南京大胜关长江大桥受力特性、计算方法、桥面疲劳和防腐问题研究
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摘要
随着中国高速铁路建设的快速发展,中国的铁路特大钢桥迅速增多,目前已建、在建和正在设计中的有近10座。其中,京沪高速铁路上的南京大胜关长江大桥是最早也最具影响力的一座高速铁路钢桥。该桥是世界上第一座6线铁路大桥,主桥为(108+192+336+336+192+108)m六跨连续三主桁拱结构,其中2线高速铁路设计时速为300km,预留350km。
本文在广泛收集、研究国内外相关资料的基础上,采用理论分析和试验研究相结合的方法,对该桥的桥面结构形式、受力特性、设计计算方法、正交异性钢桥面U肋与横梁连接处的疲劳性能、钢桥面的防腐等问题作了较为系统的研究。本文的研究得到铁道部三个重点科研项目的支持。主要取得了如下创新性成果：
1、针对南京大胜关长江大桥线路多,跨度大,行车速度高的特点,经多方面综合对比研究,为南京大胜关长江大桥推荐(并被采纳)了密布横梁体系正交异性板整体钢桥面结构方案。该方案整体性好、刚度大,由于下弦杆和系梁加高,不仅桥梁的整体变形减小,而且也改善了桥面系的受力状态。
2、研究了密布横梁体系正交异性板整体桥面板桁组合结构桥面荷载的传力途径和传力比及其影响因素。首次定量地给出了两条路径的传力比,其中通过节间横梁传至下弦杆或系梁再传至下弦杆节点的桥面荷载有50%以上,这部分荷载会引起下弦杆和系梁的竖向弯曲。
3、研究了桥面荷载在三主桁拱中的分配。提出了桥面荷载在三主桁中两次分配的概念、两次分配的分配比及其影响因素,提出了密布横梁体系的正交异性板整体钢桥面板桁组合结构在桥面荷载作用下主桁的受力模式,该模式可用于三主桁拱的设计。
4、研究了整体桥面板桁组合结构的设计计算方法,总结归纳了整体分析和关键部位局部分析相结合的二步分析法、整体分析的三种实用有限元分析方法：空间板梁法、系统分解法和空间杆系结构法。空间板梁法适用于设计的中、后期,对桥梁施工过程和运营阶段的强度、刚度和稳定性作全面的检算；系统分解法适用于结构构造和构件的尺寸频繁改变的设计初期；空间杆系结构法适用于考察桥梁刚度、主桁杆件和桥面系骨架的强度和稳定性,对斜拉桥、拱桥等施工过程的优化计算、成桥的索力张拉顺序、张拉力的优化计算等也非常有效。
5、对正交异性板U肋与横梁连接处的疲劳性能进行了试验研究。参照南京大胜关长江大桥正交异性板整体桥面系制作了U肋与横梁连接处2个1:1的整体模型,完成了精细的有限元分析和疲劳试验。得出结论：正交异性板U肋与横梁连接处有较好的抗疲劳性能；U肋下方腹板开平底形孔还是苹果形孔对疲劳性能影响不大；U肋上方与横梁腹板、翼板连接处腹板开不开小孔无关紧要；铁路桥梁应避免钢轨位于U肋的正上方；对U肋与横梁腹板连接处的疲劳性能进行了评估,把U肋下方横梁腹板孔边归为Ⅰ类疲劳类别(母材),具有足够的安全性。
6、提出了一种具有柔性防水层的复合防腐体系,并完成了各种试验。结果表明：该体系具有较好的防腐、防水、抗磨、抗滑性能,施工工艺简单。但其防腐的长效性还有待长时间的考验,工地现场施工对环境的要求有待进一步降低。
7、提出了厚度组合为(3+16)mm的321-Q370q不锈钢复合钢板的防腐体系,并完成了各种试验。结果表明：321-Q370q不锈钢复合钢板几乎不增加桥面恒载,材料来源方便,板面尺寸大,爆炸焊接工艺成熟,防腐、抗滑性能好。但其长效性还有待长时间的考验,价格有待降低。
以上研究成果1-5已应用于南京大胜关长江大桥、济南黄河大桥、安庆铁路长江大桥、新广州站东平水道桥等多座特大铁路钢桥的设计。研究成果6、7还需进一步完善并经受长时间的考验。
In China, super steel railway bridges are increasing quickly with the rapid development of high speed railway construction; now there are about 10 super steel bridges built-up or under construction or under design. Nanjing Dashengguan Yangtze River Bridge (NDB) on Beijing-Shanghai high speed railway is the earliest and the most influential one among the steel bridges mentioned above, and is the first railway bridge with 6 lines in the world. The main bridge of NDB is a continuous three main truss arch structure with span arrangement as (108+192+336+336+192+108) m. Among the 6 railway lines of NDB, there are 2 high speed ones with 300km/h designed speed and 350km/h reserved speed.
