An all-assembled three-dimensional truss material shed product system

Abstract

The application discloses a kind of full assembly three-dimensional truss material shed product systems, belong to large-span steel structure material shed technical field.The system includes main truss, secondary truss, roof system and connecting node system.Main truss adopts quadrilateral section three-dimensional truss, chord and web are all used rectangular steel pipe, the distance between two adjacent main trusses is 12m~30m.Secondary truss is used triangular tube truss or plane truss, and is arranged between two adjacent main trusses.Main truss is manufactured as segmented unit in factory, and main truss butt joint and secondary truss and main truss connection are all used full assembly bolt connection, and all welding operations are completed in factory, and only bolt fastening assembly is needed on site.When the span of material shed is greater than 150m, the lower chord of main truss can be additionally provided with cable to form a cable-strut truss structure.The application has less components, low steel consumption and fast construction speed, and is particularly suitable for engineering scenarios of adding closed material shed to existing coal mine or ore field.

Description

Technical Field

[0001] This invention relates to the field of large-span steel structure material shed technology, and in particular to a fully prefabricated three-dimensional truss material shed product system, which is suitable for new construction or renovation projects of existing coal mines or ore yards with enclosed material sheds. Background Technology

[0002] In the environmental protection and enclosure renovation of bulk material storage yards such as coal mines and ore yards, large-span steel structures are the most common form of material sheds. Currently, there are two main approaches in engineering.

[0003] One type is the inverted triangular truss system, which consists of two upper chords and one lower chord forming a triangular cross-section truss, with the chords mostly being circular tubes. The problem with this structure is that the lower chord of the inverted triangular cross-section has weak out-of-plane stiffness, making the truss prone to out-of-plane instability during construction and service. Therefore, secondary trusses and temporary supports must be densely arranged. Even more problematic are the joints. The intersections of circular tubes require open space curves at the ends of the branch pipes, demanding high machining precision. During on-site assembly, secondary components often fail to fit into their intended positions, and the hard installation poses safety risks—slight construction errors result in gaps of varying widths between the main and branch pipes, making it difficult to guarantee the quality of on-site welding. Furthermore, these intersecting joints are almost always welded on-site, and strong winds, high humidity, and temperature changes directly affect the weld quality, leading to a high rate of rework during inspection.

[0004] Another type is the dense planar truss system. Planar trusses themselves have no out-of-plane stiffness and can only maintain overall stability by reducing the spacing between the main trusses, which is usually only 6 to 8 meters apart. A large number of secondary trusses and tie rods are also crammed in between. A single material shed can easily have hundreds or even thousands of members, with densely packed node plates. Factory welding and on-site welding are required, doubling the amount of welding. The construction cycle and economy are not ideal.

[0005] The two systems mentioned above are adequate for ordinary construction sites, but the renovation of existing material yards often involves working in narrow factory areas with material piles, narrow transport channels, and tight deadlines. Coastal material yards also experience high humidity, salt spray, and frequent strong winds, making on-site welding and painting operations extremely limited. Using the old method of building enclosed sheds will either lead to a loss of control over the construction schedule or raise questions about the quality.

[0006] Faced with these problems, could we adopt a different approach—making the truss cross-section quadrilaterals, replacing circular tubes with rectangular tubes, and giving the structure sufficient out-of-plane stiffness, thereby increasing the spacing between the main trusses and eliminating a large number of secondary components; at the same time, moving all welding to the factory, with only bolt connections done on-site? Based on this concept, this invention proposes a fully prefabricated three-dimensional truss material shed product system. Summary of the Invention

[0007] This invention provides a fully prefabricated three-dimensional truss material shed product system to solve the technical problems of poor out-of-plane stability, complex node connections, large amount of welding work, large number of components, high steel consumption, and low construction efficiency of existing inverted triangular tube truss systems.

[0008] To achieve the above objectives, the present invention adopts the following technical solution: a fully prefabricated three-dimensional truss material shed product system, including a main truss, a secondary truss, a roof system, and a connection node system.

[0009] 1. Main Truss

[0010] The main truss adopts a quadrilateral cross-section three-dimensional truss. The quadrilateral cross-section consists of two upper chords, two lower chords, and vertical and diagonal web members connecting the upper and lower sections, forming a spatial closed section force system.

[0011] The top chord, bottom chord, vertical web members, and diagonal web members are all made of rectangular steel tubing (square or rectangular). Using rectangular tubing for all components offers the following advantages:

[0012] (1) Simplified node connection: The connection between rectangular tubes can be made by node plate connection or direct welding, without the need to open complex intersection holes, resulting in high factory processing efficiency and reliable on-site assembly accuracy.

[0013] (2) High section efficiency: The moment of inertia of the rectangular tube in the weak axis direction is larger than that of the circular tube with the same cross-sectional area, and the bending resistance is stronger. The vertical web members and the diagonal web members using rectangular tubes also have higher compressive stability bearing capacity.

