This disclosure relates to a prefabricated, prestressed bridge system and a method for making same.
This disclosure relates to a prefabricated, prestressed bridge system and a method for making same. Prefabricated, prestressed bridges are commonly known, however, the prefabricated, prestressed bridges currently available are cumbersome to manufacture and difficult to erect resulting in an expensive, labor-intensive final product. Prefabricated, prestressed bridges are used in a variety of civil engineering applications such as disclosed in U.S. Pat. No. 5,471,694 Prefabricated Bridge with Prestressed Elements (“Meheen patent”); U.S. Pat. No. 4,493,177 Composite, Pre-Stressed Structural Member and Method for Forming Same (“Grossman patent”); and U.S. Pat. No. 2,373,072 Rigid Frame Bridge and Method of Making the Same (“Wichert patent”). However, improvements are desired to use new construction materials, provide a more easily manufacturable, more robust system with more standardized components which assist in providing the prestress to the bridge beams. Implementation of these improvements results in lower cost and increased speed of construction of a prefabricated, prestressed bridge system.
The Meheen patent discloses a prefabricated bridge beam with prestressed elements comprising a rectangular girder-box assembly which includes a bottom plate prestressed in compression and a pair of upstanding side members each having its upper portions prestressed in tension. A poured and cured bridge deck is supported by the said side members, the cured deck securing in place the said tension and compression stresses.
The Grossman patent discloses a composite, prestressed structural member comprised of concrete and a lower metal support member, and a method for forming and prestressing the same.
The Wichert patent relates to rigid frame bridges and the fabrication and construction thereof. The Wichert method for fabricating the rigid frame bridge discloses holding the metal span portion of the bridge against sagging upon application of the concrete or, alternatively, positively pressing upwardly the metal span portion prior to pouring the concrete.
According to one aspect of the present disclosure, a method for making a prefabricated, prestressed module includes the steps of arranging one or more steel beams atop a supporting formwork element in a direction transverse to the supporting formwork element. The method further includes arranging one or more precast deck elements across the one or more steel beams to create a substantially continuous surface wherein the one or more precast deck elements have pockets for receiving connectors that protrude from the one or more steel beams. The method further includes arranging the supporting formwork element to allow the one or more steel beams to bend into a cambered shape to impart compressive stresses to a bottom flange of the one or more steel beams and tension stresses to a top flange of the one or more steel beams. The method also includes inserting grout into the pockets to hold the cambered shape and to bond the one or more precast deck elements to the connectors and the top flange.
According to another aspect of the present disclosure, a prefabricated, prestressed bridge module includes one or more precast deck elements arranged across one or more steel beams. The one or more steel beams are arranged on three or more supporting formwork elements such that the first supporting formwork element is at a first outer end of the one or more steel beams, the second supporting formwork element is at a middle of the one or more steel beams, and the third supporting formwork element is at a second outer end of the one or more steel beams. The one or more precast deck elements include pockets for receiving connectors that protrude from the one or more steel beams. At least one of the three or more supporting formwork elements is adjusted to stress the one or more steel beams. Grout is inserted in the pockets to bond the one or more precast deck elements to the one or more steel beams and the connectors such that a resulting compression stress of the one or more precast deck elements and the grout secures in place the stresses imparted to the one or more steel beams.
According to yet another aspect of the present disclosure, a prefabricated, prestressed bridge-forming module includes one or more steel beams atop a supporting formwork element in a direction transverse to the supporting formwork element, and one or more precast deck elements across the one or more steel beams creating a substantially continuous surface, the one or more precast deck elements having connectors that extend between the one or more steel beams and the one or more precast deck elements. The supporting formwork element supports the one or more steel beams while bent into a cambered shape resulting in compressive stresses to a bottom flange of the one or more steel beams and tension stresses to a top flange of the one or more steel beams. Grout is disposed on the one or more steel beams and at least between adjacent precast deck elements of the one or more precast deck elements. The grout bonds the one or more precast deck elements together and maintains the cambered shape of the one or more steel beams.
According to yet another aspect of the present disclosure, a prefabricated, prestressed bridge-forming module includes one or more cambered steel beams, and a plurality of precast deck elements disposed across the one or more cambered steel beams creating a substantially continuous surface. The one or more precast deck elements have pockets for receiving connectors that protrude from a top flange from each cambered steel beam. Grout is disposed in the pockets. The grout holds the cambered steel beams in a cambered shape and bonds the one or more precast deck elements to the connectors and the top flange of the cambered steel beams.
