In factory design, beams and slabs play a crucial role in ensuring structural integrity and load-bearing capacity.
In factory design, beams and slabs play a crucial role in ensuring structural integrity and load-bearing capacity. The beam and slab system is a primary load-bearing component, distributing loads from the roof, walls, equipment, and interior furnishings to the foundation, while also providing stability to the entire floor system. Selecting and designing beams and slabs according to proper standards not only affects durability but also impacts construction costs, maintainability, and the long-term operational efficiency of the factory.
Overview of Beams and Slabs in Factory Design
What are Beams and Slabs?
Beams and slabs are essential structural components in construction, responsible for bearing loads and transferring them from the floor, walls, and roof to the columns and foundation. Beams are typically horizontal or inclined members, primarily subjected to bending.
With their simple design and low production cost, beams are widely used in structures such as floor beams, roof beams, crane beams, bridge beams, etc. Based on their role in the structure, beams are divided into two types: main beams – which bear direct loads and transfer them to the columns, and secondary beams – which help distribute the load onto the main beams, making the structure more stable.
Types of Beams
Beams in factory design are mainly divided into two types: rolled beams and built-up beams, depending on their construction and manufacturing method.
1. Rolled Beams
Rolled beams are manufactured from a single rolled steel section, with a symmetrical or asymmetrical cross-section. Some common types include:
- I-beams: Have a symmetrical cross-section about both horizontal axes (x-x), commonly used for beams subjected to planar bending, such as floor beams, and floor supports due to their good load-bearing capacity.
- Channel beams (C-beams): Have a cross-section that is not symmetrical about the vertical axis (y-y), making them susceptible to torsion when subjected to planar bending. This type of beam is suitable for structures subjected to oblique bending or as roof purlins and wall girts.
2. Built-Up Beams
Built-up beams are made from rolled steel sections combined with steel plates, connected by welding, bolts, or rivets. This type of beam helps optimize load-bearing capacity and is suitable for projects requiring robust and durable structures.
The Benefits of Steel Beams
Steel beams play a crucial role in factory design, enhancing durability, stability, and optimizing construction efficiency. Here are the main benefits of steel beams:
- Load Bearing and Force Distribution: Steel beams are designed to bear loads from the floor, roof, walls, and internal equipment within the structure. Thanks to their excellent load-bearing capacity, steel beams help transfer loads to the columns and foundation, ensuring the structure remains stable and durable. They are widely used in various types of structures such as factories, bridges, high-rise buildings, and other industrial structures.
- Increased Rigidity and Load-Bearing Capacity of the Structure: The steel beam system helps increase the overall rigidity of the structure by reducing deflection and limiting deformation when subjected to heavy loads. This helps the structure withstand environmental impacts such as wind, earthquakes, or vibrations, while ensuring long-term safety during use.
- Cost and Time Savings in Construction: Compared to concrete beams, steel beams are lighter but still ensure high load-bearing capacity. This helps reduce pressure on the building's foundation, thereby saving foundation costs. In addition, because steel beams can be prefabricated to standard sizes, the construction process becomes faster and more labor-saving than pouring concrete on-site.
- Flexibility in Factory Design: Steel beams can be easily fabricated into various sizes and shapes to suit the design requirements of each project. This is especially useful for complex designs that require special structural solutions that other materials struggle to meet.
- Easy installation and maintenance: Steel beams can be manufactured as standardized sections, making them easy to transport and install on-site. When replacement or repair is needed, disassembly and reassembly are also much simpler compared to concrete beams. This helps save on maintenance costs and extends the lifespan of the structure.
With the above advantages, steel beams are increasingly being used in construction, especially in industrial, commercial, and civil projects that require durable, flexible, and cost-effective structures.
Industrial Factory Floor Beam Design Process
Designing floor beams for industrial factories is a crucial step to ensure the structure's durability, load-bearing capacity, and cost-effectiveness. This process is carried out in the following specific steps:
Step 1: Cost Estimation
Before starting the structural design, it is necessary to prepare a cost estimate based on various factors such as material unit prices, labor costs, construction standard regulations, and the project's technical requirements. The estimate helps determine the total cost required, thereby enabling a reasonable financial plan and avoiding unexpected costs during construction. Cost estimation in factory design typically includes design and construction costs, blueprint design, and associated technical requirements.
Step 2: Floor Beam System Design
The floor beam system design must ensure structural integrity, good load-bearing capacity, and suitability for the factory's function. This step requires calculating the dimensions and positions of the beams to optimize them, preventing floor deflection or structural imbalance. Design principles also need to be thoroughly studied to ensure the highest utilization efficiency, meeting the requirements for operating machinery, storing goods, or other production activities within the factory.
Step 3: Selection of Main Materials
Choosing appropriate materials is a decisive factor in the durability, load-bearing capacity, and construction cost. Depending on the project's requirements, steel beams or reinforced concrete beams can be used. Steel beams have the advantages of being lightweight and easy to construct, making them suitable for projects requiring rapid construction times. Meanwhile, reinforced concrete beams have good load-bearing capacity, are less affected by corrosion, and are suitable for projects requiring high stability.
Step 4: Beam and Slab System Arrangement
After selecting materials, the beam and slab system needs to be arranged based on the dimensions and overall structure of the building. There are several options for arranging the beam network supporting the slab, including a simple beam system (secondary beams distributing the load to primary beams), a common beam system (beams arranged in a grid pattern), and a complex beam system (applied to structures with special loads or specific structural requirements). Choosing the appropriate method helps optimize load-bearing capacity and save materials.
