CONSTRUCTION PROCESS OF STRUCTURES WITH EMPTY SEGMENTS AND CONSTRUCTION SYSTEM OF STRUCTURES WITH EMPTY SEGMENTS

Abstract

The present invention relates to an industrialized construction process of at least part of a structure (1) to be constructed, by applying it, for example, to bridge decks, in which the filling material (8) is poured in situ on empty segments (3) prefabricated ex situ.

The construction process according to the present invention comprises the prefabrication of empty segments (3) including the assembling of steel reinforcement elements (9) and assembling fixing elements (4) whereby these comprise rigid elements (22) and at least part of the moulds (13), which occur at a location (5) ex situ, for example at the factory, construction site or at a place close to the works front line; transport and placement of the empty segments (3) in the final position in the structure (1); the operation of pouring the filling material (8); consolidation or curing of the filling material; prestressing the structure (1), if applicable; removal of the moulds (13) and fixing elements (4); followed by the start of the next cycle, if applicable.

The present invention also relates to a construction system adapted for carrying out a construction process of a structure (1) to be constructed.

Claims

1. Process for industrialized construction of at least part of a structure (1) configured to be divisible into one or more reference segments (2), and comprising at least one cycle that includes the following steps: prefabrication ex situ of empty segments (3) configured with a general geometry corresponding to the geometry of respective reference segments (2) and adapted in order to receive the respective filling material (8), wherein the prefabrication of said empty segments (3) includes the assembling of steel reinforcement (9) and the assembling of fixing elements (4) that include at least part of the moulds (13) necessary for the execution of at least part of said structure (1) corresponding to said reference segments (2), and at least a system of rigid elements (22), wherein said fixing elements (4) are provided to ensure the stability and geometry of said empty segments (3) in the transport phase to the in situ location and placement in situ, and are further provided in a manner compatible with moulds (13) which are not included in said fixing elements (4), and wherein said system of rigid elements (22) has a structural capacity sufficient enough to support itself and to support said steel reinforcements (3) and said moulds (13) included in said fixing elements (4); transport of said empty segments (3) from the ex situ to the in situ location; in situ placement of said empty segments (3) in a final placement position corresponding to the respective reference segment (2) of said structure (1); in situ filling of said empty segments (3) with filling material (8) without discontinuity of said filling material (8) in existing interface areas between any two adjacent reference segments (2) of said structure (1); consolidation of the filling material (8) in order to obtain at least part of the structure (1) to be constructed, and removal of said fixing elements (4) and existing moulds (13) and not included therein.

2. Process according to claim 1, characterized in that said prefabrication of empty segments (3) includes the assembling of prestressing ducts (10).

3. Process according to claim 1, characterized in that it comprises the following steps: in situ introduction of prestressing cables (11) after the in situ assembling of at least one empty segment (3), and carrying out the tensioning of said cables (11) in situ, after said filling with filling material (8) and consolidation thereof.

4. Process according to claim 1, characterized in that it includes the step of designing the structure (1), which includes the verification of the limit states and use in existing interface sections between any two adjacent reference segments (2) and not trespassed by steel reinforcement elements (9).

5. Process according to claim 1, characterized in that said prefabrication of an empty segment (3) includes the step of introducing prestressing cables (11) ex situ and carrying out a tensioning of the said prestressing cables (11) in situ, after filling with filling material (8) and consolidation thereof.

6. Process according to any one of claim 1, characterized in that said prefabrication of empty segments (3) includes the assembling of interface elements and/or inserts (12), including profiles of metallic material, and/or carbon fiber (31), and/or prefabricated anchoring blocks (29), and/or other prefabricated elements (33), and/or positioning elements of the steel reinforcements (23), and/or the isolation devices (25) for execution of negatives in the filling material (8) or of a combination of at least part of these.

7. Process according to any one of claim 1, characterized in that said prefabrication of empty segments (3) includes the assembling of seals (30) adapted to be arranged as interface elements between moulds (13), or other interface elements to be arranged between said empty segments (3).

8. Process according to any one of the preceding claim 1, characterized in that it includes the in situ application of additional steel reinforcements (21) in said empty segments (3).

9. Process according to any one of the preceding claim 1, characterized in that it includes the step of in situ application of additional elements of moulds (24) in said empty segments (3).

10. Process according to claim 1, characterized in that said step of ex situ prefabrication of empty segments (3) includes the following steps: introduction of prestressing cables (11), and tensioning of these prestressing cables (11), and also includes the in situ step of pre-tensioning transmission of said fixing elements (4) to the filling material (8).