The present disclosure includes a novel prefabricated, prestressed bridge system and method for making same. The prefabricated, prestressed bridge system can be used in a variety of construction applications including, but not limited to, bridge applications. The prefabricated, prestressed bridge system includes one or more prefabricated, prestressed bridge modules fabricated from different prefabricated elements of varying strengths and modulus of elasticity. The different materials used for the elements are designed to minimize the material quantities of each specific element, minimize the fabrication duration, maximize the strength of the final products and meet any specific need of the final prefabricated, prestressed bridge system.
In one aspect of the present disclosure, a method for making the prefabricated, prestressed bridge module comprises providing and arranging one or more steel beams on three or more supporting formwork elements such that the first supporting formwork element is at a first outer end of the one or more steel beams, the second supporting formwork element is at the middle of the one or more steel beams, the third supporting formwork element is at a second outer end of the one or more steel beams, and the additional formwork elements are at one or more intermediary locations between the first outer end and the middle of the one or more steel beams and at one or more intermediary locations between the second outer end and the middle of the one or more steel beams. The method further comprises welding shear connectors to the top flanges of the one or more steel beams, adjusting the height of one or more of the supporting formwork elements to allow bending of the one or more steel beams under the self-weight, weight of the precast concrete deck elements and an externally applied load, placing and connecting the precast concrete deck elements by means of, for example, an ultra-high performance cementitious grout with a compressive strength of at least 14,500 psi and modulus of elasticity of at least 6,300 ksi placed into pockets in the precast deck elements aligned with and containing the welded shear studs and also placed atop the precast concrete deck elements to form a concrete surface bonded to the top of the precast concrete deck panels, such that the resulting compression stress of the concrete deck and overlay secure in place the stresses imparted to the one or more steel beams and creates a completed module having an increased load carrying capacity with less material and at a reduced cost as compared with current practice.
Grout can be in the form of HPC (High Performance Concrete), UHPC (Ultra High Performance Concrete), or other similar cementious material. The grout can be an overlay and can be limited to between the precast deck elements.
Each prefabricated, prestressed bridge module comprising of one or more steel beams, shear connectors attached to the one or more steel beams, and connecting the precast concrete deck elements to the beams to form a surface atop the beams, then forms a prefabricated, prestressed bridge system comprising two or more prefabricated, prestressed bridge modules secured together with ultra-high performance concrete joints is also a subject of the present disclosure.
Accordingly, an object of the present disclosure is to provide a prefabricated, prestressed bridge module in which camber is produced by selectively varying the heights of supporting formwork elements under the bridge module components while the prefabricated, prestressed bridge module is being made. Alternatively, camber may be achieved by selectively raising one or more supporting formwork elements under the bridge module components while the prefabricated, prestressed bridge module is being made.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module which utilizes the weight of precast deck panels placed atop the beams in combination with the adjustment of supporting formwork elements to produce camber.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module which uses the weight of deck panels placed atop the beams, the varying height supporting formwork elements, and an externally applied load to produce camber.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module which uses the weight of deck panels placed atop the beams, the varying height supporting formwork elements, to produce camber in the steel beam that is secured in place with a shear connection between the deck panels and steel beams.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module which uses precast concrete deck panels placed atop high density polyethylene shims with compressive strength of at least 40 psi which are placed atop the top flanges of the steel beams which allow for an annular space between the precast deck panel and steel beams.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module which uses precast concrete deck panels placed atop the beams that are secured in place with shear connections between the deck panels and steel beams comprising of cementitious grout bonded to the top of the steel beams and bottom of the concrete deck panels.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module which uses precast concrete deck panels placed atop the steel beams that are secured in place with cementitious grout placed in the annular void between the steel beams and the precast deck panels.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module which uses precast concrete deck panels placed atop the beams that are secured in place with shear connections between the deck panels and steel beams comprising of cementitious grout being integrally placed with an overlay surface atop the precast concrete deck panels.
It is an additional object of the disclosure to provide a prefabricated, prestressed bridge module which utilizes steel beams that are trapezoidal-shaped, I-beam-shaped, or shaped like other steel beams commonly used in the civil engineering industry.
It is an additional object of the disclosure to provide a prefabricated, prestressed bridge system that is faster to make, more efficient to fabricate, faster to install and more affordable than other prefabricated, prestressed bridges.
It is an additional object of the disclosure to provide a prefabricated, prestressed bridge system that consists of one or more prefabricated, prestressed bridge modules that can be joined with one another to make prefabricated, prestressed bridge systems of various sizes.