[0014] (3) Good out-of-plane stability: The quadrilateral closed section has a large moment of inertia in both principal axis directions, and its out-of-plane bending stiffness is much greater than that of the inverted triangular section. It can maintain stability without a large number of temporary supports during construction.

[0015] Because quadrilateral trusses exhibit significantly better out-of-plane stability than planar trusses and inverted triangular trusses, the spacing between main trusses can be greatly increased. In this invention, the spacing between main trusses can be set to 12m to 30m, which is more than 50% larger than that of traditional inverted triangular truss systems (spacing typically 8m to 12m) or densely packed planar truss systems (spacing typically 6m to 10m). This increased spacing directly leads to a reduction and optimization in the number of main trusses and secondary trusses.

[0016] When the span of the material shed is large (greater than 150m), the deflection and structural deformation of the main truss become the controlling factors. In this case, cables can be added to the lower chord of the main truss to form a tensioned truss structure. The cables are made of high-strength steel wire bundles or steel strands, connected to the lower chord of the main truss through struts, applying prestress to the main truss, thereby effectively reducing the vertical deformation of the main truss, improving the overall structural stiffness, and ensuring that the ultra-large span material shed structure can still meet the requirements of the normal serviceability limit state.

[0017] 2. Secondary Truss

[0018] Secondary trusses, which are triangular tubular trusses or planar trusses, are set between two adjacent main trusses to bear the roof load and transfer it to the main trusses.

[0019] The reason for using triangular tubular trusses for the secondary truss:

[0020] (1) The secondary truss section height is relatively small (usually 1 / 20 to 1 / 15 of the main truss spacing). Within this section height range, the three chords and a small number of web members of the triangular tube truss can meet the requirements of bearing capacity and stiffness. The number of components is small and the amount of steel used is low.

[0021] (2) The triangular tube truss has only three chords (one less than the four chords of the quadrilateral truss), and the number of web members is also reduced accordingly, which helps to reduce the amount of steel used and the amount of manufacturing work.

[0022] (3) The upper chord surface of the triangular tube truss (the plane between the two upper chord members) can provide a natural support surface for the roof system, which is convenient for the laying of membrane structure or profiled steel sheet.

[0023] Because the main trusses themselves have good stability and large spacing, the span of the secondary trusses between two adjacent main trusses increases, but the number of secondary trusses can be reduced accordingly. In this invention, 5 to 6 secondary trusses are generally set between two adjacent main trusses, and the spacing between the secondary trusses is 1 / 6 to 1 / 5 of the spacing between the main trusses, which is much less than the number of secondary trusses in traditional densely packed planar truss systems.

[0024] Using planar trusses for secondary trusses makes connections quicker and facilitates transportation of secondary trusses. When planar trusses are used for secondary trusses, the number of secondary trusses between two adjacent main trusses is 8 to 10.

[0025] 3. Connection Node System (Fully Prefabricated)

[0026] One of the core features of this invention is that the main truss is manufactured as segmented units in the factory, and the connections between the segmented units, such as the main truss docking and the secondary truss connecting to the main truss, are all made using fully assembled bolted connections, without any on-site welding operations.

[0027] (1) Main truss chord segment connection node

[0028] Based on transportation width and length restrictions (road transport width generally does not exceed 3.5m, and length generally does not exceed 15m-18m), the main truss is manufactured in sections at the factory as transportation segment units. Segmentation points are preferentially located at positions with lower chord bending moments. Flange joints are installed at the chord segmentation locations.

[0029] The flange plate is welded to the end of the chord in the factory by full penetration butt weld; the flange plate is a steel plate with bolt holes, and the width is the same as or slightly wider than the chord section; after each segment unit is transported to the site, the flange plates of adjacent segment units are fitted and aligned, high-strength bolts (10.9S grade or 8.8S grade) are inserted and tightened according to the specified torque, thus completing the weldless splicing of the chord.

[0030] (2) Connection node between main truss and secondary truss

[0031] The secondary truss ends are connected to the main truss via gusset plates:

[0032] The gusset plates are welded to the predetermined positions of the main truss chords or vertical web members in the factory. The main truss is shipped as a segmented unit with the gusset plates already attached. Bolt holes are pre-drilled on the gusset plates. The chords or end plates at the ends of the secondary trusses are also drilled in the factory. The secondary trusses are also shipped as independent segmented units. After each segmented unit is transported to the site, the ends of the secondary trusses are attached to the gusset plates and high-strength bolts are inserted and tightened.

[0033] By using rectangular chord members and factory-welded node plates, the problem of secondary trusses being difficult to insert and position in the intersection of circular tubes is completely avoided—the node plate connection is a "face-to-face" contact and mating, which has high positioning accuracy and large assembly tolerance.

[0034] (3) Main truss height segmented connection node

[0035] When the truss height exceeds the transportation height limit (generally no more than 4.0m to 4.5m for highway transportation), the main truss can be divided into two segments along the height direction: an upper segment and a lower segment. The segmentation location is selected at the intersection of the vertical and diagonal web members (i.e., the truss joint point), and a flange connection node is set at this location.

