Pier_v1/src/core/rebar/bearing-block.ts

import type { PierModel } from '../geometry';
import { INTEGRATED_BLOCK, type IntegratedBlock } from '../integrated-block';

/**
 * 받침블럭 철근 (spec §6.3 · plan C2), 배치 분리: one block per bearing, 1200 × 1200.
 * S2 is the upper bar (cover 50 from the block top); S1 is the lower bar (69.1 below the top).
 * Both have the same layout: 7@125 = 875 with ends of 162.5 in a 1200 mm block, and legs of 700 below the bar.
 */
export const BLOCK_REBAR = {
  dim: 1200,
  cover: 50,
  firstBarGap: 75,
  spacing: 125,
  legLength: 700,
  /** Depth of each bar centre below the block top (mm). */
  depthS2: 50,
  depthS1: 69.1,
} as const;

export interface BarRow {
  name: 'S1' | 'S2';
  /** Bars along one block side. */
  count: number;
  spacing: number;
  /** Position of the first bar from the block edge. */
  firstEnd: number;
  /** Straight length plus two legs (mm). */
  length: number;
  /** Coping embedment of the legs (mm): 700 − (block height − bar depth). */
  embedment: number;
}

/** Bars along one 1200 mm side: available = dim − 2·(cover + first gap); gaps = floor(available / spacing). */
export function barsAcross(dim: number = BLOCK_REBAR.dim): { count: number; spacing: number; firstEnd: number } {
  const available = dim - 2 * (BLOCK_REBAR.cover + BLOCK_REBAR.firstBarGap);
  const gaps = Math.floor(available / BLOCK_REBAR.spacing);
  const span = gaps * BLOCK_REBAR.spacing;
  const leftover = available - span;
  return { count: gaps + 1, spacing: BLOCK_REBAR.spacing, firstEnd: BLOCK_REBAR.cover + BLOCK_REBAR.firstBarGap + leftover / 2 };
}

/** Length of one bar (mm): the straight part a − 2·c_s plus two legs of 700 (spec §5; 2500 for the 1200 block). */
export function barLength(dim: number = BLOCK_REBAR.dim): number {
  return dim - 2 * BLOCK_REBAR.cover + 2 * BLOCK_REBAR.legLength;
}

/** Rebar of one block; blockHeight is the bearing block height in mm (h1 front or h2 back, pad included). */
export function blockBars(blockHeight: number, dim: number = BLOCK_REBAR.dim): BarRow[] {
  const across = barsAcross(dim);
  const length = barLength(dim);
  return [
    { name: 'S1', ...across, length, embedment: BLOCK_REBAR.legLength - (blockHeight - BLOCK_REBAR.depthS1) },
    { name: 'S2', ...across, length, embedment: BLOCK_REBAR.legLength - (blockHeight - BLOCK_REBAR.depthS2) },
  ];
}

export interface BlockRebar {
  no: number;
  row: '전열' | '후열';
  bars: BarRow[];
}

/**
 * Rebar of every block of a pier. The block height h_b is the model's own block (coping top → block top, pad excluded),
 * since the bar depths are measured from the block top. h1 / h2 include the 50 pad and would count it twice.
 */
export function bearingBlockRebar(model: PierModel): BlockRebar[] {
  // 일체 (승인 2026-10-26): one block per pair replaces the two per-bearing blocks.
  if (model.integratedBlocks.length > 0) {
    return model.integratedBlocks.map((ib) => ({ no: ib.frontNo, row: '전열', bars: integratedBlockBars(ib) }));
  }
  return model.blocks.map((b) => ({
    no: b.no,
    row: b.row,
    bars: blockBars((b.top - b.bottom) * 1000),
  }));
}

/**
 * Rebar of one 일체 block (승인 2026-10-26, 받침블럭철근.md "일체 a 2500").
 * S2 runs along the 교각축 (1200), so its bars are spaced across the 2500 length: 19 bars at 125. Its legs are measured
 * from the top of the half it sits in; the bar at the step line (centre) counts with the front half.
 * S1 runs along the 2500 length, 8 bars across the 1200 depth, its depth taken from the lower top (cover on the higher half is larger).
 */
export function integratedBlockBars(ib: IntegratedBlock): BarRow[] {
  const half = INTEGRATED_BLOCK.length / 2;
  const s2 = barsAcross(INTEGRATED_BLOCK.length);
  const frontCount = Array.from({ length: s2.count }, (_, k) => s2.firstEnd + k * s2.spacing).filter((x) => x <= half + 1e-9).length;
  const backCount = s2.count - frontCount;
  const hFront = (ib.topFront - ib.bottom) * 1000;
  const hBack = (ib.topBack - ib.bottom) * 1000;
  const legS2 = (h: number) => BLOCK_REBAR.legLength - (h - BLOCK_REBAR.depthS2);
  const s1 = barsAcross(INTEGRATED_BLOCK.depth);
  const hLow = Math.min(hFront, hBack);
  const rows: BarRow[] = [
    { name: 'S2', count: frontCount, spacing: s2.spacing, firstEnd: s2.firstEnd, length: barLength(INTEGRATED_BLOCK.depth), embedment: legS2(hFront) },
  ];
  if (backCount > 0) rows.push({ name: 'S2', count: backCount, spacing: s2.spacing, firstEnd: s2.firstEnd, length: barLength(INTEGRATED_BLOCK.depth), embedment: legS2(hBack) });
  rows.push({ name: 'S1', count: s1.count, spacing: s1.spacing, firstEnd: s1.firstEnd, length: barLength(INTEGRATED_BLOCK.length), embedment: BLOCK_REBAR.legLength - (hLow - BLOCK_REBAR.depthS1) });
  return rows;
}

/** Total bars of one pier: bars per block × blocks, for S1 and S2 separately. */
export function totals(rebar: BlockRebar[]): { S1: number; S2: number } {
  return rebar.reduce(
    (sum, blk) => {
      for (const bar of blk.bars) sum[bar.name] += bar.count;
      return sum;
    },
    { S1: 0, S2: 0 },
  );
}