It is an additional object of the disclosure to provide a method of making a prefabricated, prestressed bridge system that can be made in a first location and delivered to a second location for installation and use.
It is an additional object of the disclosure to provide a method of making a prefabricated, prestressed bridge system in which the components can be manufactured in separate locations and delivered to a common location for assembly, installation and use.
An additional object of the disclosure is to provide a prefabricated, prestressed bridge system that can serve as a prefabricated, prestressed beam that can be used in a variety of construction applications, including but not limited to bridge applications.
It is an additional advantage of utilizing connections between modules with ultra-high performance concrete and making them more economical, faster to fabricate, and easier to install.
An additional advantage of this disclosure is a modular system which is lighter in weight than other systems, can be fabricated in a location other than its final use and easily moved and installed in its final location.
It is an additional object of the disclosure to provide shear force transfer from the beam's elements to the deck panel elements that utilizes roughened surfaces on top of the beams and bottom of the deck panels which are then bonded with ultra-high performance concrete.
The principle objective of the disclosure is to provide a more economical bridge system, with an improved configuration that allows the final bridge element to have a longer service life than current conventional materials and procedures.
Another objective of this disclosure is to provide a method for making the bridge element which reduces the in place stresses imparted to each individual element.
It is an additional object of the disclosure to provide a geometric configuration that utilizes and economizes the properties of the specific materials used to fabricate the bridge.
It is an additional object of the disclosure to provide a protective coating of the beam elements that enables the bridge to have an even longer service life in environments typically encountered.
It is an additional object of the disclosure to utilize cold formed steel which has the advantage of reduced cost over current fabrication of steel girders.
Another advantage is the ease of construction installation that speeds installation and reduces end-user delays when compared with current practice.
Another objective is to utilize newly developed cementitious materials to further ease fabrication and speed installation.
The present innovations are improvements (and have advantages) over known similar bridge systems such as shown in Nelson U.S. Pat. No. 7,600,283 “Prefabricated, Prestressed Bridge System and Method of Making Same,” including at least the following:
The UHPC overlay provides approximately an additional 40 years of maintenance free service life to the bridge deck surface (longer service life, lower life cycle costs).
The UHPC overlay allows for thinner precast concrete deck panels (less concrete material, shallower overall depth of module).
The UHPC fill in the precast concrete panel voids allows for larger spacing of the welded shear connectors (less shear connector material, lower cost).
The top of the precast concrete deck panels will have a roughened surface with and amplitude of at least ¼″ so that the UHPC overlay will bond to the precast concrete panel and provide additional stiffness to the bridge module (shallower overall depth of module).
The UHPC overlay is extremely dense and impermeable giving further protection and longer service life to the underlying precast concrete deck panel (longer service life, lower life cycle costs).
The UHPC placed into the annular space between the top of the steel beams and the bottom of the precast concrete deck panel provides additional bonding and shear resistance further strengthening the final bridge module (this option would eliminate shear connectors, lower cost).
The UHPC overlay places an extremely stiff, dense and impermeable layer at the top extreme fiber of the bring module allowing for shallower modules, which is a benefit not only for decreased weight in shipping, but increase clearance for bridges and less tall structures for buildings (shallower overall depth of module).
The use of precast concrete deck panels (rather than casting wet concrete on steel beam) allows for flexibility of the fabrication process. Material can be allocated and manufactured in parallel rather than in series (faster fabrication, lower cost).
The use of the weight of the precast concrete deck panels for providing camber in the steel beams allows for the elimination of backwalls and intermediate diaphragms (faster fabrication, lower cost).
The use of UHPC in the joint to connect individual modules increases the load carrying capacity of the joint, reduces the width of the joint, speed of the installation of the modules and allows for the connected modules to support load sooner (faster installation, reduced material).
These and other features, advantages, and objects of the present disclosure will be further understood and appreciated by reference to the following specification, claims, and appended drawings.
For purposes of description herein, the terms “upper,” “lower,” “right,” “left,” “rear,” “front,” “vertical,” “horizontal,” and derivatives thereof shall relate to the disclosure as oriented in
With reference to
Referring to
Referring to
The deck elements 17 and cementitious grout overlay 19 are an integral part of the prefabricated, prestressed structures of bridge module 2 that serve the additional function of producing and retaining camber in the one or more steel beams.