[0036] The upper and lower segment units are manufactured, welded, and painted independently in the factory; flange plates are installed on the upper and lower chords at the segment; after each segment unit is transported to the site, the flange plates of the upper and lower segments are aligned and high-strength bolts are inserted and tightened to complete the weldless assembly of the truss in the height direction.

[0037] (4) The prefabrication rate of fully prefabricated construction

[0038] In this invention system, the cutting, drilling, welding, rust removal, and anti-corrosion coating (primer + intermediate coat + topcoat) of components are all completed in the factory. The main truss is shipped in segmented units, and the secondary trusses are also manufactured as segmented units in an independent factory. Factory welding accounts for more than 99% of the total welding. Each segmented unit arrives on site with a complete anti-corrosion coating, and only the following operations are required on site:

[0039] Main truss chord flange connection—tighten bolts to assemble adjacent segment units into a complete main truss; Main truss height segment connection (if required)—tighten bolts to assemble upper and lower segment units into a complete height; Secondary truss installation—tighten bolts to connect secondary truss segment units to main truss segment units; Support system installation—tighten bolts; Roofing system installation.

[0040] The on-site construction work is simplified to a single bolt tightening operation, assembling the factory-supplied segmented units into a complete structure. It does not involve welding, rust removal, or painting. The construction process is simple, the quality is reliable, and the construction speed is extremely fast.

[0041] 4. Roofing System

[0042] The roofing system of this invention provides two alternatives, both of which are compatible with the main truss-secondary truss frame structure:

[0043] Option A – Membrane Structure Roof: A tensile membrane structure is used to cover the frame. The membrane material is directly fixed to the upper chord of the main truss using specialized clamps and connecting components. Membrane structure roofs are lightweight (typically 10 kg / m²). 2 ~15kg / m 2 This can further reduce structural load and steel consumption. Membrane structure roofs are suitable for scenarios where light transmission is required.

[0044] Option B—Corrugated Steel Sheet Metal Roofing: Cold-formed thin-walled steel purlins are directly laid on the upper chord of the main truss, and corrugated steel sheets (color steel sheets) are laid on the purlins to form a metal roofing system. Metal roofing has good durability and low maintenance costs, and is suitable for scenarios with high requirements for durability and fire resistance.

[0045] The choice between the two roofing options is determined by the engineering design based on project requirements.

[0046] Compared with the prior art, the present invention has the following beneficial effects:

[0047] 1. Significantly reduce the number of components and steel consumption: The spacing between the main trusses of the quadrilateral three-dimensional truss can reach 12m to 30m (more than 50% larger than the traditional system). With the arrangement of 5 to 6 secondary trusses per span, the overall number of components is reduced by 40% to 60% compared with the traditional dense planar truss system, and the steel consumption is reduced by 15% to 25%.

[0048] 2. Good stability during construction: The quadrilateral closed section three-dimensional truss has excellent out-of-plane stability during construction, and is not prone to out-of-plane instability and deformation, which reduces the number of temporary supports and the amount of erection work, and improves construction safety.

[0049] 3. Fully prefabricated construction, extremely fast construction speed: More than 99% of the welding work is completed in the factory, and only bolt tightening is required on site. The construction process is simple and uniform, and the construction speed is more than 3 times faster than the traditional welding and assembly method.

[0050] 4. Simplified node connections and high assembly precision: The connection method of rectangular chord members with factory-welded node plates completely avoids the quality problem of secondary trusses being difficult to position in the intersection of circular pipes. The node plates have "face-to-face" contact and mating, resulting in high positioning accuracy and large assembly tolerance.

[0051] 5. Factory manufacturing, controllable quality: The cutting, welding, rust removal and anti-corrosion coating of components are all completed in the factory, which can make full use of the factory's equipment precision and quality management system to ensure that the manufacturing quality of each component is uniform and stable.

[0052] 6. Wide applicability and flexible adjustment: The spacing of the main trusses, the cross-sectional dimensions of the trusses, the number of secondary trusses, and the roof form can all be flexibly adjusted according to specific project requirements. When the span exceeds 150m, tensioned trusses can be formed by adding cables, effectively controlling structural deformation and making ultra-large span material sheds possible. The compatibility and adaptability of membrane structure and profiled steel sheet roofing options enable this system to adapt to projects with different climatic conditions, different functions, and different owner requirements. Attached Figure Description

[0053] Figure 1 A three-dimensional schematic diagram of the overall structure of the fully prefabricated three-dimensional truss material shed product system;

[0054] Figure 2 A three-dimensional schematic diagram of a single main truss splicing unit;

[0055] Figure 3 Schematic diagram of the connection nodes between main trusses;

[0056] Figure 4 Schematic diagram of connection nodes in the height direction of the main truss;

[0057] Figure 5 Schematic diagram of the connection nodes between the main truss and the secondary truss (vertical connecting plates and bolt connections);

[0058] Figure 6 A schematic diagram of the connection node between the main truss and the secondary truss (partial reinforcement of the main truss chord).

