7) Cast the joint area between the precast column segment 2 and the precast prestressed beam, the post-cast strip between the precast floor slab 4 and the precast prestressed beam 3, the post-cast strip between the precast floor slab 4 and the precast prestressed beam 3, and the post-cast strip between the precast floor slab 4 and the precast prestressed beam 3 and the precast wall panel 6; to obtain the post-cast section of the precast column and the post-cast beam, the post-cast beam and the precast prestressed beam form a pre-prestressed composite beam 3, and to obtain the first layer frame structure; (8) After curing for a period of time, remove the column stabilizing support of this layer after the structure is stable;

[0075] (9) Install the second-layer precast column segment 2 above the precast column segment 2 of the first-layer frame structure, and install the column stabilizing bracket. Then repeat steps (4) to (7) until all beams, columns and slabs of the second layer are completed to obtain the second-layer frame structure.

[0076] (10) This process is repeated to form a multi-layered frame structure system.

[0077] Specifically, the precast wall panels 5 in the first-floor frame structure can be installed according to building requirements; the precast wall panels 5 in the first floor can be installed or not; when the precast wall panels 5 are not installed, the construction process of the edge beams and main beams is the same. The second-floor frame structure and the upper-level second-floor frame structure are usually equipped with precast wall panels 5.

[0078] Specifically, during the construction of the lower-level frame structure, after hoisting the lower-level precast wall panel 5, the wall beam connecting steel bars 5 set at the top of the precast wall panel 5 are hung at the position of the second post-cast beam, and the steel cage of the second post-cast beam is erected. At the same time, the L-shaped anchor plate 54 is pre-embedded and fixed on the steel cage of the second post-cast beam. Then, concrete is poured to form the L-shaped anchor plate 54, which forms an integral whole with the second post-cast beam. At this time, the precast wall panel 5 acts as a non-removable formwork for the inner side of the post-cast beam. During the construction of the upper-level frame structure, after hoisting the upper-level precast wall panel 5, the insertion holes at the bottom of the upper-level precast wall panel 5 are first connected to the upper-level precast beam. Align the reinforcing bars 55 at the top of the precast wall panel 5, and simultaneously align the limiting connector 53 at the lower inner side of the upper precast wall panel 5 with the mounting groove on the L-shaped anchor plate 54. When the insertion hole is fitted onto the reinforcing bar 55, the limiting connector 53 is installed in the mounting groove on the L-shaped anchor plate 54. Install a nut at the end of the limiting connector 53 to fix the limiting connector 53 to the L-shaped anchor plate 54, thus fixing the bottom of the upper precast wall panel 5 to the top of the lower precast wall panel 5 and the lower second post-cast beam. After that, the other processes of the upper precast wall panel 5 can be completed, and so on. This process realizes the synchronous casting of the precast column post-cast section, the first post-cast beam, and the second post-cast beam, which not only solves the casting problem but also ensures the integrity of the joint.

[0079] Example 2;

[0080] Please refer to Figure 8 In the system proposed in this invention, secondary beams are generally used as little as possible. The one-piece molded non-overlapping precast floor slab 4 is placed directly on the main beam (prestressed composite beam 3). If secondary beams are required, please refer to [reference needed]. Figure 8 As shown, the precast secondary beam 6 is supported on the temporary steel bracket 37 of the prestressed composite beam 3. The precast secondary beam 6 includes the main reinforcement 61, the stirrups 62, and concrete. The upper layer of the main reinforcement 61 of the precast secondary beam 6 is anchored to the post-cast concrete of the prestressed composite beam 3 with the overlapping reinforcement (including the stirrups 31) to form a prefabricated integral structure. At this time, at the connection between the precast secondary beam 6 and the prestressed composite beam 3, the prestressed composite beam 3 does not have an edge bracket 36, and the end of the precast secondary beam 6 directly contacts the side of the prestressed composite beam 3.

[0081] Layout: The precast secondary beam 6 is erected vertically between two adjacent main beams (prestressed composite beam 3).

[0082] Connection method: The precast secondary beam 6 is supported at both ends on temporary steel brackets 37 on the upper side of the prestressed composite beam 3. The main reinforcement 61 of the precast secondary beam 6 is anchored to the reinforcement of the post-cast concrete strip above the prestressed composite beam 3, and finally forms a whole through the post-cast concrete. Figure 8 (As shown).