In combination with the self-weight of the steel beams 10, 11 atop the varying heights of the supporting formwork elements 14, 15, 16, the weight of the deck elements 17 stresses the one or more steel beams 10, 11 before the overlay 19 is cast atop the deck elements 17. The deck elements 17 and overlay 19 form a surface 39 atop the one or more steel beams 10, 11 such that resulting compression stress of the concrete deck 42 secures in place the stresses imparted to the one or more steel beams 10, 11 that maintain the cambered configuration of each module 2.
Referring to
Referring to
Referring to
Referring to
Referring to
Referring to
An alternate aspect may be made by utilizing steel beams that have a different shape than the depicted trapezoidal steel beams 10, 11. The alternate aspect utilizes steel beams that are in an “I-beam” shape that is commonly used in the construction industry.
An alternate aspect may be made by utilizing beams 10, 11 that are of different material than steel.
An alternate aspect may be made by utilizing deck elements 17 that are of different material than concrete.
An alternate aspect may be made by utilizing grout 36 that is made of different material than cement.
With reference to
In various aspects of the disclosure, the prefabricated, prestressed bridge system 8 can be used in a variety of construction applications including, but not limited to, bridge applications. The prefabricated, prestressed bridge system 8 includes one or more prefabricated, prestressed bridge modules 2, 3, and 4 fabricated from different prefabricated elements of varying strengths and modulus of elasticity. The different materials used for the elements are designed to minimize the material quantities of each specific element, minimize the fabrication duration, maximize the strength of the final products and meet any specific need of the final prefabricated, prestressed bridge system.
In one aspect of the present disclosure, a method for making the prefabricated, prestressed bridge module 2 comprises providing and arranging one or more steel beams 10, 11 on three or more supporting formwork elements 14, 15, 16 such that the first supporting formwork element 14 is at a first outer end of the one or more steel beams 10, 11, the second supporting formwork element 15 is at the middle of the one or more steel beams 10, 11, the third supporting formwork element 16 is at a second outer end of the one or more steel beams 10, 11, and the additional formwork elements are at one or more intermediary locations between the first outer end and the middle of the one or more steel beams and at one or more intermediary locations between the second outer end and the middle of the one or more steel beams. The method further comprises welding shear connectors 12, 13 to the top flanges 30, 32 of the one or more steel beams 10, 11, adjusting the height of one or more of the supporting formwork elements 14, 15, 16 to allow bending of the one or more steel beams under the self-weight, weight of the precast concrete deck elements 17 and an externally applied load F, placing and connecting the precast concrete deck elements 17 by means of a ultra-high performance cementitious grout 36 with a compressive strength of at least 14,500 psi and modulus of elasticity of at least 6,300 ksi placed into pockets 18 in the precast deck elements 17 aligned with and containing the welded shear studs and also placed atop the precast concrete deck elements 17 to form an overlay 19 bonded to the top of the precast concrete deck panels 17, such that the resulting compression stress of the concrete deck 42 and overlay 19 secure in place the stresses imparted to the one or more steel beams 10, 11 and creates a completed module 2 having an increased load carrying capacity with less material and at a reduced cost as compared with current practice.
Each prefabricated, prestressed bridge module 2, 3, 4, comprising of one or more steel beams 10, 11, shear connectors 12, 13 attached to the one or more steel beams 10, 11, and connecting the precast concrete deck elements 17 to the beams 10, 11 to form a surface 38 atop the beams 10, 11, then forms a prefabricated, prestressed bridge system 8 comprising two or more prefabricated, prestressed bridge modules 2, 3, 4, secured together with ultra-high performance concrete joints 44, 46 is also a subject of the present disclosure.
Accordingly, an object of the present disclosure is to provide a prefabricated, prestressed bridge module 2 in which camber is produced by selectively varying the heights H of one or more supporting formwork elements 14, 15, 16 under the bridge module 2 components while the prefabricated, prestressed bridge module 2 is being made. Alternatively, camber may be achieved by selectively raising one or more supporting formwork elements 14, 15, 16 under the bridge module components while the prefabricated, prestressed bridge module 2 is being made.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module 2 which utilizes the weight of precast deck elements 17 placed atop the steel beams 10, 11 in combination with the adjustment of supporting formwork elements 14, 15, 16 to produce camber.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module 2 which uses the weight of deck panels precast deck elements 17 placed atop the steel beams 10, 11, the varying height (H) supporting formwork elements 14, 15, 16 and an externally applied load (F) to produce camber.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module 2 which uses the weight of deck panels (precast deck elements 17) placed atop the beams, the varying height supporting formwork elements 14, 15, 16 to produce camber in the steel beam 10, 11 that is secured in place with shear connection between the deck panels (precast deck elements 17) and steel beams 10, 11.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module 2 which uses precast concrete deck panels (precast deck elements 17) placed atop high density polyethylene shims 9 with compressive strength of at least 40 psi which are placed atop the top flanges 30, 32 of the steel beams 10, 11 which allow for an annular space 48 between the precast deck panel (precast deck elements 17) and steel beams 10, 11.