[0059] Figure 7 A schematic diagram of the support nodes of the enclosure system;

[0060] Figure 8 This is a schematic diagram of a purlin support node for a metal roof.

[0061] Figure 9 This is a local reinforcement node between the web member and the chord member;

[0062] Figure 10 This is a splicing node between a web member and a chord member;

[0063] Figure 11 This is a flowchart illustrating the construction process of a fully prefabricated three-dimensional truss material shed.

[0064] Explanation of reference numerals in the attached drawings: 1. Main truss; 2. Secondary truss; 3. Tensioned chord system; 11. Butt joint connection between main trusses; 12. Connection joint in the height direction of the main truss; 13. Connection joint between the main truss and the secondary truss; 14. Roof support joint; 15. Local reinforcement joint between web member and chord member. Detailed Implementation

[0065] The following is in conjunction with the appendix Figures 1 to 11 The specific implementation of the fully assembled three-dimensional truss material shed product system of the present invention will be further described in detail.

[0066] I. Overall System Structure

[0067] like Figure 1 As shown, the fully prefabricated three-dimensional truss shed product system provided by the present invention includes a main truss 1, a secondary truss 2, and a roof system ( Figure 1 The roof system is not shown to avoid obscuring the lower frame structure. The main trusses 1 consist of several segments, arranged parallel to each other along the longitudinal direction of the shed. Secondary trusses 2 are installed between adjacent main trusses 1, with both ends of the secondary trusses 2 connected to the main trusses 1 on either side. The roof system is laid above the main trusses 1 and the secondary trusses 2.

[0068] When the span of the material shed is greater than 150m, such as Figure 1 As shown, a tensioned truss structure is formed by adding cables to the lower chord of the main truss 1. The cables are arranged longitudinally along the lower chord of the main truss 1 and connected to the lower chord nodes of the main truss 1 through vertical struts. The cables are made of high-strength steel wire bundles or steel strands, and the application of prestress can effectively control the vertical deformation of the main truss.

[0069] The main truss 1 is manufactured in the factory as segmented units, and adjacent segmented units are connected by main truss inter-connection nodes 11. The main truss 1 and the secondary truss 2 are connected by main truss-to-secondary truss connection nodes 13.

[0070] II. Main Truss Structure

[0071] like Figure 2 As shown, the single-segment main truss splicing unit adopts a quadrilateral cross-section three-dimensional truss. The main truss 1 includes two upper chords and two lower chords, which are connected by vertical web members and diagonal web members to form a spatial closed cross-section force system.

[0072] The top chord, bottom chord, vertical web members, and diagonal web members are all made of rectangular steel tubing (square or rectangular). The connections between the rectangular steel tubing members are made by welding in the factory. Figure 2 The exhibition showcases a 3D schematic of a single-segment main truss splicing unit after the segmented manufacturing process is completed. Each member has been welded and assembled in the factory to form an overall segmented unit before leaving the factory.

[0073] The spacing between two adjacent main trusses 1 is 12m to 30m. Depending on the project requirements, the main truss 1 can have the maximum height at mid-span and gradually decrease towards both ends to form a variable cross-section design, or it can adopt a constant cross-section design.

[0074] like Figure 9 As shown, a local reinforcement node 15 can be installed between the web member and the chord member. In the area where the chord member and web member meet, the load-bearing capacity of the node can be improved by adding stiffening plates or increasing the thickness of the node plate.

[0075] like Figure 10 As shown, the splicing node between the web member and the chord member is constructed by welding the web member and the chord member together in the factory using gusset plates. All welding is completed before the segment unit leaves the factory.

[0076] III. Segmental Connection Nodes of Main Truss Chords

[0077] like Figure 3 As shown, the main truss connection node 11 is a chord segment connection node. According to highway transport width and length restrictions (width generally not exceeding 3.5m, length generally not exceeding 15m-18m), the main truss 1 is manufactured in sections at the factory as transport segment units. Segmentation points are preferentially located at positions with smaller chord bending moments.

[0078] The specific construction of the segmented joint of the chord members is as follows: flange plates are welded to the joint ends of two adjacent chord members, and bolt holes are made on the flange plates. After the flange plates of the two chord members are fitted and aligned, high-strength bolts are inserted and tightened to complete the joint.

[0079] The flange is welded to the end of the chord member in the factory using a full penetration butt weld. The width of the flange is equal to or slightly larger than the width of the chord member cross-section. High-strength bolts are grade 10.9S or 8.8S.

[0080] After each segment unit is transported to the site, the flange plates of adjacent segment units are aligned and fitted together, high-strength bolts are inserted and tightened to the specified torque to complete the weldless splicing of the chord.

