钢结构厂房托梁拔柱改造技术与安全管理研究
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摘要
据测算，我国既有建筑物面积约400亿m2，其中工业建筑约100亿m2。上世纪五六十年代我国大量兴建的工业厂房长期经受高温、高湿、腐蚀性气体、粉尘以及重载等恶劣环境影响，其结构损伤严重，大部分进入了老年期。随着科学技术的快速发展，工业生产也正在步入机械化、现代化时代，既有工业建筑设施的适应性改造日益活跃。托梁拔柱作为有效扩大柱间距的改造方法得到了广泛应用，然而复杂的生产环境条件决定了改造质量的参差不齐和高风险性。
针对钢结构厂房的托梁拔柱改造，目前已有许多施工技术和研究成果，但在托梁拔柱改造过程中对支撑体系的设计、原结构的变形控制以及改造后组合结构的整体工作性能等方面仍存在较多问题没有解决。因此，研究钢结构厂房托梁拔柱改造系统理论与方法，使托梁拔柱改造设计和施工标准化、规范化，对降低改造过程的安全风险具有重大理论意义和现实意义。
本文运用现代安全管理理论、系统工程原理，采用结构分解（WBS）方法、工程现场测试以及事故树（FTA）分析方法，建立了钢结构厂房托梁拔柱的标准化设计流程和施工工艺，构建了托梁拔柱全过程安全评价指标体系，同时给出了安全风险控制对策，以期改进托梁拔柱项目质量，控制安全风险。本文的主要研究内容如下：
（1）托梁拔柱设计原则与方法
参考国家标准、规范，通过专家访谈，总结了既有建筑托换设计的一般原则以及托梁拔柱防倒塌设计原则。针对钢结构厂房托梁拔柱改造，重点介绍了结构构造设计原则，并对关键构件——托梁（或托架）的极限状态、刚度控制以及结构布置的设计原则进行了总结和阐述，最后提出了钢结构厂房托梁拔柱改造设计的一般流程。
（2）托梁拔柱施工工艺与施工关键技术
通过专家访谈，比较研究了目前常见的三种托梁拔柱方法——非完整托架顶升施工方法、完整托架顶升施工方法以及完整托架不顶升施工方法各自的优、缺点，并推荐“完整托架不顶升施工方法”作为托梁拔柱的首选方法。采用结构分解（WBS）方法和流程图的形式识别了该方法的一般施工工艺，并对其施工过程的关键技术——基础和钢柱加固技术、托架原位制作技术、截柱卸载技术等进行了详细阐述。
（3）现场测试与理论分析对比
利用SAP2000有限元软件对某单层钢结构厂房托梁拔柱改造前、后抗震性能以及关键构件的承载力等进行了验算，结果表明采用前述成果，托梁拔柱结构的承载能力和刚度满足规范要求，验证了设计原则和施工方案的可行性。通过托梁拔柱工程现场试验，对托换过程关键构件的应力和挠度进行测试和分析，获得截柱、卸载过程中关键构件托架和柱子的内力变化规律，并与有限元计算结果进行了对比，分析了理论值与测试值出现偏差的主要影响因素氧炔焰切割钢柱导致柱子的温度升高，从而证实了采用完整托架不顶升施工方法进行托梁拔柱施工的科学性。
（4）托梁拔柱安全风险管理
识别了托梁拔柱施工过程中潜在的主要安全事故类型高处坠落、物体打击、坍塌、机具伤害以及触电，采用事故树（FTA）方法对导致各主要安全事故类型的风险因素进行分解，并采用事故树的定性计算方法，得出不同事件的结构重要性系数。据此建立了钢结构厂房托梁拔柱安全评价指标体系，并提出了托梁拔柱安全风险控制对策。
According to estimation, there is about40billion square meters existing buildings inChina, and the industrial building area is about10billion square meters. A large number ofindustrial buildings of1950's and1960's, which withstood long-term bad environmentsuch as high temperature, high humidity, corrosive gases, dust and heavy load, had seriousstructural damage and have been into elderly stage. With the rapid development of scienceand technology, industrial production is moving into a mechanization and modern era,besides, the adaptable reformation technology has become increasingly actively. Bracketgirder and cut column (BGCC), as an effective way to expand the column space, has beenwidely used, however, complex environmental conditions resulted in uneven quality andhigh-risk.
There is a lot of construction technique and research about BGCC for steel structuralindustrial buildings; however, there are many problems which have been unresolved, suchas support-system design, primary structure deformation control and the whole workperformance of composite construction, etc. In order to make the design and constructiontechnology of BGCC normal and standard, and reduce the reformation safety risk, thesystematic theory and applied research of BGCC for steel structural industrial buildingswas promoted.