On base of extensive collection and study of relevant information from home and abroad, combing theoretical analysis and experimental research, systematic research aiming at NDB was carried out in the thesis, including deck structural forms, mechanical characteristics, design and calculation methods, fatigue performance of U rib-to-diaphragm connection in orthotropic steel bridge deck and the anticorrosion problem of steel deck. The research of this thesis is supported by three key projects founded by Ministry of Railways. The innovative results are as follows:
1. Aiming to the characteristics of multi-line, great span, high speed of NDB, after comprehensive comparison and study, orthotropic monolithic steel deck system with dense transverse girder (OSDTS) was recommended (and adopted) for NDB. OSDTS not only has good wholeness, big stiffness, but also decreases the whole deformation of bridge and improves the mechanical behavior of deck with the bottom chord and tie beam heightened.
2. The transmission paths were studied for the deck loads on truss-girder composite structures with OSDTS, so was the load ratio through the paths and influence factors. The ratio of deck loads transferred through the two paths was given quantitatively for the first time. There is over 50% deck loads transferred from panel transverse girders to bottom chords or tie beam and then to bottom chord joints, which will cause vertical bending of the bottom chords and tie beam.
3. Deck loads allocation among the three main trusses or arches were researched in the thesis. A concept of two steps allocation, ratio of the two allocations and its influence factors were put forward for the deck load on the three main trusses or arches. With the action of deck loads, load models of the three main trusses were put forward for truss-girder composite structures with OSDTS, which can be used for the design of the three main trusses or arches.
4. According to the mechanical characteristics of truss-girder composite structures with monolithic steel deck, Two Step Analysis Method combing global analysis and local analysis of key parts, and three practical FEA methods for global analysis, namely, SPBM, SSM and SFM were summarized. SPBM is applicable for the middle and later design periods, for overall checking the stiffness, strength and stability of the bridges in construction or in service. SSM is good for the beginning design period, in which the bridge structure and member dimensions will be changed frequently. SFM is applicable for checking bridge stiffness, strength and stability of the main truss and deck frameworks, it is also effective for the construction procedure optimization calculation, tension order and forces of cable tension optimization calculation of cable stayed bridges and arch bridges.
5. Experimental research was carried out on the fatigue performance of the U rib-to-diaphragm connection in orthotropic steel bridge deck. Referring to the orthotropic monolithic steel deck system of NDB, two full scale monolithic models of U rib-to-diaphragm connection were fabricated, refined finite element analysis and fatigue experiments were carried out on the two models. Results show that the U rib-to-diaphragm connection has good fatigue performance, which is neither influenced by hole shape in the diaphragm web under U rib, no matter it is apple shaped or flat bottom shaped nor by holes at the upper rib-diaphragm web-flange connections. The steel rails should be avoided to be located on the deck right above U ribs. The fatigue life of U rib-to-diaphragm connection was evaluated and the hole edge of diaphragm web under U rib was categorized into I fatigue type, corresponding to basic metal.
6. A kind of compound preservation system with flexible waterproof layer for ballast orthotropic monolithic steel deck was presented and relevant tests were done. The results show that the antiseptic property, waterproofness, abrasion resistance and anti-skidding performance of this preservation system are good and the construction technology is simply. The long-term effectiveness of antiseptic property is still under observation. The environmental request of in-site operating should be reduced further more.
7. The 321-Q370q stainless composite steel plate preservation system with the thickness (3+16) mm was presented and relevant tests were done. The results show that the 321-Q370q stainless composite steel plate hardly increases the deck load of the bridge while the material resources is wide and the plate size is large, the explode weld technique is mature, the antiseptic property and anti-skidding performance are good. The long-term effectiveness of antiseptic property is still under test. The price should be reduced further more.
