Steel Shell Plate and Steel Frame, S3rc Building Structure

The present invention relates to a building structure, especially to a tri-layer steel reinforced concrete (S3RC) building structure that covers the concrete and the internal steel constructions of walls, columns, beams, and floors with steel plates and steel frames to form a continuous building structure.

In the civil engineering field, the modern building structures are mainly constructed by the Reinforced Concrete structure (RC structure), and whereby the Steel Reinforced Concrete structure (SRC structure), which includes the Steel Construction structure (SC structure, known as the Steel-Concrete Composite structure or the Structural Concrete structure) as main support, is developed based on the RC structure. The high-rise buildings constructed only with steel frames are not suitable for residential uses since large horizontal displacements would occur to the high floors due to high malleability of steel materials when stricken by earthquakes or horizontal winds, and thus the people on the high floors may feel uncomfortable.

Besides, in the conventional SRC structure, the columns and the beams are supported by steel frames disposed within, and then embedded by the concrete which has a thickness of about 15 to 20 centimeters. The concrete embeds large main rebars and rebar hoops, and the rebars and the steel frame work together. The construction of the SRC structure needs formworks, rebars assembling and processing, and plastering works.

Patent publication TWM358176 discloses a reinforced concrete wall, the constructing process of which serially includes light steels assembling, external steel meshes laying, internal rebars installing, and grouting. The construction period of said reinforced concrete wall is short, but the steel-meshed wall surfaces are weak in waterproofness, and thus the waterproof treatment would be required when said reinforced concrete wall is applied to be an exterior wall, and the reinforced concrete wall is not recommended to be applied as a shear wall or a load-bearing wall. Furthermore, the patent publication teaches constructing the steel-meshed wall by assembling several precast steel beams and two steel meshes and cement grouting; and then the two steel meshes would be surface-treated with plastering either manually or by machine after the concrete completes formation with maintenance and drying, and is treated with plaster finish or monolithic treatment in the last to form and modify a layered body, such that the construction of the steel-meshed wall is finished.

Moreover, the conventional RC, SC, and SRC structures are like the muscles of the musculoskeletal system, and thus the concrete and the rebars are prone to exposure in the air; the structures lack external protections and thus have low tensile resistances, hence easy to be affected and lead to structural deterioration, reducing the earthquake resistance. Once the earthquake occurs, the broken pieces of the concrete would be scattered over, and thus the structure would fall apart immediately. In addition, the conventional RC, SRC, and SC structures are easy to be damaged by the harmful environmental factors due to exposure in the air, for example, the concrete may bulge due to the electrochemical reactions occurring in the concrete or the rebars, or the structural strength may be reduced as the reduction-oxidation reactions occur in the concrete due to moisture, water, or seawater erosion.

To overcome the shortcomings of the conventional RC structure, SRC structure, and SC structure, the present invention provides an S3RC building structure to mitigate or obviate the aforementioned problems.

The main objective of the present invention is to provide a tri-layer steel reinforced concrete (S3RC) building structure that is capable of mitigating the disadvantages of the RC construction, the SRC construction, and the SC construction mentioned in the prior arts.

The S3RC building structure has An S3RC building structure comprises a steel frame, at least one steel shell layer, multiple rebars, and a concrete. The at least one steel shell layer is mounted on the steel frame. The at least one steel shell layer comprises multiple steel bearing plates arranged side by side, and each one of the steel bearing plates has a main portion and two connecting portions. The main portion is rectangular in shape, and the two connecting portions are connected to and extend away from two opposite edges of the main portion respectively. Each one of the connecting portions protrudes from one of two sides of the at least one steel shell layer. Wherein the two connecting portions between any adjacent two of the steel bearing plates are connected to each other. The rebars are connected to the steel frame and located at one of the two sides of the at least one steel shell layer. The concrete is disposed at the side of the at least one steel shell layer where the rebars are located, and the concrete embeds the rebars.

