A method for producing a three-dimensional construction material component preferably having at least one curved surface. A plurality of spacers are arranged in a formwork. A textile reinforcement is supported on the spacers, such that the textile reinforcement has a defined position within a formwork interior of the formwork. A tensile force is applied via a tensioning device to the textile reinforcement in at least one tension direction. Construction material is introduced into the formwork interior and surrounds the textile reinforcement. The construction material is then hardened, wherein the tensile force is maintained during the hardening. During this process, the spacers are integrated into the construction material component. The tensioning device has at least one clamping unit for clamping an end portion of the textile reinforcement between two clamping surfaces. The clamping surfaces are provided on clamping insert bodies, which are of a plastic material of a defined hardness.

A conduit segment casting mold system includes at least one inner mold; at least one outer mold configured as at least two outer mold sections of opposed shapes that define a cavity between the at least two outer mold sections that is sized to at least partially enclose the at least one inner mold, each of the at least two outer mold sections including a respective mating surface, each of the at least two outer mold sections including at least one hole sized to receive a cable, and the at least one hole of a particular one of the at least two outer mold sections is aligned with the at least one hole of another particular one of the at least two outer mold sections when the mating surfaces of the particular one and the another particular one of the at least two outer mold sections are mated; and a mold base.

Disclosed invention comprises innovations in the fabrication process and the associated design methodology for producing refined prestressed concrete elements/components. The innovations disclosed are fabrication using multiple stages, the use of ultra high strength materials for only critical subcomponents, utilizing thinner sections made of ultra high strength materials, and a unique method of inducing and controlling camber. The embodiments of this invention enable the accelerated construction of concrete structures that are both durable and cost effective. This disclosure demonstrates the significant improvements to the prior art in the areas of durability, constructability, and cost reduction for prestressed concrete components. The embodiments presented in this disclosure are for bridge superstructure applications.

In a method for producing a plurality of concrete cast elements of prestressed concrete, in particular for producing of railway sleepers, in a long bed which is a multiple of the length of a concrete cast element, in which separating elements are installed in the long bed to define the length of each of the concrete cast elements to be casted, a first and a second separating element for defining the length of a concrete cast element together with a tensioning device with tensioning elements for tensioning the concrete cast element between the two separating elements are mounted in the long bed, whereupon the concrete cast element is cast between the two separating elements and is at least partially hardened in the long bed.

Prestressed carbon fibers of at least one textile structure comprising carbon fibers are embedded in a concrete matrix. At least one textile structure comprising carbon fiber bundles is laid in a mold at a distance from one another, into two accommodation elements which are arranged at two diametrical end faces of the mold. Hollow spaces within the accommodation element are filled with a rapid-curing viscous composition having a mineral basis or rapid-curing polymer. After curing the composition or of the polymer, tensile forces act on the accommodation element(s) in the longitudinal direction of the carbon fiber bundles with a tensioning device. During the tensile force the interior of the mold is subsequently filled completely with viscous concrete. After curing of the concrete, the tensile forces on the prestressed carbon fiber bundles are largely transferred to the cured concrete and the concrete component can then be removed from the mold.

Disclosed invention comprises innovations in the fabrication process and the associated design methodology for producing refined prestressed concrete elements/components. The innovations disclosed are fabrication using multiple stages, the use of ultra high strength materials for only critical subcomponents, utilizing thinner sections made of ultra high strength materials, and a unique method of inducing and controlling camber. The embodiments of this invention enable the accelerated construction of concrete structures that are both durable and cost effective. This disclosure demonstrates the significant improvements to the prior art in the areas of durability, constructability, and cost reduction for prestressed concrete components. The embodiments presented in this disclosure are for bridge superstructure applications.

A pre-stressed concrete box culvert includes a three-sided culvert top section having a pre-stressed top slab, a first sidewall and a second sidewall. The first and the second sidewalls extend orthogonally from opposite ends of the pre-stressed top slab, and the first and the second sidewalls each include a free end that has at least one male or female connector. The pre-stressed concrete box culvert includes a three-sided culvert bottom section having a pre-stressed bottom slab and a third sidewall and a fourth sidewall. The third and the fourth sidewalls extend orthogonally from opposite ends of the pre-stressed bottom slab, and the third and the fourth sidewalls each include a free end that has at least one male or female connector to mate with the at least one corresponding male or female connector arranged at one of the respective free ends of the first and the second sidewalls.

A pre-stressed concrete box culvert includes a three-sided culvert top section having a pre-stressed top slab, a first sidewall and a second sidewall. The first and the second sidewalls extend orthogonally from opposite ends of the pre-stressed top slab, and the first and the second sidewalls each include a free end that has at least one male or female connector. The pre-stressed concrete box culvert includes a three-sided culvert bottom section having a pre-stressed bottom slab and a third sidewall and a fourth sidewall. The third and the fourth sidewalls extend orthogonally from opposite ends of the pre-stressed bottom slab, and the third and the fourth sidewalls each include a free end that has at least one male or female connector to mate with the at least one corresponding male or female connector arranged at one of the respective free ends of the first and the second sidewalls.

A conduit segment casting mold system includes at least one inner mold; at least one outer mold configured as at least two outer mold sections of opposed shapes that define a cavity between the at least two outer mold sections that is sized to at least partially enclose the at least one inner mold, each of the at least two outer mold sections including a respective mating surface, each of the at least two outer mold sections including at least one hole sized to receive a cable, and the at least one hole of a particular one of the at least two outer mold sections is aligned with the at least one hole of another particular one of the at least two outer mold sections when the mating surfaces of the particular one and the another particular one of the at least two outer mold sections are mated; and a mold base.

A conduit segment casting mold system includes at least one inner mold; at least one outer mold configured as at least two outer mold sections of opposed shapes that define a cavity between the at least two outer mold sections that is sized to at least partially enclose the at least one inner mold, each of the at least two outer mold sections including a respective mating surface, each of the at least two outer mold sections including at least one hole sized to receive a cable, and the at least one hole of a particular one of the at least two outer mold sections is aligned with the at least one hole of another particular one of the at least two outer mold sections when the mating surfaces of the particular one and the another particular one of the at least two outer mold sections are mated; and a mold base.