[0081] IV. Main Truss Height Segment Connection Nodes

[0082] like Figure 4As shown, the connection node 12 in the height direction of the main truss is a height segment docking node. When the height of the main truss 1 exceeds the height limit for highway transportation (generally not exceeding 4.0m to 4.5m), the main truss 1 can be divided into two segment units along the height direction: an upper segment unit and a lower segment unit.

[0083] The segment location is selected at the intersection of the vertical and diagonal web members (i.e., the truss joint point), and a flange connection node is set at this location. Specifically, flange plates are installed at the lower end of the upper segment unit and the upper end of the lower segment unit, respectively. The two flange plates are welded to the chord ends of their respective segment units at the factory.

[0084] The upper and lower units are manufactured, welded, and painted independently in the factory before being shipped out. After each segment unit is transported to the site, the flange plates of the upper and lower units are aligned, and high-strength bolts are inserted and tightened to complete the weldless assembly of the truss in the height direction.

[0085] like Figure 4 As shown, the connection node 12 in the height direction of the main truss is set at the intersection of the vertical web members and the diagonal web members, so that the segment position avoids the area of ​​large stress of the members and ensures the reliability of the node connection.

[0086] V. Connection nodes between main truss and secondary truss

[0087] like Figure 5 As shown, the connection node 13 between the main truss and the secondary truss adopts a vertical connecting plate and bolt connection method. Node plates are installed at the ends of the secondary truss 2, and connecting plates are installed on the chords or vertical web members of the main truss 1. Both the node plates and connecting plates are welded in the factory.

[0088] Bolt holes are pre-drilled on both the node plates and the connecting plates. The segmented units of the main truss 1 and the secondary truss 2 are shipped to the site after leaving the factory. During installation, the node plates at the ends of the secondary truss 2 are attached to the connecting plates on the main truss 1, high-strength bolts are inserted and tightened to complete the connection between the secondary truss 2 and the main truss 1.

[0089] like Figure 6 As shown, another embodiment of the connection node 13 between the main truss and the secondary truss is to install a connection plate after local reinforcement of the chord members of the main truss. When the chord section of the main truss 1 is small, stiffening plates can be added in the chord connection area or thicker node plates can be used to ensure that the load-bearing capacity of the connection node meets the design requirements. Figure 6 The diagram shows the specific structure of the local reinforcement of the main truss chord. The reinforcement plate is welded to the side or bottom of the chord, the node plate is welded to the reinforcement plate, and then the node plate at the end of the secondary truss is fastened to the connecting plate on the main truss by bolts.

[0090] The method of using rectangular chord members and factory-welded node plates, with the node plates connected in a "face-to-face" contact and mating manner, has high positioning accuracy and large assembly tolerance, completely avoiding the problem of secondary trusses being difficult to insert and position in the intersection of circular tubes.

[0091] VI. Roofing System and Support Nodes

[0092] The roofing system of the present invention provides two alternative solutions, which are connected to the main truss 1 via roof support nodes 14.

[0093] like Figure 7 As shown, the roof support node 14 is located on the upper chord of the main truss 1. The roof support node 14 includes a support plate, a stiffening plate, and connecting bolts. The support plate is factory-welded to the top of the upper chord of the main truss 1, and bolt holes are provided on the support plate. The connecting components of the roof system are fixedly connected to the support plate by bolts.

[0094] When a membrane structure roof is used, the membrane material is fixedly connected to the roof support node 14 on the upper chord of the main truss 1 using special clamps and connecting components. When a profiled steel sheet metal roof is used, such as Figure 8 As shown, a roof purlin support node (metal roof purlin support node) is set on the upper chord of the main truss 1. Cold-formed thin-walled steel purlins are laid on the purlins, and profiled steel sheets are laid on the purlins.

[0095] like Figure 8 As shown, the metal roof purlin support node includes a purlin support plate and stiffening ribs. The purlin support plate is welded to the top of the upper chord of the main truss 1, and the stiffening ribs are welded between the purlin support plate and the chord. The purlins are connected to the purlin support plate by bolts, and the profiled steel sheet is laid on top of the purlins and fixed to the purlins by self-tapping screws or interlocking methods.

[0096] like Figure 7 and Figure 8 As shown, regardless of whether a membrane structure roof or a profiled steel sheet metal roof is used, all connecting components of the roof system are connected to the roof support nodes 14 on the main truss 1 on site by bolts or fasteners, without the need for on-site welding.

[0097] When a membrane structure roof is used and the secondary truss 2 is a triangular tubular truss, the secondary truss 2 can be set as a variable-height shape with a reduced mid-span height to avoid contact with the tensioned membrane. Alternatively, membrane structure supports of a certain height can be set on the chords of the main truss 1, so that the secondary truss 2 is set at the same height while also avoiding contact with the tensioned membrane, thus ensuring the overall shape of the roof structure and natural drainage of the membrane roof.