To address the issues, another S3RC building structure is provided, which comprises at least one steel shell layer, and the at least one steel shell layer is attached to a surface of a Reinforced Concrete (RC) structure and thus covers the RC structure. Wherein the at least one steel shell layer comprises multiple steel bearing plates arranged side by side, and each one of the steel bearing plates has a main portion and two connecting portions. The main portion is rectangular in shape, and two connecting portions are connected to and extends away from two opposite edges of the main portion respectively. Each one of the connecting portions protrudes from one side of the at least one steel shell layer. Wherein the two connecting portions between any adjacent two of the steel bearing plates are connected to each other.

To address the issues, another S3RC building structure is provided, which has at least one steel shell layer, and the at least one steel shell layer is attached to a surface of a Steel Reinforced Concrete (SRC) structure and thus covers the SRC structure. Wherein the at least one steel shell layer comprises multiple steel bearing plates arranged side by side, and each one of the steel bearing plates has a main portion and two connecting portions. The main portion is rectangular in shape, and two connecting portions are connected to and extends away from two opposite edges of the main portion respectively. Each one of the connecting portions protrudes from one side of the at least one steel shell layer. Wherein the two connecting portions between any adjacent two of the steel bearing plates are connected to each other.

To address the issues, another S3RC building structure is provided, which has at least one steel shell layer, and the at least one steel shell layer is attached to a surface of a Steel Construction (SC) structure and thus covers the SC structure.

With the steel shell layer and/or the steel frame covering the concrete and the rebars, the tensile resistance of the concrete may be improved from the exterior, enhancing the earthquake resistance; if the earthquake occurs and the concrete is shattered, the broken pieces may be covered by the steel shell layer rather than fall apart, thereby avoiding the collapse of the overall structure. In addition, the steel shell layer can also protect the concrete from being affected by the atmosphere and water, preventing the concrete from bulging and weathering, and thus maintains a fine structure of the concrete. Each one of the columns, beams, walls, and slab structures of the S3RC building structure has at least one steel plate and at least one steel frame, and the walls and the slabs may help improve the tensile resistance of the whole construction, dispersing the external forces and reducing the deformation; when the earthquake occurs, the horizontal inertia force of the earthquake may be counteracted, the shaking degree of the construction may be reduced, the comfort degree would not decrease much, and the likelihood of wall cracking caused by the earthquake may be lowered.

Other objectives, advantages and novel features of the invention will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.

With reference to, a tri-layer steel reinforced concrete (S3RC) building structure in accordance with the present invention comprises at least one steel shell layer, a steel frame, multiple rebars, and a concrete. In this disclosure, the steel frameis covered by the rebarsand the concretejust like the steel frameis immersed in a reinforced concrete, and the steel shell layercovers the aforementioned structure from the exterior. The whole structure may be divided into two layers including an inner layer and an outer layer, by which the outer layer may be a Steel Construction (SC) structure and the inner layer may be a Reinforced Concrete (RC) structure, and the two layers are fully covered by the steel shell layer. The aforementioned structure would show three layers of steel (Steel*) and a reinforced concrete (RC) on a cross-section, and thus is named “the S3RC building structure.”

Besides, as shown in, the user may apply the steel shell layerto cover an RC structure or an SC structure to achieve the effects of enhancing the structural strength, resisting earthquake, and protecting those building constructions.

With reference to, the rebarsare connected to the steel frameand located at a side of the steel shell layer. The steel shell layercomprises multiple steel bearing platesand multiple fixing units, but a configuration of the steel shell layeris not limited thereto, as the steel shell layermay include C-shaped steels or steel sheets.

The steel bearing platesare arranged side by side, and each one of the steel bearing plateshas a main portionand two connecting portions. The main portionis rectangular in shape, and the two connecting portionsare connected to two opposite edges of the main portionrespectively. Each one of the two connecting portionsextends along and extends away from the edge of the main portionto which it is connected, protruding from one side of the steel shell layer. The two connecting portionsbetween any adjacent two of the steel bearing platesare connected to each other, but a configuration of the connecting portionis not limited thereto.