In the thesis, modern safety management theory, system engineering principle, workbreakdown structure(WBS), project in-situ monitoring and fault tree analysis (FTA)method were applied to establish standard design process and construction technology ofBGCC for steel structural industrial buildings. In order to improve the construction qualityof BGCC and control the safety risk, the whole process of safety evaluation system andsafety risk control measures were provided.The main contents of the thesis are as follows:
(1) Design principles and methods of BGCC
Referring to the national standards, norms, and through expert interview, the generaldesign principles of underpinning design for existing buildings and anti-collapse designprinciples of BGCC were summarized.The thesis emphatically introduced the structureconstruction design principles, and expounded the design principles of limit state, stiffnesscontrol and structural arrangement for the key components-the bracket girder (or bracket).Finally, the general process of transformation design for steel structural industrialbuildings was proposed.
(2) Construction technology and key construction technique of BGCC
Through expert interview, according to the comparison of advantages anddisadvantages of the current three common methods of BGCC-non-complete bracketjacking construction method, complete bracket jacking construction method and completebracket without jacking construction method, complete bracket without jackingconstruction method was recommended in the thesis. By the use of work breakdownstructure (WBS) and the flow chart method, the general construction processes wereidentified. Finally, the key construction technology, which contained reinforcementtechnology of the foundation and steel columns, production technology of brackets in situ,and technology of cutting column with uninstallation, was described detailedly.
(3) Comparison of project in-situ monitoring and theoretical result
The checking calculation result of seismic performance and bearing capacity of thecritical components between the original steel structural industrial building and the BGCCreform industrial building, which was used by SAP2000finite element software, showedthat the bearing capacity and the stiffness met standard, and the design principles andconstruction methods were feasible. It was found that the internal forces changes law ofthe bracket and the column during cut-off column and uninstalling process after the in-situmonitoring of BGCC project after the analysis of stress and deflection of the keycomponents during underpinning. By analyzing the main reasons why the results betweentheory and test different, it was found that the temperature of the cutting part of columnincreased was due to the oxygen-acetylene flame. Therefore, it was confirmed that thecomplete bracket without jacking construction method was scientific.
(4) Safety risk management of BGCC
After identifing the potential major accident types during the construction ofBGCC-fall, object hitting, collapse, equipment damage and electric shock, the major riskfactors of accidents were decomposed. Then through fault tree analysis (FTA) method, theimportance coefficient of the accident event was found. Accordingly, safety evaluationsystem for BGCC of steel structural industrial buildings was established and the safetyrisk control measures were proposed.
针对钢结构厂房的托梁拔柱改造，目前已有许多施工技术和研究成果，但在托梁拔柱改造过程中对支撑体系的设计、原结构的变形控制以及改造后组合结构的整体工作性能等方面仍存在较多问题没有解决。因此，研究钢结构厂房托梁拔柱改造系统理论与方法，使托梁拔柱改造设计和施工标准化、规范化，对降低改造过程的安全风险具有重大理论意义和现实意义。
本文运用现代安全管理理论、系统工程原理，采用结构分解（WBS）方法、工程现场测试以及事故树（FTA）分析方法，建立了钢结构厂房托梁拔柱的标准化设计流程和施工工艺，构建了托梁拔柱全过程安全评价指标体系，同时给出了安全风险控制对策，以期改进托梁拔柱项目质量，控制安全风险。本文的主要研究内容如下：
（1）托梁拔柱设计原则与方法
参考国家标准、规范，通过专家访谈，总结了既有建筑托换设计的一般原则以及托梁拔柱防倒塌设计原则。针对钢结构厂房托梁拔柱改造，重点介绍了结构构造设计原则，并对关键构件——托梁（或托架）的极限状态、刚度控制以及结构布置的设计原则进行了总结和阐述，最后提出了钢结构厂房托梁拔柱改造设计的一般流程。
（2）托梁拔柱施工工艺与施工关键技术
通过专家访谈，比较研究了目前常见的三种托梁拔柱方法——非完整托架顶升施工方法、完整托架顶升施工方法以及完整托架不顶升施工方法各自的优、缺点，并推荐“完整托架不顶升施工方法”作为托梁拔柱的首选方法。采用结构分解（WBS）方法和流程图的形式识别了该方法的一般施工工艺，并对其施工过程的关键技术——基础和钢柱加固技术、托架原位制作技术、截柱卸载技术等进行了详细阐述。
（3）现场测试与理论分析对比
利用SAP2000有限元软件对某单层钢结构厂房托梁拔柱改造前、后抗震性能以及关键构件的承载力等进行了验算，结果表明采用前述成果，托梁拔柱结构的承载能力和刚度满足规范要求，验证了设计原则和施工方案的可行性。通过托梁拔柱工程现场试验，对托换过程关键构件的应力和挠度进行测试和分析，获得截柱、卸载过程中关键构件托架和柱子的内力变化规律，并与有限元计算结果进行了对比，分析了理论值与测试值出现偏差的主要影响因素氧炔焰切割钢柱导致柱子的温度升高，从而证实了采用完整托架不顶升施工方法进行托梁拔柱施工的科学性。
（4）托梁拔柱安全风险管理
识别了托梁拔柱施工过程中潜在的主要安全事故类型高处坠落、物体打击、坍塌、机具伤害以及触电，采用事故树（FTA）方法对导致各主要安全事故类型的风险因素进行分解，并采用事故树的定性计算方法，得出不同事件的结构重要性系数。据此建立了钢结构厂房托梁拔柱安全评价指标体系，并提出了托梁拔柱安全风险控制对策。