11. Process according to any one of the preceding claim 1, characterized in that it also includes the following steps: in situ removal of the fixing elements (4) and part or all of said moulds (13); transport of said fixing elements (4) to the ex situ prefabrication area (5); start of next cycle.

12. Process according to any one of the preceding claim 1, characterized in that it comprises the ex situ assembling of a plurality of sets of fixing elements (4), in order to allow more than one front of prefabrication of empty segments (3).

13. Process according to any one of the preceding claim 1, characterized in that the construction of at least part of the structure (1) with the use of the said empty segments (3) being executed at least partly simultaneously with the construction of at least part of the structure (1) using structure segments corresponding to reference segments (2) and totally prefabricated ex situ, without the use of empty segments, and/or special pier segments (28) totally prefabricated ex situ without the use of empty segments (3), and/or at least partially being executed simultaneously with the construction in situ of at least part of the structure (1) without the use of empty segments (3).

14. Construction system adapted for carrying out a construction process of a structure (1) to be constructed, configured so that it can be divisible into one or more reference segments (2), in particular the construction process according to claim 1, characterized in that it presents at least one empty segment (3) provided with a general geometry corresponding to that of a respective reference segment (2) and adapted so that it can be prefabricated and so as to receive the respective filling material (8), wherein said empty segments (3) comprise at least fixing elements (4), including at least one system of rigid elements (22), at least part of the moulds (13), and steel reinforcement elements (9), and wherein said fixing elements (4) are provided to ensure the stability and the geometry of said empty segments (3) in the phases of transport and placement, and compatibility with the moulds (13) which are not included in these fixing elements (4), and wherein said system of rigid elements (22) has structural capacity at least sufficient to support itself and support said steel reinforcements (9) and said moulds (13) which are included in said fixing elements (4).

15. Construction system according to claim 14 characterized in that at least one of said fixing elements (4) of said empty segments (3) is a retractable structure and/or at least includes a system of mechanically adjustable elements (15) and/or is provided as a system that can be separated into parts and/or as a structure provided with isolation devices (25) to trespass the filling material.

16. Construction system according to claim 14, characterized in that at least one of said fixing elements (4) of said empty segments (3) includes gripping devices (27) and/or sliding devices (26) and/or fixing interfaces (16) and/or a concrete accelerating admixtures system.

17. Construction system according to claim 14, characterized in that it presents at least one fixing element (4) provided so that it presents an autonomous and sufficient structural capacity, being preferably configured so that it can sustain the load of the filling material (8) in order to ensure stability of said empty segment (3) during the filling thereof with filling material (8).

18. Construction system according to claim 14, characterized in that it presents at least one fixing element (4) provided so that it has sufficient structural capacity to be pre-tensioned, including sufficient capacity to sustain the action of the pre-tensioning of the cables (11), and wherein said fixing element (4) includes rigid reaction devices adapted for tensioning (32) to provide reaction in said tensioning.

19. Construction system according to claim 14, characterized in that said structure (1) or part thereof, presents a box girder section, a rectangular section, a square section, a ‘Pi’ section, a ‘T’ section, a section in double ‘T’, a circular section, a triangular section, or any other form of section that is mechanically feasible for executing said structure (1) to be constructed, or portion thereof.

20. Construction system according to claim 14, characterized in that said structure (1) to be constructed is at least part of a bridge deck or overpass, a pier, an arc, a beam, a structural element with vertical walls, a sloping element or a complex structural element with another shape.

21. Construction system according to claim 14, characterized in that said filling material (8) of said empty segments (3) is a concrete, a hydraulic binder, a glass, a ceramic material, a plastic material, or an alloy.

22. Construction system according to claim 14, characterized in that it includes a shoring system (6) adapted so that it has kinematic and geometric compatibility with said empty segments (3), so as to ensure the possibility of said empty segments (3) passing in the support elements (20) of said shoring system (6), and/or to ensure that said shoring system (6), or the moulds (13) coupled therein, present interface fixing devices (16) to ensure the positioning of said empty segments (3) that may also present interface fixing devices (16), and/or auxiliary means (19) for handling loads incorporated in the shoring system (6) to supply the empty segments (3) depending on the means of transport (17) adopted in the works logistics, and/or the shoring system (6) presenting concrete accelerating system, like for example concrete accelerating by steam (31).

Description

DESCRIPTION OF THE FIGURES

[0060] The invention will now be explained in greater detail based on preferred embodiments and the Figures that are attached.