[0083] The temporary steel bracket 37 is only used for temporary placement and positioning of the precast secondary beam 6 during the construction phase. After the post-poured concrete reaches the design strength and the precast secondary beam 6 and the prestressed composite beam 3 form an integral load-bearing node, the temporary steel bracket 37 should be removed in a timely manner to ensure clear structural stress and meet the requirements for subsequent corrosion prevention, fire prevention and building use.

[0084] The frame structure system of this invention encourages the avoidance of secondary beams, but also provides flexibility, in which secondary beams may be required in the following situations:

[0085] (1) The span of the precast floor slab is extremely large: when the spacing of the main beam (prestressed composite beam 3) (i.e. the slab span) exceeds the economic or safe span limit of the selected non-composite precast slab.

[0086] (2) Excessive local load: There are heavy equipment or large concentrated loads in specific areas of the factory building, and it may be insufficient to rely solely on the slab to directly transmit the force to the main beam (prestressed composite beam 3).

[0087] (3) Irregular plan shape: Locally set in places where the building plan is irregular in order to reasonably transfer the load.

[0088] Please refer to Figure 1 , Figure 1 There is a gap between the precast column segment 2 and the precast floor slab 4. There are two ways to deal with this gap. One is to fill it with the precast secondary beam 6 in Example 2. The other is to cantilever the precast floor slab 4 on both sides of the gap beyond the precast prestressed beam, so that part of the precast floor slab 4 is directly connected to the post-cast section of the precast column.

[0089] This invention significantly reduces the reinforcement density in the core area of ​​the joint by cutting off the prestressed steel bars 35 at the bottom of the beam outside the joint and retaining only the main reinforcement bars 34 of the lower layer of the beam bent and anchored into the joint. On the one hand, it clears the channels for concrete flow and vibration, eliminates the problems of concrete segregation and inadequate vibration caused by excessive reinforcement, and ensures that the concrete in the joint area is fully compacted, guaranteeing a reliable bond between the reinforcement bars and the concrete. On the other hand, the densely wrapped concrete and the appropriate amount of main reinforcement bars 34 of the lower layer of the beam together provide moderate restraint, avoiding bond slip failure of the reinforcement bars under seismic cyclic loading, expanding the range of plastic hinges, and achieving the seismic design goal of "strong joint and weak component". Thus, while improving construction quality, it significantly enhances the ductility of the joint and the overall seismic performance of the structure.

[0090] It should be noted that not all reinforcing bars are shown in some of the accompanying drawings. The arrangement of the reinforcing bars can be obtained by those skilled in the art from other drawings of the present invention or from common technical knowledge in the field.

[0091] The above are merely preferred embodiments of the present invention and do not constitute any limitation on the present invention. Any equivalent substitutions or modifications made by those skilled in the art to the technical solutions and content disclosed in the present invention without departing from the scope of the present invention shall be deemed to have remained within the protection scope of the present invention.

Claims

1. A prefabricated frame structure system for large-span, multi-story industrial plants, comprising foundations, prestressed composite beams, precast columns, precast floor slabs, and precast wall panels; characterized in that: The precast column is installed on the foundation at its bottom. The precast column includes several precast column segments and a precast column post-cast section located between adjacent precast column segments. Each precast column segment is provided with a column corbel at its upper end. The prestressed composite beam includes a precast prestressed beam and a post-cast beam. The two ends of the precast prestressed beam are supported on the column corbels and connected to the post-cast section of the precast column. The side of the precast prestressed beam is provided with side corbels. The two ends of the precast floor slab are supported between the side corbels of the two oppositely arranged precast prestressed beams. The post-cast beam is cast above the precast prestressed beam and is integrally cast with the post-cast section of the precast column at both ends. The two sides of the post-cast beam are connected to the precast floor slab or precast wall panel.

2. The prefabricated frame structure system for large-span multi-story industrial plants according to claim 1, characterized in that: The precast prestressed beam is made of high-strength concrete. Prestressed steel bars are arranged at the bottom of the beam and anchored at the beam ends. The bottom of the beam is also equipped with lower layer main reinforcement bars, which extend beyond the precast prestressed beam to form beam-column anchorage reinforcement bars. Several stirrups are provided inside the precast prestressed beam, with the top of the stirrups exposed beyond the top of the precast prestressed beam. Several web reinforcement bars are also provided on the side of the precast prestressed beam.