[0098] VII. Construction Process Flow

[0099] like Figure 11 As shown, the construction process of the fully prefabricated three-dimensional truss material shed of the present invention is as follows:

[0100] (1) Factory manufacturing stage:

[0101] First, the components are cut and holes are drilled. The upper chord, lower chord, vertical web members, and diagonal web members of the main truss 1 are cut according to the design dimensions, and bolt holes or weld bevels are drilled at the ends of the members and at the joints.

[0102] Next, factory welding is performed. The members of the main truss 1 are assembled and welded according to the segmented unit divisions to form complete segmented units. All member connections within the segmented units (welding between chords and web members, welding between gusset plates and chords, etc.) are completed in the factory. The secondary truss 2 also has its members welded and assembled in the factory.

[0103] Then, rust removal and anti-corrosion coating are performed. After welding, the segmented units undergo sandblasting or shot blasting to remove rust, achieving the required rust removal level as designed. Then, primer, intermediate coat, and topcoat are applied sequentially. After the anti-corrosion coating is completed, the segmented units are shipped with a complete anti-corrosion coating.

[0104] (2) Transportation stage:

[0105] After each segment unit passes inspection, it is loaded and transported according to road transport restrictions. The segment units of main truss 1 are transported according to the chord segment length (usually 15m to 18m), while secondary truss 2 is transported as an independent, smaller segment unit. The segment units arrive at the site with a complete anti-corrosion coating.

[0106] (3) On-site assembly stage:

[0107] Only bolt tightening work was carried out on site. First, the assembly of each segment unit of the main truss 1 was carried out: the flange plates of adjacent segment units were aligned and fitted together, high-strength bolts were inserted and tightened to the specified torque to complete the connection of the chords of the main truss 1. When the main truss 1 has height segments, the flange plates of the upper and lower segments were aligned and high-strength bolts were inserted and tightened to complete the assembly of the main truss 1.

[0108] After the main truss 1 is assembled as a whole, it is hoisted into place. The assembled main truss 1 is hoisted to the design position, temporarily fixed, and then each main truss 1 is hoisted in sequence.

[0109] Then, install the secondary truss 2: attach the node plate at the end of the secondary truss 2 to the connecting plate on the main truss 1, insert high-strength bolts and tighten them to connect the secondary truss 2 to the main truss 1.

[0110] (4) Tensioning cables (if required):

[0111] When the span of the material shed is greater than 150m, a tensioned truss structure is formed by adding cables to the lower chord of the main truss 1. After each main truss 1 is hoisted into place, the lower chord cables and vertical struts are installed, prestress is applied according to the design requirements, and the tension is increased to the design cable force value.

[0112] (5) Roofing system construction (enclosure system installation):

[0113] Finally, the roofing system is constructed. When using profiled steel sheet metal roofing, cold-formed thin-walled steel purlins are laid on the upper chord of the main truss 1, connected to the purlin supports with bolts, and then profiled steel sheets are laid on the purlins. When using membrane structure roofing, membrane clamps are installed at the support nodes on the upper chord of the main truss 1 to tension and fix the membrane.

[0114] Throughout the construction process, the assembly of each segment unit, the installation of the secondary truss, the installation of the support system, and the laying of the roof system were all completed by bolt fastening. No welding work, rust removal, or painting was involved on site. All construction work was simplified to a single bolt fastening operation and roof laying operation. VIII. Specific Implementation Methods

[0116] Example 1: A 120m span enclosed material shed project in a coal mine stockpile

[0117] Project Overview: A coal mining company plans to install a large-span, fully enclosed material shed in its existing open-pit coal storage yard. The shed will have a span of 120m, a longitudinal length of 300m, and an eaves height of 25m. The storage yard area is approximately 35,000m², and the site is located inside the mining area with poor construction conditions (high dust levels and limited space). The client requires the construction period to be no more than 6 months.

[0118] Structural design: The fully assembled three-dimensional truss material shed product system of the present invention is adopted.

[0119] (1) Design of main truss 1:

[0120] Main truss type: Quadrilateral cross-section solid truss (e.g.) Figure 2 (As shown).

[0121] Main truss span: 120m.

[0122] Main truss spacing: standard spacing 24m, with adjustments made in some areas based on soil conditions (spacing adjusted to 18m in soft soil areas), a total of 14 main trusses are installed.

[0123] Main truss height: 7.5m at mid-span and 3.0m at the ends, with a variable cross-section design.

[0124] Chord section: Rectangular steel pipe opening 280mm×180mm×12mm (Q355B).

[0125] Vertical web member cross-section: rectangular steel pipe opening 160mm×160mm×8mm.

[0126] Diagonal web section: rectangular steel pipe opening 120mm×80mm×6mm.

[0127] Main truss transportation sections: The chord members are manufactured in the factory as transportation section units in 15m sections, with a total of 8 sections / truss (including flange plates).

[0128] The connections of the main truss segment units (welding between chords and web members, welding between node plates and chords) are all completed in the factory before being shipped out, including welding, rust removal, and anti-corrosion coating.

[0129] (2) Design of secondary truss 2:

[0130] Secondary truss type: triangular tube truss.