[0061] The Figures show, in simplified schematic representations:

[0062] FIG. 1: structure (1) to be constructed of a bridge deck or overpass, including identification of possible reference segments (2) and empty segments (3);

[0063] FIG. 2: structure (1) to be constructed of an arc, including identification of possible reference segments (2) and empty segments (3);

[0064] FIG. 3: structure (1) to be constructed with sloping elements, including identification of possible reference segments (2) and empty segments (3);

[0065] FIG. 4: structure (1) to be constructed of a pier, including identification of possible reference segments (2) and empty segments (3);

[0066] FIG. 5: structure (1) to be constructed of a rigid core of a building, including identification of possible reference segments (2) and empty segments (3);

[0067] FIG. 6: structure (1) to be constructed in a multi-story frame, including identification of possible reference segments (2) and empty segments (3);

[0068] FIG. 7: general structure (1) to be constructed, including identification of possible reference segments (2) and empty segments (3) with total length of span;

[0069] FIG. 8: cross-section of a structure to be constructed coincident with the cross-section of the reference segment (2) with a general configuration and identification of empty segments (3); symbolically represented fixing elements (4); filling material (8); steel reinforcements (9); any active steel reinforcement ducts (10) and respective steel reinforcements (11) and any inserts (12), moulds (13) and prefabricated anchoring blocks (29);

[0070] FIG. 9: three-dimensional scheme, with cutaway views, elevations views and details, of an empty segment (3) with fixing element (4) with part of the moulds (13) and with possible functional devices of the moulds;

[0071] FIG. 10: cross-section of a work with empty segments (3) incorporating fixing elements (4) that include all the moulds (13);

[0072] FIG. 11: cross-section and elevation views of a horizontal structure (1) to be constructed, with an empty segment (3) which incorporates the fixing element (4) that includes the mould (13);

[0073] FIG. 12: cross-section and elevation views of vertical or inclined structures (1) to be constructed, with an empty segment (3) which incorporates the fixing element (4) that includes the mould (13);

[0074] FIG. 13: two cross-sections and two longitudinal sections of an empty segment (3) with fixing elements (4) with partial inclusion of moulds (13) and possible solutions of mould interfaces (13) and additional devices;

[0075] FIG. 14: two cross-sections and two side views of an empty segment (3) with retractable fixing elements (4) with inclusion of the inner part of the moulds (13) and possible solutions of mould interfaces (13) and additional devices, namely seals (30);

[0076] FIG. 15: prefabrication area (5) and prefabrication sequence of empty segments (3) including the fixing elements (4) making use of auxiliary means (7), means of transport (17) of the empty segments (3) and works front line with the structure (1) to be constructed whose cross-section is shown in cutaway A-A, divided by sections to be executed by phases separated by the construction joints (18), the empty segments being represented (3) in the final position corresponding to the counterpart reference segments (2) and also showing the shoring system (6) where the empty segments are positioned (3);

[0077] FIG. 16: works front line area including means of land transport (17) of the empty segments (3) and including auxiliary equipment (19) belonging to the shoring system (6) to assist in the handling and placement of the empty segments (3) in the final position on the shoring system (6);

[0078] FIG. 17: works at front line area including means of nautical transport (17) of the empty segments (3) and including auxiliary equipment (19) belonging to the shoring system (6) to assist in the handling and placement of the empty segments (3) in the final position under the shoring system (6);

[0079] FIG. 18: works front line area including lesser means of land transport (17) of the empty segments (3) and including auxiliary equipment (19) belonging to the shoring system (6) to assist in the handling and placement of the empty segments (3) in the final position on the shoring system (6);

[0080] FIG. 19: overlap or overlaps passive elements (21) placed in situ between empty segments (3) in the final position thereof;

[0081] FIG. 20: empty segments (3) that include fixing elements (4) that include steel reinforcement spacing elements (23) and concrete accelerating system, for example, by steam (31);

[0082] FIG. 21: use of mould closing elements (24) placed in situ to close the moulds (13) previously placed;

[0083] FIG. 22: special pier segments (28) placed on the pier prior to the start cycle of the respective span;

[0084] FIG. 23: cross-section of the structure to be constructed (1) with T elements;

[0085] FIG. 24: cross-section of the structure to be constructed (1) with double flange elements;

[0086] FIG. 25: cross-section of the structure to be constructed (1) with bi-cellular box elements;

[0087] FIG. 26: cross-section of the structure to be constructed (1) with predominantly triangular elements;

[0088] FIG. 27: cross-section of the structure to be constructed (1) of elements with oval sections;

[0089] FIG. 28: cross-section of the structure to be constructed, with elements with circular sections;

[0090] FIG. 29: empty segment with inclusion of prefabricated elements (33) (integral prefabricated elements, already with filling material).

