concrete encased beam

Concrete Encased Beam | High-Performance Composite Structural Solutions  Product Description

Concrete encased beams from Shenyang Zhongda Steel Structure provide enterprise-grade performance when your infrastructure requires maximum strength, fireproofing, and seismic resilience. With an 80,000-ton annual production capacity and ISO 9001-certified processes, we fabricate composite beams combining Q345B/C high-strength steel cores with C40-C60 grade concrete (≥50 MPa compressive strength). Our solutions eliminate expensive secondary fire ratings, pass rigorous 8-degree seismic tests with 20mm joint rib reinforcement, and are supported by EN 1090-2 EXC3 certification and third-rate the highest international standards.

 

 

Product Advantages

1. Superior Fire Protection Without Additional Coatings

Your bare steel requires expensive intumescent fireproofing. Our composite design provides inherent 4-hour fire resistance, saving you 30-40% on fireproofing costs across large commercial projects.

2. Enhanced Seismic Ductility

The concrete confinement increases steel core ductility by 35%, allowing controlled plastic deformation during earthquakes. This makes our beams ideal for high-seismic zones like Japan and California.

3. Improved Stiffness for Long-Span Applications

With a modular ratio advantage and 2-3x higher moment of inertia compared to bare steel, you can confidently design spans exceeding 12 meters while controlling deflection.

4. Corrosion Barrier in Harsh Environments

The reinforced concrete shell (40-50mm cover depth) acts as a primary defense against chloride ingress in coastal infrastructure, extending service life by 20+ years.

5. Industrial Facilities' Vibration Damping

These beams are ideal for crane runway systems and floors that support machines because the additional mass decreases structural resonance by 40%.

6. Efficiency of Lifecycle Costs

Although the initial expenditures are 15–20% more than those of bare steel, over a 30-year period, the total cost of ownership is reduced by 25% due to the elimination of fireproofing and corrosion treatment maintenance..

Technical Specifications & Customization

Manufacturing & Quality Control

Precision Fabrication at Scale

Your beams are manufactured in our 75,000 m² facility equipped with:

· CNC Drilling Systems: ±0.1mm tolerance for shear stud positioning

· Automated Welding Lines: Consistent penetration per AWS D1.1 standards

· 1200-Ton Plate Rolling: For curved or arched beam profiles

Rigorous Composite Action Verification

We conduct push-out tests during design validation and perform 100% shear stud welding inspections using magnetic particle testing (MPT).

Zero-Defect Concrete Placement

· Self-consolidating concrete (SCC) or controlled vibration to eliminate honeycombing

· Real-time slump flow testing ensures proper encasement under bottom flanges

· Post-casting Ground Penetrating Radar (GPR) scans detect any internal voids

Third-Party Certification Protocol

Every batch includes:

· Material Test Certificates (MTC) per EN 10204 3.1

· Load test reports from accredited labs

· Ultrasonic Pulse Velocity (UPV) records confirming bond integrity

Project Cases / Success Stories

Case 1: Shenyang High-Speed Railway Station Expansion

· Challenge: 18-meter spans requiring 3-hour fire rating without exposed fireproofing

· Solution: 60 customized concrete encased beams with embedded HVAC conduits

· Result: Passed final inspection 15 days ahead of schedule, zero fire-rating deficiencies

Case 2: Coastal Logistics Hub – Dalian Port

· Challenge: High chloride exposure threatening bare steel corrosion

· Solution: C60 concrete with stainless steel rebars and 50mm cover depth

· Result: Third-party corrosion monitoring shows zero steel degradation after 5 years

Case 3: Heavy Equipment Manufacturing Plant – Anshan

· Challenge: 80-ton overhead crane causing excessive floor vibration

· Solution: Composite beams with 40% higher damping capacity

· Result: Vibration amplitude reduced by 45%, meeting ISO 10816 industrial standards

 

Cases

 

Compliance & Certifications

✅ EN 1090-2 EXC3 – European execution class for load-bearing structures

✅ ISO 9001:2015 – Quality management system

✅ ISO 14001 – Environmental management

✅ ISO 45001 – Occupational health & safety

✅ AISC 360 Chapter I – Composite member design compliance

✅ Eurocode 4 (EN 1994) – Steel-concrete composite structure standards

✅ AWS D1.1 – Structural welding code

All certifications are available for download upon request. We provide full English documentation including MTC, inspection reports, and technical drawings for international projects.

Frequently Asked Questions (FAQ)

Q1: How does your concrete encased beam improve seismic performance?

A: The concrete confinement increases steel core ductility, allowing controlled plastic deformation during earthquakes without sudden failure. Our 20mm joint ribs further enhance connection integrity.

Q2: Is the cost higher than bare steel structures?

A: Initial material and formwork costs run 15-20% higher, but you eliminate fireproofing expenses and reduce maintenance by 70%, lowering lifecycle costs by 25%.

Q3: Can these beams support long-span designs?

A: Absolutely. They excel in spans exceeding 12 meters where deflection control is critical. We've successfully delivered 24-meter spans for transportation hubs.

Q4: How do you verify bond strength between steel and concrete?

A: We perform push-out tests during design validation and conduct 100% shear stud welding inspections using magnetic particle testing (MPT) during fabrication.

Q5: What if the concrete develops cracks?

A: Hairline shrinkage cracks (≤0.3mm) are normal and harmless. Structural cracks require immediate epoxy injection repair, which we support through our maintenance services.

Q6: What's your standard delivery timeline?

A: Standard beams ship in 30 days (including 7-day concrete curing). Complex geometries or custom specifications require 45 days.

Contact Us

Ready to enhance your infrastructure with fire-resistant, seismic-ready concrete encased beam? Our engineering team is here to support your project from design optimization to final installation.

 Email:   Ava@zd-steels.com