[0131] Secondary truss span: 24m (spacing between main trusses).

[0132] Number of secondary trusses: 5 trusses per span, with 5 secondary trusses set between two main trusses, spaced approximately 4m apart.

[0133] Secondary truss section height: 1.5m.

[0134] Stringer cross section: circular steel pipe d=89mm×5mm.

[0135] Web member cross section: circular steel pipe d=48mm×3.5mm.

[0136] (3) Connection node design:

[0137] Main truss chord segment connection node 11 (e.g.) Figure 3 (As shown): Flange plate thickness 20mm, material Q355B, M24 high-strength bolts (10.9S grade), 8 bolts per pair of flanges. Adjacent chord segment units are aligned by fitting the flange plates together, inserting bolts and tightening them to complete the connection.

[0138] Main truss height segmented connection node 12 (e.g.) Figure 4 As shown): The mid-span truss height is 7.5m, exceeding the transport height limit by 4.0m. It is divided into upper and lower units at a distance of 3.5m from the lower chord (the intersection of the vertical and diagonal web members). The upper and lower units are manufactured separately in the factory and assembled on site using flange plates and M24 bolts.

[0139] Connection node 13 between main truss and secondary truss (e.g.) Figure 5 , Figure 6As shown): In the factory, the connecting plates are welded to the chords of the main truss 1, and the node plates are welded to the ends of the secondary truss 2. On site, the node plates at the ends of the secondary truss 2 are attached to the connecting plates on the main truss 1 and secured with M20 high-strength bolts (10.9S grade), 6 bolts at each end.

[0140] (4) Roofing system:

[0141] The proposed metal roofing scheme uses profiled steel sheets: C220×75×20×2.5 cold-formed thin-walled C-shaped steel purlins are laid on the upper chord of the main truss 1 through purlin support nodes, spaced 1.5m apart. 0.6mm thick profiled color steel sheets (V-820 type) are then laid on the purlins. The roof's self-weight is approximately 15kg / m². 2 .

[0142] (5) Construction implementation (e.g.) Figure 11 (as shown)

[0143] Factory manufacturing cycle: 45 days (including material cutting, welding, painting, and factory inspection).

[0144] Component transportation: Approximately 30 truckloads will be used to transport each segment unit to the site.

[0145] On-site assembly cycle: 75 days. On-site, the 8 chord segments of the main truss 1 will be assembled into a complete main truss through flange node 11 (the mid-span height segment will be assembled through node 12), totaling 14 trusses; the 70 secondary truss 2 segments will be connected to the main truss 1 through node 13; finally, the roofing system will be laid.

[0146] Total construction period: approximately 5 months (including design and foundation construction), meeting the owner's requirement of a 6-month construction period.

[0147] There was no welding or rust removal / painting work at the construction site; the main tasks were only bolt tightening and roof paving.

[0148] Example 2: A 150m span enclosed material shed project (membrane structure roof) for an iron ore stockpile.

[0149] Project Overview: A steel company is installing an enclosed storage shed at its existing open-pit iron ore storage yard. The shed has a span of 150m, a longitudinal length of 200m, and an eaves height of 30m. The storage yard area is approximately 30,000m². 2 The highest point of the ore pile is approximately 18 meters. The site is a stockpile currently in production and operation, and construction must minimize disruption to production. The client requires a construction period not exceeding 5 months.

[0150] The main differences from Example 1 are:

[0151] The main truss spans 150m and is spaced 30m apart (a total of 8 main trusses are set longitudinally). The chord section is enlarged to 350mm x 220mm x 14mm (Q355B).

[0152] Because the truss height reaches 9.0m (mid-span), exceeding the transportation height limit, it is divided into two segments, an upper segment and a lower segment, at a distance of 4.0m from the lower chord. The upper and lower segments are transported separately and connected by flanges on site.

[0153] Design of the tensioned truss: Due to the span of 150m, tensioned cables were added to the lower chord of the main truss to form a tensioned truss. The cables are made of 1860MPa high-strength steel strand (7 strands, 15.2mm in diameter), with 4 strands on the lower chord of each main truss, connected to the lower chord via vertical struts (circular steel pipes d=180mm x 8mm). The prestressing of the cables was applied according to the mid-span deflection control value L / 400 of the main truss, ensuring that the mid-span deflection of the structure under the combination of self-weight and live load does not exceed 375mm (150m / 400). The tensioned truss effectively reduced the vertical deformation of the main truss and improved the overall stiffness of the structure.

[0154] The secondary truss spans 30m, with 6 trusses per span (5m spacing) and a section height of 2.0m.

[0155] The selected roofing scheme uses PVDF membrane material, which is directly fixed to the upper chord of the main truss via aluminum alloy clamps and stainless steel connecting components. Due to the lighter weight of the membrane structure roof (12kg / m² vs. 15kg / m² for profiled steel roof), the chord cross-sections of the main and secondary trusses can be appropriately reduced, further decreasing steel consumption.