According to estimation, there is about40billion square meters existing buildings inChina, and the industrial building area is about10billion square meters. A large number ofindustrial buildings of1950's and1960's, which withstood long-term bad environmentsuch as high temperature, high humidity, corrosive gases, dust and heavy load, had seriousstructural damage and have been into elderly stage. With the rapid development of scienceand technology, industrial production is moving into a mechanization and modern era,besides, the adaptable reformation technology has become increasingly actively. Bracketgirder and cut column (BGCC), as an effective way to expand the column space, has beenwidely used, however, complex environmental conditions resulted in uneven quality andhigh-risk.
There is a lot of construction technique and research about BGCC for steel structuralindustrial buildings; however, there are many problems which have been unresolved, suchas support-system design, primary structure deformation control and the whole workperformance of composite construction, etc. In order to make the design and constructiontechnology of BGCC normal and standard, and reduce the reformation safety risk, thesystematic theory and applied research of BGCC for steel structural industrial buildingswas promoted.
In the thesis, modern safety management theory, system engineering principle, workbreakdown structure(WBS), project in-situ monitoring and fault tree analysis (FTA)method were applied to establish standard design process and construction technology ofBGCC for steel structural industrial buildings. In order to improve the construction qualityof BGCC and control the safety risk, the whole process of safety evaluation system andsafety risk control measures were provided.The main contents of the thesis are as follows:
(1) Design principles and methods of BGCC
Referring to the national standards, norms, and through expert interview, the generaldesign principles of underpinning design for existing buildings and anti-collapse designprinciples of BGCC were summarized.The thesis emphatically introduced the structureconstruction design principles, and expounded the design principles of limit state, stiffnesscontrol and structural arrangement for the key components-the bracket girder (or bracket).Finally, the general process of transformation design for steel structural industrialbuildings was proposed.
(2) Construction technology and key construction technique of BGCC
Through expert interview, according to the comparison of advantages anddisadvantages of the current three common methods of BGCC-non-complete bracketjacking construction method, complete bracket jacking construction method and completebracket without jacking construction method, complete bracket without jackingconstruction method was recommended in the thesis. By the use of work breakdownstructure (WBS) and the flow chart method, the general construction processes wereidentified. Finally, the key construction technology, which contained reinforcementtechnology of the foundation and steel columns, production technology of brackets in situ,and technology of cutting column with uninstallation, was described detailedly.
(3) Comparison of project in-situ monitoring and theoretical result
The checking calculation result of seismic performance and bearing capacity of thecritical components between the original steel structural industrial building and the BGCCreform industrial building, which was used by SAP2000finite element software, showedthat the bearing capacity and the stiffness met standard, and the design principles andconstruction methods were feasible. It was found that the internal forces changes law ofthe bracket and the column during cut-off column and uninstalling process after the in-situmonitoring of BGCC project after the analysis of stress and deflection of the keycomponents during underpinning. By analyzing the main reasons why the results betweentheory and test different, it was found that the temperature of the cutting part of columnincreased was due to the oxygen-acetylene flame. Therefore, it was confirmed that thecomplete bracket without jacking construction method was scientific.
(4) Safety risk management of BGCC
After identifing the potential major accident types during the construction ofBGCC-fall, object hitting, collapse, equipment damage and electric shock, the major riskfactors of accidents were decomposed. Then through fault tree analysis (FTA) method, theimportance coefficient of the accident event was found. Accordingly, safety evaluationsystem for BGCC of steel structural industrial buildings was established and the safetyrisk control measures were proposed.
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