DESCRIPTION OF PREFERRED EMBODIMENTS OF THE INVENTION

[0091] The present invention relates to a new construction process and a construction system of structural elements, for example, reinforced concrete, with several configurations, as shown in FIGS. 1, 2, 3, 4, 5, 6 and 7, in which the structures (1) or parts of structures (1) to be constructed are divisible into one or more so-called reference segments (2). The proposed methodology entails a major component of prefabrication, but in which the basic structural material—filling material (8)—which can be concrete, for example, is poured in situ. For the purposes of this description of preferred methods of execution, this will be made with reference primarily to the construction process and thereby including the reference to the main elements of the associated construction system, as perceived by someone skilled in the art.

[0092] In order to understand better, the reference segments (2) may coincide in terms of form and constitution with the conventional prefabricated concrete elements and may be segments that cover the span (corresponding to prefabricated beams) or segments with integral cross-section (corresponding to prefabricated segments), or to integral segments (corresponding to complete prefabricated segments), or segments of prefabricated piers, segments of other prefabricated elements, such as curved elements, sloped elements, concrete cores, etc.

[0093] Analyzing FIGS. 7 and 8, the structure (1) to be constructed, and which may have any configuration, is divided into one or more reference segments (2), which may have any configuration. The empty segments (3) have direct correspondence with the reference segments (2) regarding the same final position (counterparts). Each empty segment (3) is placed on the structure (1) in the position of the corresponding reference segment (2) having a fixing element incorporated (4) which ensures the geometry and stability of the empty segment (3) during transport and placement, until the consolidation of the filling material (8) (for example, concrete) that is poured into the empty segment (3). The empty segments (3) have, therefore, direct correspondence with the reference segments (2), but do not yet have the filling material (8).

[0094] Analyzing FIG. 8, in which the structure (1) to be constructed is seen as a cutaway view and coinciding, therefore, in that section, with the reference segment (2), the empty segment (3) consists of part or all of the elements that make up the reference segment (2), except for the filling material (8). The geometry and stability of the empty segment (3) in the manufacture, transport and installation, is ensured by the fixing element (4) shown symbolically in FIG. 8.

[0095] In the case of, for example, reinforced concrete structures, the empty segment (3) comprises passive steel reinforcements (9) already with the final geometric configuration.

[0096] In the case of structures (1) of, for example, prestressed reinforced concrete, the empty segments (3) include prestressing ducts (10) and the prestressing cables (11) can be introduced after the assembling of one set of empty segments (3) that are concreted in one same operation, for example, corresponding to a span in the case of a bridge deck. The cables can be fully placed if their length is equal to or less than the empty segment (3).

[0097] If the structure (1) is composite or has interface elements or inserts incorporated (12) (for example, metallic elements) that become incorporated in the filling material (8), these elements can also be incorporated in the empty segments (3).

[0098] By means of the operation of pouring the filling material (8), and after consolidation of the filling material, the empty segment (3) becomes, therefore, the reference segment (2). In the case of structures (1) of reinforced concrete, this pouring operation is the concreting operation.

[0099] With reference to FIG. 1, the construction process in accordance with the invention can, for example, be applied to the construction of structures (1) like bridge decks, dividing each span into several reference segments (2), or just one reference segment (2), and in this kind of application, use shoring systems (6), such as ground scaffolding or self-launching scaffolding that will sustain the said empty segments (3) until the filling material (8) is consolidated, in case the fixing element (4) does not have resistant capacity to cover the span in question.

[0100] If the fixing element (4) is dimensioned to have structural capacity to support the filling material (8), then the empty segment (3) can be placed without the use of shoring systems (6), as shown schematically in FIGS. 6 and 11.

[0101] With reference to FIGS. 4 and 12, in the case of construction of structures (1) of the vertical elements type, for example, it is also not necessary to use shoring systems (6), and the empty segments (3) can have interfaces (16) to fit directly into reference segments (2) previously executed, or into empty segments (3) previously placed.

[0102] An important aspect in the application of the construction process in accordance with the present invention is the fixing element design (4). This element must comply with three requirements: i) ensure the final geometry, or close to the final one, of the elements that make up the empty segment (3) so that, by means of quick and simple operations, it is easy to ensure the desired geometry for the empty segment (3) after it is placed; ii) have the structural capacity to ensure the empty segment stability (3) in its transport and placement; and (iii) be compatible with the moulds (13) of the element to be constructed that are not included in the fixing element (4), or including those same moulds (13).

[0103] Additionally, it may also be advantageous, for the fixing element (4) to be previously prepared so as to be easily positioned, for example including fixing devices (16) that can be both positioners and fixing devices (16), or other devices which ensure the correct positioning of the empty segment (3).