The above research achievements from 1-5 have been applied in the design of many a great steel bridge, such as Nanjing Dashengguan Yantze River Bridge, Jinan Yellow River Bridge, Anqing Railway Yantze River Bridge, Dongping River Bridge. The last two researches still need further improvement and long time observation.
本文在广泛收集、研究国内外相关资料的基础上,采用理论分析和试验研究相结合的方法,对该桥的桥面结构形式、受力特性、设计计算方法、正交异性钢桥面U肋与横梁连接处的疲劳性能、钢桥面的防腐等问题作了较为系统的研究。本文的研究得到铁道部三个重点科研项目的支持。主要取得了如下创新性成果：
1、针对南京大胜关长江大桥线路多,跨度大,行车速度高的特点,经多方面综合对比研究,为南京大胜关长江大桥推荐(并被采纳)了密布横梁体系正交异性板整体钢桥面结构方案。该方案整体性好、刚度大,由于下弦杆和系梁加高,不仅桥梁的整体变形减小,而且也改善了桥面系的受力状态。
2、研究了密布横梁体系正交异性板整体桥面板桁组合结构桥面荷载的传力途径和传力比及其影响因素。首次定量地给出了两条路径的传力比,其中通过节间横梁传至下弦杆或系梁再传至下弦杆节点的桥面荷载有50%以上,这部分荷载会引起下弦杆和系梁的竖向弯曲。
3、研究了桥面荷载在三主桁拱中的分配。提出了桥面荷载在三主桁中两次分配的概念、两次分配的分配比及其影响因素,提出了密布横梁体系的正交异性板整体钢桥面板桁组合结构在桥面荷载作用下主桁的受力模式,该模式可用于三主桁拱的设计。
4、研究了整体桥面板桁组合结构的设计计算方法,总结归纳了整体分析和关键部位局部分析相结合的二步分析法、整体分析的三种实用有限元分析方法：空间板梁法、系统分解法和空间杆系结构法。空间板梁法适用于设计的中、后期,对桥梁施工过程和运营阶段的强度、刚度和稳定性作全面的检算；系统分解法适用于结构构造和构件的尺寸频繁改变的设计初期；空间杆系结构法适用于考察桥梁刚度、主桁杆件和桥面系骨架的强度和稳定性,对斜拉桥、拱桥等施工过程的优化计算、成桥的索力张拉顺序、张拉力的优化计算等也非常有效。
5、对正交异性板U肋与横梁连接处的疲劳性能进行了试验研究。参照南京大胜关长江大桥正交异性板整体桥面系制作了U肋与横梁连接处2个1:1的整体模型,完成了精细的有限元分析和疲劳试验。得出结论：正交异性板U肋与横梁连接处有较好的抗疲劳性能；U肋下方腹板开平底形孔还是苹果形孔对疲劳性能影响不大；U肋上方与横梁腹板、翼板连接处腹板开不开小孔无关紧要；铁路桥梁应避免钢轨位于U肋的正上方；对U肋与横梁腹板连接处的疲劳性能进行了评估,把U肋下方横梁腹板孔边归为Ⅰ类疲劳类别(母材),具有足够的安全性。
6、提出了一种具有柔性防水层的复合防腐体系,并完成了各种试验。结果表明：该体系具有较好的防腐、防水、抗磨、抗滑性能,施工工艺简单。但其防腐的长效性还有待长时间的考验,工地现场施工对环境的要求有待进一步降低。
7、提出了厚度组合为(3+16)mm的321-Q370q不锈钢复合钢板的防腐体系,并完成了各种试验。结果表明：321-Q370q不锈钢复合钢板几乎不增加桥面恒载,材料来源方便,板面尺寸大,爆炸焊接工艺成熟,防腐、抗滑性能好。但其长效性还有待长时间的考验,价格有待降低。
以上研究成果1-5已应用于南京大胜关长江大桥、济南黄河大桥、安庆铁路长江大桥、新广州站东平水道桥等多座特大铁路钢桥的设计。研究成果6、7还需进一步完善并经受长时间的考验。
In China, super steel railway bridges are increasing quickly with the rapid development of high speed railway construction; now there are about 10 super steel bridges built-up or under construction or under design. Nanjing Dashengguan Yangtze River Bridge (NDB) on Beijing-Shanghai high speed railway is the earliest and the most influential one among the steel bridges mentioned above, and is the first railway bridge with 6 lines in the world. The main bridge of NDB is a continuous three main truss arch structure with span arrangement as (108+192+336+336+192+108) m. Among the 6 railway lines of NDB, there are 2 high speed ones with 300km/h designed speed and 350km/h reserved speed.