To be more precise, in this embodiment, the two connecting portionsof each one of the steel bearing platesinclude a first connecting portionand a second connecting portion. The first connecting portionis curved away from the second connecting portionand forms a connecting groove, and the second connecting portionis curved toward the first connecting portion. When the adjacent two steel bearing platesare connected to each other, the second connecting portionof one of the steel bearing platesis located in the connecting grooveof the first connecting portionof another one of the steel bearing plates, but it is not limited thereto.

The S3RC building structure in this embodiment comprises a plurality of the fixing units, and each one of the fixing unitsis mounted through the two connecting portionsbetween any adjacent two of the steel bearing plates. To be more precise, the fixing unitmay be a shear nail which penetrates and engages with the first connecting portionand the second connecting portionthat are connected to each other, and thereby fixes the relative positions between the two steel bearing plates, and further combines more steel bearing platesto form the steel shell layer, but it is not limited thereto. There may be no fixing unitin other embodiments, but directly connecting multiple steel bearing platesto form the steel shell layerby welding.

The rebarsare located at a side of the steel shell layer, and the concreteis also located at the same side of the steel shell layer, embedding the rebars.

The S3RC building structure in this disclosure may be applied to construct wall structures, column structures, and slab structures, and details about constructing the aforementioned structure are below.

With reference to, in the wall structure, the steel framecomprises a steel beamand a steel columnwhich are connected to each other. The steel columnextends along an up-down direction and the steel beamextends along a horizontal direction. A number of the steel shell layersis two, and the two steel shell layersare spaced apart from and face towards each other, but it is not limited thereto. The steel shell layersare connected to the steel beamand the steel column. The rebarsare crisscross connected to each other, and the two steel shell layersare disposed between two baseline C-shaped steels. In addition, a distance between the two steel shell layersmay be altered according to needs.

When constructing the wall structure, the steel columnand the steel beamof the steel framemay be set first. The two baseline C-shaped steelsare mounted on the steel beamaccording to laser positioning. The two baseline C-shaped steelsare disposed spaced apart from each other. The two steel shell layersare connected to the two baseline C-shaped steelsrespectively, and the two steel shell layersare located between the two baseline C-shaped steels. The steel shell layersand the baseline C-shaped steelsare preferably connected by welding.

Next, set multiple horizontal rebarsat the side of each one of the steel shell layerswhich faces towards the other steel shell layer, and mount multiple vertical rebarson the horizontal rebars. The horizontal rebarsand the vertical rebarsmounted on each one of the steel shell layerstogether form an outer rebar mesh. The horizontal rebarsand the steel shell layersare preferably connected by welding, and the horizontal rebarsand the vertical rebarsare preferably connected by welding after tied together, but it is not limited thereto. In other embodiments, the horizontal rebarsmay be replaced with stainless steel circulation tubes, thereby building a circulating flow path to control the temperature of the wall structure. In addition, in this embodiment, an interval between any adjacent two of the horizontal rebarsis about 50 centimeters, and an interval between any adjacent two of the vertical rebarsis about 15 centimeters, but it is not limited thereto, and the aforementioned intervals may be altered according to needs.

An inner rebar meshis installed at a central line between the two steel shell layerswith laser positioning; in this embodiment, the inner rebar meshmay be provided as a rebar mesh formed by deformed rebars, but it is not limited thereto. Each one of the lattices of the inner rebar meshmay have a length about 10 centimeters and a width about 10 centimeters, but it is not limited thereto, as the intervals among the rebars of the inner rebar meshmay be adjusted according to needs. The two outer rebar meshesare disposed apart from the inner rebar meshrespectively and located between two steel shell layers. Distances between each one of the two outer rebar meshesand the inner rebar meshmay be adjusted according to needs. Then the plumbing system, the electrical conduits, and the fire pipelines are installed between the inner rebar meshand the horizontal rebar, and holes reserved for setting the water inlets/outlets, the electrical components, the firework facilities, or the windows are formed on the steel shell layer. Next, multiple thickness fixing wall rebarsare installed to fix a distance between the two steel shell layers. In this embodiment, the distance between any adjacent two of the thickness fixing wall rebarsis about 20 centimeters, but it is not limited thereto, as the aforementioned distance may be adjusted according to needs. The installing process of the thickness fixing wall rebaris commonly known in the technical field and thus is omitted here.