3. The prefabricated frame structure system for large-span multi-story industrial plants according to claim 2, characterized in that: The precast column segments are made of high-strength concrete. The main reinforcement bars inside the precast column segments extend beyond the upper end of the precast column segments to form the connecting reinforcement bars of the post-cast segments. A corresponding reinforcement sleeve is provided at the lower end of the precast column segments.

4. The prefabricated frame structure system for large-span multi-story industrial plants according to claim 3, characterized in that: The post-cast section of the precast column includes post-cast section connecting steel bars and post-cast concrete of the precast column, wherein the end of the post-cast section connecting steel bars is connected to the steel bar sleeve at the lower end of the adjacent precast column segment.

5. The prefabricated frame structure system for large-span multi-story industrial plants according to claim 4, characterized in that: The precast floor slab is selected from one of the cross-sectional types of hollow slab, trough slab or ribbed slab, and is made of high-strength concrete. The transverse steel bars of the precast floor slab extend beyond the transverse ends of the precast floor slab to form beam-slab connecting steel bars.

6. The prefabricated frame structure system for large-span multi-story industrial plants according to claim 5, characterized in that: The upper inner side of the precast wall panel is provided with a shear keyway, and a wall beam connecting steel bar is also provided on the inner side of the precast wall panel at the position of the shear keyway; a limiting connector is also pre-embedded on the lower inner side of the precast wall panel, one end of the limiting connector is pre-embedded in the precast wall panel, and the other end extends to the inner side of the precast wall panel; a dowel bar is also pre-embedded on the top of the precast wall panel, and a dowel hole matching the dowel bar is also formed on the bottom of the precast wall panel.

7. The prefabricated frame structure system for large-span multi-story industrial plants according to claim 6, characterized in that: The post-cast beam is divided into a first post-cast beam and a second post-cast beam; The first post-cast beam is located between adjacent precast floor slabs and includes upper beam reinforcement and post-cast concrete. The upper beam reinforcement is connected to the exposed stirrups and beam-slab connecting reinforcement at the top of the precast prestressed beam. The post-cast concrete is poured on top of the precast prestressed beam and wraps the upper beam reinforcement, exposed stirrups, and beam-slab connecting reinforcement. The second post-cast beam is located between the precast floor slab and the precast wall panel, and includes the upper layer of beam reinforcement and post-cast concrete. The upper layer of beam reinforcement is connected to the exposed stirrups, wall beam connecting reinforcement, and beam slab connecting reinforcement. The post-cast concrete is poured on top of the precast prestressed beam, wrapping the upper layer of beam reinforcement, exposed stirrups, wall beam connecting reinforcement, and beam slab connecting reinforcement, and forming a shear key in the shear keyway.

8. The prefabricated frame structure system for large-span multi-story industrial plants according to claim 7, characterized in that: An L-shaped anchor plate is installed on the upper surface of the second post-cast beam along the length direction. The upper end of the L-shaped anchor plate has a pre-reserved installation groove for a limiting connector. After the limiting connector is inserted into the installation groove, it is fixedly connected to the L-shaped anchor plate by bolts.

9. The construction method of the prefabricated frame structure system for large-span multi-story industrial plants according to any one of claims 1-8, characterized in that: Includes the following steps: Step 1: Install the foundation; Step two: Install precast column segments above the foundation; Step 3: Install precast prestressed beams on the column brackets between adjacent precast column segments; Step 4: Install precast floor slabs between the side corbels of two relatively positioned precast prestressed beams; Step 5: Install precast wall panels on the outside of the precast prestressed beam; Step 6: Concrete is poured integrally between adjacent precast column segments and above the precast prestressed beams to form the post-cast sections and post-cast beams of the precast columns. The post-cast beams are connected with the precast prestressed beams to form prestressed composite beams. The post-cast beams are connected with the precast floor slabs and precast wall panels to form a whole; thus forming the first-floor frame structure. Step 7: Continue installing precast column segments above the first-layer frame structure, repeating steps 3 to 6 to form the second-layer frame structure, and so on to form a multi-layer frame structure.

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