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module 2 which uses precast concrete deck panels (precast deck element 17) placed atop the beams that are secured in place with shear connections between the deck panels (precast deck element 17) and steel beams 10, 11 comprising of cementitious grout 36 bonded to the top of the steel beams 10, 11 and bottom of the concrete deck panels (precast deck element 17).
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module 2 which uses precast concrete deck panels (precast deck element 17) placed atop the steel beams 10, 11 that are secured in place with cementitious grout placed in the annular void (annular space 48) between the steel beams 10, 11 and the precast deck panels (precast deck element 17).
It is an additional object of this disclosure to provide a prefabricated, prestressed bridge module 2 which uses precast concrete deck panels (precast deck element 17) placed atop the beams 10, 11 that are secured in place with shear connection 12, 13 between the deck panels (precast deck elements 17) and steel beams 10, 11 comprising of cementitious grout 36 being integrally placed with an overlay 19 surface atop the precast concrete deck panels (precast deck elements 17).
It is an additional object of the disclosure to provide a prefabricated, prestressed bridge module 2 which utilizes steel beams 10, 11 that are trapezoidal-shaped (10, 11), I-beam-shaped (100, 101), or shaped like other steel beams commonly used in the civil engineering industry.
It is an additional object of the disclosure to provide a prefabricated, prestressed bridge system 8 that is faster to make, more efficient to fabricate, faster to install and more affordable than other prefabricated, prestressed bridges 1.
It is an additional object of the disclosure to provide a prefabricated, prestressed bridge system 8 that consists of one or more prefabricated, prestressed bridge modules 2 that can be joined with one another to make prefabricated, prestressed bridge systems 8 of various sizes.
It is an additional object of the disclosure to provide a method of making a prefabricated, prestressed bridge system 8 that can be made in a first location and delivered to a second location for installation and use.
It is an additional object of the disclosure to provide a method of making a prefabricated, prestressed bridge system 8 in which the components can be manufactured in separate locations and delivered to a common location for assembly, installation and use.
An additional object of the disclosure is to provide a prefabricated, prestressed bridge system 8 that can serve as a prefabricated, prestressed beam that can be used in a variety of construction applications, including but not limited to bridge applications.
It is an additional advantage of utilizing connections 44, 46 between modules 2, 3, 4, with ultra-high performance concrete and making them more economical, faster to fabricate, and easier to install.
An additional advantage of this disclosure is a modular system which is lighter in weight than other systems, can be fabricated in a location other than its final use and easily moved and installed in its final location.
It is an additional object of the disclosure to provide shear force transfer from the beam elements (steel beams 10, 11) to the deck panel elements (precast deck element 17) that utilizes roughened surfaces on top of the beams 10, 11 and bottom of the deck panels (precast deck element 17) which are then bonded with ultra-high performance concrete.
The principle objective of the disclosure is to provide a more economical bridge system with an improved configuration that allows the final bridge element to have a longer service life than current conventional materials and procedures.
Another objective of this disclosure is to provide a method for making the bridge element which reduces the in place stresses imparted to each individual element.
It is an additional object of the disclosure to provide a geometric configuration that utilizes and economizes the properties of the specific materials used to fabricate the bridge.
It is an additional object of the disclosure to provide a protective coating of the beam elements that enables the bridge to have an even longer service life in environments typically encountered.
It is an additional object of the disclosure to utilize cold formed steel which has the advantage of reduced cost over current fabrication of steel girders.
Another advantage is the ease of construction installation that speeds installation and reduces end-user delays when compared with current practice.
Another objective is to utilize newly develop cementitious materials to further ease fabrication and speed installation.
The present innovations are improvements (and have advantages over) known similar bridge systems such as shown in Nelson U.S. Pat. No. 7,600,283 “Prefabricated, Prestressed Bridge System and Method of Making Same,” including at least the following:
The UHPC overlay 19 provides an additional 40 years of maintenance free service life to the bridge deck surface (longer service life, lower life cycle costs).