With reference to, regarding the column structure of this disclosure, the steel shell layermay be arranged along the up-down direction and surround a column space, and the steel columnof the steel frameis located in the column space.

The steel shell layerof the column structure in this embodiment may be preferably provided by multiple reinforced steel bearing platesA connected to each other, and the reinforced steel bearing platesA together surround the steel column. Each one of the reinforced steel bearing platesA is similar to the steel bearing platein structure by having a main portionA and two connecting portionsA. The two connecting portionsA are located at two opposite edges of the main portionA, and the reinforced steel bearing platesA are connected to each other via the connecting portionsA. One of the main differences between the reinforced steel bearing plateA and the steel bearing plateis that the reinforced steel bearing plateA is thicker than the steel bearing plate, and thus the reinforced steel bearing plateA may have a greater strength than the steel bearing plate. To be more precise, in this embodiment, a thickness of the steel bearing plateis about 2.8 millimeters, but a thickness of the reinforced steel bearing plateA is about 3.2 millimeters, but it is not limited thereto, as thicknesses of the steel bearing plateand the reinforced steel bearing plateA may be altered according to needs.

When constructing the column structure in this disclosure, first the user may base on the baselines of the two adjacent wall structures, specifically the extending line of the horizontal rebarsof the steel shell layerwhich is relatively located external of each one of the two adjacent wall structures, to provide the two edges of the steel columnand connect the horizontal rebarsto the steel column. The horizontal rebarsand the steel columnare preferably connected by welding. The reinforced steel bearing platesA are connected with each other to form the steel shell layer, and the reinforced steel bearing platesA together surround the steel column, such that the steel columnis located in the column spaceformed by the steel shell layer. Furthermore, the drainage system, the plumbing system, and/or the electrical conduits may be disposed in the column space. In this embodiment, the steel shell layermay be integrally connected to the steel columnby welding, specifically the steel shell layerswhich are relatively located externally of adjacent two of the wall structures are securely connected to the steel columnby welding to enhance the structural strength. Thereby, the steel shell layersof the wall structure and the steel bearing plateof the column structure form a continuous structure, and the space within may be grouted in one step, and thus the concrete in the wall structure and the column structure may form a continuous structure.

The column structure in this embodiment may further have a steel tightening ring, which is located at an external side of the steel shell layer, surrounding and mounted on the steel shell layer. Specifically, the steel tightening ringin this embodiment may be manufactured by bending a C-shaped steel, and the steel tightening ringis securely connected to the external side of the steel shell layerto tighten the steel shell layerof the column structure, such that the structural strength is enhanced, but it is not limited thereto. In other embodiments, the column structure may not have the steel tightening ring, or the user may securely connect the steel tightening ringand the steel shell layerswhich are located relatively external of adjacent two of the wall structures by welding.

The steel shell layerslocated externally and the reinforced steel bearing plateA may be provided by galvanized steel bearing plates or stainless steel bearing plates to enhance the water-proof effect; in addition, additional rebars may be securely connected to the reinforced steel bearing platesA and the connecting portionsA by welding to enhance the strength. Additional rebars may be securely connected to the reinforced steel bearing platesA and the steel shell layersby through-hole reflow welding to enhance the connection of the wall structures and the column structure; the rebarsmay be securely connected to the reinforced steel bearing platesA by through-hole reflow welding with additional rebars, but the constructing way is not limited thereto. The steel tightening ringis securely connected to the reinforced steel bearing plateA by welding to enhance the effect of earthquake-resisting. The steel tightening ringmay be placed at a bottom part of the building, and the amount of the steel tightening ringmay be adjusted according to needs.