[0156] This project involves a stockpile in production and operation, requiring unobstructed ore transportation routes during construction. The fully prefabricated construction method simplifies on-site operations to bolt tightening, resulting in low construction noise and dust, minimizing interference with ore transportation. The total number of components—8 main trusses and 48 secondary trusses—is only about 10% of that of a traditional inverted triangular truss system (approximately 500+ components), significantly reducing on-site hoisting operations and shortening the construction period. All segmented units (main truss chord segments, main truss height segments, and secondary truss segments) are welded and painted in the factory before leaving the site; on-site assembly and connection between segments is achieved solely through bolt tightening.

[0157] The above description is merely a preferred embodiment of the present invention. The scope of protection of the present invention is not limited to the above embodiments. All technical solutions falling within the scope of the present invention's concept are within the scope of protection of the present invention. It should be noted that for those skilled in the art, any improvements and modifications made without departing from the principles of the present invention should also be considered within the scope of protection of the present invention.

Claims

1. A fully prefabricated three-dimensional truss material shed product system, characterized in that, include: The main truss is a quadrilateral cross-section three-dimensional truss. The chords and web members of the quadrilateral cross-section three-dimensional truss are all made of rectangular steel pipes. The spacing between two adjacent main trusses is 12m to 30m. Secondary trusses, which are triangular tubular trusses or planar trusses, are arranged between two adjacent main trusses, and 3 to 10 secondary trusses are arranged between two adjacent main trusses. A roofing system, wherein the roofing system is disposed above the main truss and the secondary truss; The connection node system is as follows: the main truss is manufactured in the factory as segmented units, and the docking connections between the segmented units of the main truss and the connections between the secondary truss and the main truss are all made of fully assembled bolted connections. The members inside the segmented units of the main truss are connected by welding in the factory. After the segmented units of the main truss and the secondary truss are transported to the site, the assembly between the segmented units is completed on site only by bolt assembly and tightening, and no welding work is carried out on site.

2. The fully prefabricated three-dimensional truss material shed product system according to claim 1, characterized in that, The quadrilateral cross-section of the main truss consists of a spatial force-bearing system composed of an upper chord, a lower chord, vertical web members, and diagonal web members. There are two upper chord members and two lower chord members.

3. The fully prefabricated three-dimensional truss material shed product system according to claim 1, characterized in that, When the secondary truss is a triangular tubular truss, 5 to 6 secondary trusses are set between two adjacent main trusses; when the secondary truss is a planar truss, 8 to 10 secondary trusses are set between two adjacent main trusses.

4. The fully prefabricated three-dimensional truss material shed product system according to claim 1, characterized in that, When the span of the material shed is greater than 150m, a tension cable is added to the lower chord of the main truss to form a tensioned truss structure.

5. The fully prefabricated three-dimensional truss material shed product system according to claim 1, characterized in that, The connection node system includes: The main truss chord is segmented and connected at the joints. The main truss is segmented according to transportation restrictions. Flange or bolt joints are set at the chords at the segment. The connecting plate is welded to the chord in the factory. After each segment unit is transported to the site, the adjacent segment units are connected by installing and tightening high-strength bolts. The main truss and the secondary truss are connected at the node. The secondary truss is equipped with a node plate at its end and a connecting plate is installed on the main truss. Both the node plate and the connecting plate are welded in the factory. After each segment unit is transported to the site, the connection between the secondary truss and the main truss is completed by installing and tightening high-strength bolts. The main truss is segmented and connected at height. When the height of the main truss exceeds the transportation height limit, the web members are segmented along the height direction of the main truss, dividing the main truss into upper and lower units. Bolt connection nodes are set at the web member segmentation points. After each segment unit is transported to the site, the main truss is assembled and formed by installing and tightening high-strength bolts.

6. The fully prefabricated three-dimensional truss material shed product system according to claim 5, characterized in that, The segmentation points of the main truss chord segment connection nodes are set at positions where the bending moment of the chord is relatively small.

7. The fully prefabricated three-dimensional truss material shed product system according to claim 5, characterized in that, The segmented connection points of the main truss height segments are located at the intersection of the vertical web members and the diagonal web members.

8. The fully prefabricated three-dimensional truss material shed product system according to claim 1, characterized in that, The roofing system is a membrane structure roof or a profiled steel sheet metal roof.

9. The fully prefabricated three-dimensional truss material shed product system according to claim 8, characterized in that, When the roof system adopts a membrane structure roof and the secondary truss is a triangular tube truss, the secondary truss is configured as a variable height shape with a reduced mid-span height; or membrane structure supports are provided on the chords of the main truss.

10. The fully prefabricated three-dimensional truss material shed product system according to claim 1, characterized in that, The main truss segments are welded, rust-removed, and coated with anti-corrosion paint in the factory before leaving the factory. The factory welding accounts for more than 99% of the total welding, and only the bolt insertion and tightening are performed on site.

Images