Step 5: Reinforcement Calculation
The final step is to calculate and arrange the reinforcing steel (rebar) within the beams and slabs to ensure the structural load-bearing capacity. Longitudinal rebar plays a role in resisting bending moments, while transverse rebar resists shear forces. Determining the quantity, diameter, and location of the rebar needs to be based on structural calculations and construction standards. For industrial workshops, rebar requirements may be higher than for civil structures due to the large loads and high frequency of use.
Completing the above steps helps ensure that the beam and slab system meets standards for durability, load-bearing capacity, and suitability for the usage requirements of the industrial factory design.
Standard Procedure for Constructing Beams and Slabs in Factories
Beam and slab construction is a critical process in factory building design, requiring strict adherence to technical steps to ensure the structure's durability and safety. The following is the standard procedure for beam and slab construction:
Step 1: Erecting Scaffolding
Before commencing construction, engineers, supervisors, and foremen must accurately inspect and locate the elevation and centerlines of the structure. The scaffolding must be installed in the correct position according to the design, ensuring its firmness and stability to facilitate subsequent stages. Proper scaffolding erection enhances safety and reduces risks during construction.
Step 2: Fabricating and Erecting Beam and Slab Formwork
Formwork plays a crucial role in shaping and molding the concrete. First, the formwork panels must be thoroughly inspected to ensure quality, free from warping or damage. Then, install the beam formwork first, followed by the slab formwork, ensuring correct technique and avoiding deviations. Upon completion, re-inspect the entire formwork system and roughen the column heads to increase adhesion with the concrete. Subsequently, clean the construction area and prepare to move the steel reinforcement onto the slab.
Step 3: Fabricating and Installing Steel Reinforcement
The fabrication and installation of steel reinforcement must comply with current construction standards to ensure the quality of the structure. The steel reinforcement must be fabricated to the correct dimensions and bent according to design requirements. During installation, accurately position the spacing of the steel reinforcement according to the drawings, ensuring the correct placement of longitudinal load-bearing steel, stirrups, and distribution steel. After installation, thoroughly inspect for errors and secure the steel to prevent displacement during concrete pouring.
Step 4: Installation of Under-Slab Electrical and Plumbing Systems
If the project includes under-slab electrical and plumbing systems, these need to be installed before pouring the concrete. Use rigid conduits for electrical wiring to ensure durability and minimize damage during use. Simultaneously, install sleeves for the water supply and drainage systems through the slab in the correct locations according to the factory design. This prevents incorrect installation that could affect the finishing process later.
Step 5: Inspection and Concrete Pouring for Floor Beams/Slabs
After completing the installation of the reinforcing steel and electrical/plumbing systems, re-inspect the entire structure to ensure it meets technical specifications. Then, proceed with pouring the concrete according to regulations, using a vibrator to remove air bubbles and achieve maximum concrete density.
After pouring the concrete, it needs to be cured for the first 12 to 24 hours to prevent cracking due to rapid water loss. Use burlap or plastic sheeting under the slab to retain moisture, which improves the curing process and ensures the quality of the hardened concrete.
Completing all the above steps will help ensure the safe execution of the floor beam/slab construction process, guaranteeing the quality and durability of the structure.
Things to Note When Constructing Beams and Floors
Beam and floor construction is a crucial process that directly impacts the quality and lifespan of a building. To ensure effective, safe, and technically sound construction, the following points should be considered:
1. Ensure Workplace Safety
Workplace safety is the top priority during construction. Workers on the construction site must be fully equipped with protective gear such as helmets, gloves, non-slip shoes, and reflective vests. Simultaneously, workplace safety training sessions should be organized to ensure they understand safety regulations while working. When workers feel safe, they will be more confident in their work, thereby improving efficiency and construction quality.
2. Properly Maintain Construction Equipment
Construction equipment such as scaffolding, concrete mixers, vibratory compactors, formwork, etc., should be stored in a dry place to avoid damage or loss. Only qualified personnel who have received technical training are allowed to operate machinery and equipment to prevent unexpected incidents. Regular maintenance is also crucial to ensure that the equipment always operates stably, without causing interruptions during construction.
3. Thoroughly Inspect Before Construction
Before starting beam and floor construction, thoroughly inspect all materials, equipment, and related systems. Ensure that the formwork is securely installed, the reinforcing steel is in the correct position according to the design drawings, the scaffolding is stable, and the environmental conditions are suitable to avoid errors during execution. Thorough inspection helps minimize risks, reduce technical errors, and ensure project progress.
4. Respond to Bad Weather
In case of unfavorable weather, especially heavy rain, construction should be temporarily suspended to avoid affecting the quality of the concrete and workplace safety. If it is not possible to stop work, careful measures should be taken to cover the construction area, preventing rainwater from diluting the concrete or affecting the beam and floor structure. Proactively monitoring weather forecasts will help plan construction appropriately, avoiding unnecessary risks.
5. Execute Construction According to Procedure and Design Drawings
Every construction stage must strictly adhere to technical drawings and the step-by-step sequence. Shortcuts or omissions of any stage are not permitted. Careless or inaccurate construction can lead to serious errors, affecting the structure's integrity and resulting in wasted time and costly repairs later on.
6. Emphasize Concrete Curing
After pouring concrete for beams and floors, proper curing is essential to ensure the quality and durability of the structure. Curing must follow standard procedures, including maintaining moisture on the concrete surface, preventing rapid water loss, and controlling the ambient temperature to minimize concrete cracking.
Full compliance with the above considerations will help ensure that the beam and floor construction process is safe, of high quality, and guarantees the long-term lifespan of the project.
To ensure safety and quality, accurate calculations are necessary from the design phase to construction. We hope that the knowledge BIC shares will provide you with additional experience to apply effectively in practice.
To learn more about standard-compliant factory design and construction, contact BIC now!