With reference to, a slab structure in accordance with the present invention would be illustrated in the following paragraphs.

In the slab structure, the steel frameincludes a steel beam, and the at least one steel shell layeris disposed along the horizontal direction and connected to the steel beam. The steel shell layeris lying down. A plurality of the rebarsare crisscross connected to each other and form several rebar meshes, and the rebar meshes are arranged parallel to and spaced apart from each other above the steel shell layer.

With reference to, to be more precise, the steel beamhas a top and a bottom which are opposite to each other, and the slab structure in this disclosure may include different types according to relative positions between the concreteand the steel beam, such as a “middle-positioned type” slab structure in which the concreteis placed at the same height position with the steel beamand a “top-positioned type” slab structure in which the concreteis placed on the steel beamA. When applied to the middle-positioned type slab structure, please refer tofor the middle-positioned type slab structure in which the steel shell layeris located at the primary beam bottomof the primary beamof the steel beam, and a plurality of rebar meshes are connected to the steel beam; when applied to the top-positioned type slab structure, please refer tofor the top-positioned type slab structure in which the steel shell layeris connected to the secondary beam topA of the secondary beamA of the steel beamA.

The construction of the slab structure may be conducted after the constructions of the aforementioned wall structure and the column structure are finished.

With reference to, in the middle-positioned type slab structure in this disclosure, the steel beamsinclude multiple primary beamsand multiple secondary beams. Two ends of each one of the secondary beamsare located at the middle line of the primary beams. Preferably, the primary beamand the secondary beamare securely connected to each other by welding, or may further connect with reinforced plates by all-around welding, but it is not limited thereto.

After reserving space for stairs, multiple holesare drilled along middle lines of the secondary beams. An inner diameter of each one of the holesis preferably between 6 and 10 centimeters, and the diameters of the holesin this embodiment are about 8 centimeters, but it is not limited thereto. The rebarsare arranged along extending directions of the primary beamand the secondary beam, such that the rebarsare crisscross connected to each other to form an upper rebar meshand a lower rebar mesh. The upper rebar meshis located along the middle line of the secondary beam, and the rebars of the upper rebar meshwhich extend along a length direction of the primary beamare disposed through the holeslocated along the middle line of the secondary beamand securely connected to the secondary beamby welding. In this embodiment, each one of the lattices of the upper rebar meshand the lower rebar meshhas a length and a width which are about 10-cm long, but it is not limited thereto.

The lower rebar meshis securely connected to the secondary beam bottomof each one of the secondary beamsby welding, and then the steel shell layeris mounted below the lower rebar mesh. In this embodiment, the steel shell layeris lying down and is securely connected to the lower rebar meshby welding, and each one of the steel bearing platesof the steel shell layeris arranged parallel to the primary beam, but it is not limited thereto. In addition, multiple rebar supporting chairsmay be tied or welded between the upper rebar meshand the lower rebar mesh, thereby building connections between the upper rebar meshand the lower rebar mesh, but it is not limited thereto.

With reference to, similarly, in the top-positioned type slab structure, the steel beamsA include multiple primary beamsA and multiple secondary beamsA, and the secondary beamsA are connected to primary beam topsA of the primary beamsA and spaced apart from each other. To be more precise, in this embodiment, the primary beamsA and the secondary beamsA may be connected together with reinforced plates by bolts, and then undergo all-around welding, but it is not limited thereto.

After reserving space for stairs, mount the steel shell layeron the secondary beam topsA of a plurality of the secondary beamsA, and arrange each one of the steel bearing platesof the steel shell layerto be parallel to the primary beamA.