On base of extensive collection and study of relevant information from home and abroad, combing theoretical analysis and experimental research, systematic research aiming at NDB was carried out in the thesis, including deck structural forms, mechanical characteristics, design and calculation methods, fatigue performance of U rib-to-diaphragm connection in orthotropic steel bridge deck and the anticorrosion problem of steel deck. The research of this thesis is supported by three key projects founded by Ministry of Railways. The innovative results are as follows:
1. Aiming to the characteristics of multi-line, great span, high speed of NDB, after comprehensive comparison and study, orthotropic monolithic steel deck system with dense transverse girder (OSDTS) was recommended (and adopted) for NDB. OSDTS not only has good wholeness, big stiffness, but also decreases the whole deformation of bridge and improves the mechanical behavior of deck with the bottom chord and tie beam heightened.
2. The transmission paths were studied for the deck loads on truss-girder composite structures with OSDTS, so was the load ratio through the paths and influence factors. The ratio of deck loads transferred through the two paths was given quantitatively for the first time. There is over 50% deck loads transferred from panel transverse girders to bottom chords or tie beam and then to bottom chord joints, which will cause vertical bending of the bottom chords and tie beam.
3. Deck loads allocation among the three main trusses or arches were researched in the thesis. A concept of two steps allocation, ratio of the two allocations and its influence factors were put forward for the deck load on the three main trusses or arches. With the action of deck loads, load models of the three main trusses were put forward for truss-girder composite structures with OSDTS, which can be used for the design of the three main trusses or arches.
4. According to the mechanical characteristics of truss-girder composite structures with monolithic steel deck, Two Step Analysis Method combing global analysis and local analysis of key parts, and three practical FEA methods for global analysis, namely, SPBM, SSM and SFM were summarized. SPBM is applicable for the middle and later design periods, for overall checking the stiffness, strength and stability of the bridges in construction or in service. SSM is good for the beginning design period, in which the bridge structure and member dimensions will be changed frequently. SFM is applicable for checking bridge stiffness, strength and stability of the main truss and deck frameworks, it is also effective for the construction procedure optimization calculation, tension order and forces of cable tension optimization calculation of cable stayed bridges and arch bridges.
5. Experimental research was carried out on the fatigue performance of the U rib-to-diaphragm connection in orthotropic steel bridge deck. Referring to the orthotropic monolithic steel deck system of NDB, two full scale monolithic models of U rib-to-diaphragm connection were fabricated, refined finite element analysis and fatigue experiments were carried out on the two models. Results show that the U rib-to-diaphragm connection has good fatigue performance, which is neither influenced by hole shape in the diaphragm web under U rib, no matter it is apple shaped or flat bottom shaped nor by holes at the upper rib-diaphragm web-flange connections. The steel rails should be avoided to be located on the deck right above U ribs. The fatigue life of U rib-to-diaphragm connection was evaluated and the hole edge of diaphragm web under U rib was categorized into I fatigue type, corresponding to basic metal.
6. A kind of compound preservation system with flexible waterproof layer for ballast orthotropic monolithic steel deck was presented and relevant tests were done. The results show that the antiseptic property, waterproofness, abrasion resistance and anti-skidding performance of this preservation system are good and the construction technology is simply. The long-term effectiveness of antiseptic property is still under observation. The environmental request of in-site operating should be reduced further more.
7. The 321-Q370q stainless composite steel plate preservation system with the thickness (3+16) mm was presented and relevant tests were done. The results show that the 321-Q370q stainless composite steel plate hardly increases the deck load of the bridge while the material resources is wide and the plate size is large, the explode weld technique is mature, the antiseptic property and anti-skidding performance are good. The long-term effectiveness of antiseptic property is still under test. The price should be reduced further more.
The above research achievements from 1-5 have been applied in the design of many a great steel bridge, such as Nanjing Dashengguan Yantze River Bridge, Jinan Yellow River Bridge, Anqing Railway Yantze River Bridge, Dongping River Bridge. The last two researches still need further improvement and long time observation.
引文
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