Installation Technology of the Steel Structure of the Terminal Building of Pudong International Airport

The roof structure of the terminal building at Pudong International Airport features a unique sloping steel framework, which is considered rare both domestically and internationally. The design includes a two-span elevated entrance hall in the main building and a four-span section of the boarding promenade. This large-scale steel structure is supported by an intricate system, with most of the concrete pouring involving frame-cut structures. The steel installation is massive, covering over 33,000 square meters, with a limb area of 6%. The main building and the elevated entrance hall are connected across three spans, with dimensions ranging from 4880 to 42 meters from east to west. The longitudinal length is 4.6 meters, and the first chord is a high-strength steel roof frame. The lower end is supported on a concrete frame girder, while the upper end rests on a bracket beam attached to an inclined steel column. The boarding promenade has a span of 52 meters and a longitudinal length of 1383.6 meters. The steel structure is supported by bracket beams placed on inclined steel columns with different elevations on either side. Steel columns are installed between 513 frames, and supporting cables are added between the sloping steel columns of the building. Group bridges are also installed within the promenade. One of the key engineering challenges involves the connection between the steel frame and the bracket beam, which is embedded in sections, making it difficult to form a seamless and stable structure. The steel columns are inclined, which helps maintain structural stability during construction. Special attention was given to the setting of supports and group cables between the chord columns under various cable trusses, as this makes the control of structural forces and deformations extremely complex. The three upper floors are connected in parallel with the three-span long-span structure of the elevated entrance hall. Before the steel structure was installed, the broken frame structure had already been integrated, making conventional construction methods challenging. Additionally, the double-sided inclined columns on the boarding corridor caused instability during construction, and the concrete frame extended over one kilometer, making it impossible to set up ground-based tire frames. The workload was enormous, and the construction period was tight, with only seven months allocated for the entire installation process. To address these challenges, a technical route was developed based on the unique underground conditions of the project. A series of plans were compared and optimized, leading to the formation of an overall longitudinal section that combined ground-assembled columns, roof spanning ends, and boarding promenade segments. Large lifting equipment was used to transport heavy loads to high positions. After identifying the key technical routes, research teams focused on critical technologies such as lifting equipment transformation, computer control, and hydraulic traction systems. These efforts included research, exhibitions, and comprehensive testing. Ensuring structural stability during the continuous 3-span steel structure construction of the main building and the elevated entrance hall was crucial. The steel structure, supported by inclined columns, required careful management of overall displacement. During the initial phase, the bottom end of the inclined steel roof was hinged, while the bottom end of the straight column was fixed. Both ends were treated as hinged during the displacement process. Detailed theoretical analysis and calculations were conducted for various construction stages, and physical models were created to simulate loading and traction conditions. Based on these simulations, a horizontal and vertical stabilization system was designed. A horizontal cable was placed at the end to balance the horizontal force generated by the inclined steel column. A slide rail system was installed on the side of the steel structure to manage the horizontal force during the shifting of the single-span entrance hall. Temporary cables composed of Hualan shovels and steel wire ropes were used to ensure longitudinal stability, and their importance was proven through practical application. For the boarding corridor’s steel roof, which is supported on double-sided inclined steel columns, stability during use is achieved by applying different prestresses to the group cables installed in space. Before the group cables are stressed, the structure undergoes a change. Therefore, temporary supports were installed on both sides of the inclined steel columns before hoisting the roof truss to withstand part of the load and allow for structural adjustment. These temporary supports must remain in place until the group cables are tensioned. Research into the construction of the lower chord of the roof truss involved controlling the structural size and supplementing it with cable force. Vertical cables were installed between the steel columns to ensure the stability of the steel structure. Temporary cables were first installed before the steel structure was displaced to maintain stability during the movement. Once in place, the temporary cables were removed, and curtain wall columns were installed, followed by the vertical cables and special tools for stretching. Group cables were used to stabilize the steel roof structure. Each section acted as a tensile unit, with eight steel cables per section, totaling 32 cables. The cable tension in each section met design requirements, and the structure size was controlled accordingly. The Chinese Academy of Sciences jointly studied 41 computer-designed tensioning schemes and implemented them. The implementation of the overall displacement of the steel structure was achieved using computer-controlled hydraulic traction equipment. This technology was independently developed based on previous improvements at Shanghai Oriental Pearl TV Tower and Hongqiao Airport. Through continuous traction without interruption, the steel structure was successfully displaced. Multi-objective control of posture, speed, and load allowed for intelligent automation, requiring only two people to operate from a small control room. On-site supervision needed only eight people, reducing labor intensity and increasing efficiency. The equipment functioned smoothly for over six months, with a traction speed of 8-12 meters per hour and a maximum synchronous weight difference of 201 tons. The total haulage of the steel structure exceeded 1,000 tons. On January 30, 1998, the first section of the boarding corridor was lifted successfully. The lifting was stable, and synchronization between tower cranes on the same side was achieved. The boarding corridor was assembled on the ground and completed successfully. On February 28, 1998, the long-distance shift of the first section of the main building began, and it was smoothly moved to the design position under computer control. The success of the steel structure installation at Pudong International Airport demonstrated the significant impact of technological progress on engineering construction. It showcased advanced techniques in the construction field and opened new ideas for the overall installation of large and complex structures. The experience gained from this project provided valuable insights for future designs and construction processes. The use of advanced construction technology routes led to significant economic and social benefits. The project saved millions in engineering and construction costs, reduced reinforcement costs for concrete structures, and minimized machinery investment costs. The overall displacement method improved work efficiency, ensured quality and safety, and contributed to the successful completion of the project. The process route and construction organization of factory production flow-type operations proved highly adaptable and flexible, offering new experiences for large-scale structural installations. This project marked a milestone in China's construction mechanization and highlighted the importance of optimizing existing equipment to improve efficiency and reduce costs.

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