In the top-positioned type slab structure, the rebarsA are also arranged along extending directions of the primary beamA and the secondary beamA, such that the rebarsA are crisscross connected to each other to form an upper rebar meshA and a lower rebar meshA. Similarly, in this embodiment, each one of lattices of the upper rebar meshA and the lower rebar meshA has a length and a width which are about 10-cm long, but it is not limited thereto. The lower rebar meshA is securely connected on the steel shell layerby welding, and then an interval in height is reserved for installing the upper rebar meshA; in this embodiment, the interval between the upper rebar meshA and the lower rebar meshA is about 10 centimeters, but it is not limited thereto, and the interval between the upper rebar meshA and the lower rebar meshA may be adjusted according to needs. To be more precise, the interval may be reserved by one or more rebar supporting chairs. The rebar supporting chairsare welded and tied to be fixed on the lower rebar meshA, and the rebar supporting chairsextend to the space above the lower rebar meshA, and then the upper rebar meshA is mounted on the top of the rebar supporting chairs, but it is not limited thereto.

After installation of the steel shell layers, the steel frames, and the rebarsof the column structure, the wall structure, and the slab structure, the concreteis grouted in the wall structure, the column structure, and the slab structure. In addition, when constructing the upper-positioned type slab structure, the concretemay be continued to grout for a thickness about 15 centimeters after grouted from the steel shell layerupward to embed the upper rebar meshA, but it is not limited thereto.

In addition, components like the frames of doors, windows, and corridors, the plumbing systems, the electrical conduits, and/or the frames of firework boxes may be installed before grouting the concrete.

The process of grouting the concreteis not limited thereto, the user may grout the concreteof the column structure, the wall structure, and the slab structure in one step after finishing installation of the steel shell layers, the steel frames, and the rebarsof the column structure, the wall structure, and the slab structure. In addition, the user may further set another steel shell layeror other laminates on the concreteof the slab structure, especially on the roof, to enhance an overall strength of the S3RC building structure.

When the construction of one floor of the building is finished and the construction of the next floor is starting, the baseline C-shaped steelis set on a position above the grouting level of the slab structure for 2 to 3 centimeters high to ensure positioning of horizontal surface and elevation, and then the user may securely connect the steel columnsand the steel beamsof the steel frameby welding, and then repeat the aforementioned constructing processes of the column structure, the wall structure, and the slab structure. Moreover, the user may construct the steel framefor two to four floors, and then conduct constructing the column structures, the wall structures, and the slab structures, and grouting of concrete floor by floor, but it is not limited thereto, as the user may carry out construction in two to four floors as a unit. Besides, as shown in, a C-shaped steelmay be horizontally mounted on a site between floors as a reinforcement cover. To be more precise, the C-shaped steelis mounted on the external side of the steel beam. The C-shaped steelmay be provided as a base for other steel bearing plate structures like eaves or steel rolling doors, but it is not limited thereto. In other embodiments, the S3RC building structure may not have the C-shaped steel, or the C-shaped steelmay be mounted on the internal side of the steel shell layer.

The S3RC building structure in this disclosure forms the continuous structures like wall structures, column structures, and slab structures with the steel shell layercovering the steel frame, the concrete, and the rebars. Regarding the aforementioned structures, “S3” in the term “S3RC” means “shell-beam-shell” in the slab and wall structures, “ring-shell-frame” in the column structure, and “baseline-shell/shell-baseline” in the wall structure, all of which are tri-layer structures, and thus the S3RC building structure in this disclosure would construct an “S3RC” earthquake-resisting building including the wall, column, and slab structures having the tri-layer steel structure of serially arranged “steel shell layer,” “steel frame,” and “steel shell layer.”

The S3RC building structure has the advantages below:

Even though numerous characteristics and advantages of the present invention have been set forth in the foregoing description, together with details of the structure and features of the invention, the disclosure is illustrative only. Changes may be made in the details, especially in matters of shape, size, and arrangement of parts within the principles of the invention to the full extent indicated by the broad general meaning of the terms in which the appended claims are expressed.