The UHPC overlay 19 allows for thinner precast concrete deck panels (less concrete material, shallower overall depth of module).
The UHPC fill in the precast concrete panel voids (pocket 18) allows for larger spacing of the welded shear connectors (less shear connector material, lower cost).
The top of the precast concrete deck panels (precast deck element 17) will have a roughened surface with an amplitude of at least ¼″ so that the IHPC overlay will bond to the precast concrete panel and provide additional stiffness to the bridge module (shallower overall depth of module).
The UHPC overlay 19 is extremely dense and impermeable giving further protection and longer service life to the underlying precast concrete deck panel (precast deck element 17) (longer service life, lower life cycle costs).
The UHPC placed into the annular space 48 between the top of the steel beams 10, 11 and the bottom of the precast concrete deck panel (precast deck element 17) provides additional bonding and shear resistance further strengthening the final bridge module 2 (this option would eliminate shear connectors, lower cost).
The UHPC overlay 19 places an extremely stiff, dense and impermeable layer at the top extreme fiber of the bridge module allowing for shallower modules, which is a benefit not only for decreased weight in shipping, but increase clearance for bridges and less tall structures for buildings (shallower overall depth of module).
The use of precast concrete deck panels (precast deck elements 17) (rather than casting wet concrete on steel beam) allows for flexibility of the fabrication process. Material can be allocated and manufactured in parallel rather than in series (faster fabrication, lower cost).
The use of the weight of the precast concrete deck panels (precast deck elements 17) for providing camber in the steel beams 10, 11 allows for the elimination of backwalls and intermediate diaphragms (faster fabrication, lower cost).
The use of UHPC in the joint 44, 46 to connect individual modules 2, 3, 4, increases the load carrying capacity of the joint, reduces the width of the joint, speed of the installation of the modules and allows for the connected modules to support load sooner (faster installation, reduced material).
In various aspects of the device, the shear connectors 12, 13 may be preset in the precast deck elements 17. In one aspect, the precast deck elements 17 may be arranged over one or more steel beams 10, 11 atop supporting formwork elements 14, 15, and 16 in a direction transverse to the supporting formwork elements 14, 15, and 16. The one or more precast deck elements 17 may be arranged across the one or more steel beams 10, 11 creating a substantially continuous surface 38. In various aspects, the one or more precast deck elements 17 have connectors 12, 13 that extend between the one or more steel beams 10, 11 and the one or more precast deck elements 17. The supporting formwork elements 14, 15, 16 support the one or more steel beams 10, 11 while bent into a cambered shape 28 resulting in compressive stresses to a bottom flange 34 of the one or more steel beams 10, 11 and tension stresses to a top flange 30, 32 of the one or more steel beams 10, 11. The grout 36 is disposed on the one or more steel beams 10, 11 and at least between adjacent precast deck elements 17 of the one or more precast deck elements 17 wherein the grout 36 bonds the one or more precast deck elements 17 together and maintains the cambered shape 28 of the one or more steel beams 10, 11.
Weld plates may be beneath the shear connectors 12, 13 to allow for welding of the shear connectors 12, 13 to the steel beams 10, 11 via the weld plates. Grout 36 may be inserted between the deck elements 17 and as an overlay 19 over one or more deck elements 17. In another aspect, the overlay 19 may be omitted, and grout 36 may be inserted into the pockets, such as between the deck elements 17. The grout 36 is the primary means for keeping camber in steel beams 10, 11. Retention of camber by the grout 36 can be at least partially supplemented by the welds between the weld plates attached to the shear connectors 12, 13 and the steel beams 10, 11.
It is to be understood that variations and modifications can be made on the aforementioned structure without departing from the concepts of the present disclosure, and further it is to be understood that such concepts are intended to be covered by the following claims unless these claims by their language expressly state otherwise.
This patent application is a continuation of U.S. patent application Ser. No. 15/813,423, filed on Nov. 15, 2017, entitled “PREFABRICATED, PRESTRESSED BRIDGE MODULE”, now U.S. Pat. No. 10,895,047, issued on Jan. 21, 2021, which claimed priority to and the benefit under 35 U.S.C. § 119(e) of the U.S. Provisional Patent Application No. 62/422,645, filed Nov. 16, 2016, entitled “BRIDGE CONSTRUCTION USING ULTRA-HI-PERFORMANCE MATERIALS”, the entire disclosures of which are incorporated herein.
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