[0104] In FIGS. 9, 10, 11 and 12, 13 and 14, there are some examples of drawings showing fixing elements (4). Other designs can be developed resulting from combinations or their adaptation to each case.

[0105] The fixing elements (4) may, for example, include all the moulds from the outset (13), for example the formwork, as in the cases of FIGS. 10, 11 and 12. But they may also, for example, include only part of the moulds (13), as in the example of FIG. 9, or include intermediate solutions in which the fixing elements (4) comprise individual or localized areas of moulds, as is the case of FIG. 13.

[0106] The fixing elements (4) include rigid elements (22) and may include, for example, adjusting devices (15) which may be useful not only to adjust the final geometry of the empty segment (3) but may also be useful to facilitate the removal of the fixing elements (4) after the empty segment (3) is filled by the material (8) and this is properly consolidated, or even to move or lift part or all of the fixing elements (4).

[0107] The adjusting elements (15) may consist of mechanical elements for manual adjustment, for example mechanical spindles, or other mechanical elements known in the state of the art, such as hydraulic jacks, manual spindles, retractable elements, or others with similar functions.

[0108] In FIG. 14, there is an example of retractable fixing element (4) incorporating the inner moulds (13) of the structure. This type of solution to increase productivity can, for example, require doubling or tripling, or another number of fixing elements (4) for each position of the structure to be constructed, i.e. corresponding to each reference segment (2).

Example of Application of the Invention

[0109] Next, and only by way of example, follows an explanation of the application of the construction process in accordance with the present invention to the construction of prestressed box girder decks concreted in situ using, for example, a shoring system (6) which is self-launching scaffolding. The necessary adjustments for the application of this process to other types of structures are explained later on.

[0110] This construction process, when applied to this example, comprises seven stages: [0111] A. Prefabrication of empty segments (3), including assembling of fixing elements (4) in an ex situ prefabrication area (5); [0112] B. Transport and placement of the empty segments (3) in the scaffolding (6); [0113] C. Concreting of the structural element (1); [0114] D. Curing period; [0115] E. Prestressing of the structure (if any) and removal of scaffolding; [0116] F. Removal of the fixing elements (4) and transport to prefabrication area (5).

[0117] With reference to FIG. 15, the L1 portion of structure (1) to be constructed in a cycle, limited by two construction joints (18) may have, for example, a dimension equal to that of the L span, corresponding to the spacing of the piers, but may have other dimensions, for example, 2×L among others.

[0118] It is possible that, for example, the deck (1), with a box girder cross-section indicated in cutaway A-A, for example, can be executed with several reference segments (2) per span. Each reference segment (2) to be constructed corresponds to an empty segment (3).

[0119] With reference to FIG. 15, it is possible to use overhead self-launching scaffolding (6) (other types of scaffolding can be used, for example, lower scaffolding, ground scaffolding, etc.), with construction joints (18), located, for example, close to ¼ or ⅕ of the span or in another section, and the location of the construction joint (18) may be on the pier, or in another section closer to or away from the pier than indicated, to be defined on a case by case basis.

Phase A—

[0120] Prefabrication of empty segments (3), including assembling of fixing elements (4) in an ex situ prefabrication area (5);

[0121] This phase is explained based on FIGS. 14 and 15 and 29.

[0122] The fixing elements (4) could, in this example, have the configuration defined in FIG. 14, but could have other configurations as mentioned before. Therefore, in this example, the fixing elements (14) include the inner moulds (13) (or inner formwork) having adjustment elements (15) in that area to facilitate subsequent adjustment and removal, and include rigid elements (22) to stabilize and ensure geometry of the steel reinforcement (9).

[0123] The fixing elements (4) to use in each cycle (except in the first cycle) are from the works front line, where they were used in a previous cycle. A preliminary operation, applicable to this example, consists in cleaning and painting with form release agents, or similar products, the modules, the inner formwork (13) that, in this example, are an integral part of the fixing element (4).

[0124] The empty segments (3) are prefabricated by assembling the steel reinforcements (9) in a manner compatible with the assembling of fixing elements (4) that integrate the empty segments (3), and part of the moulds (13) (inner formwork) which in this example is also part of the fixing element (4), and these three activities must be carried out in order to comply with the geometry of the reference segment (2) corresponding to the segment to be executed of the works, i.e. complying with the geometry of the final structure (1).

[0125] To increase productivity and quality control, steel reinforcement spacing elements can be used (23) i.e. ‘gabarits’ for positioning the steel reinforcements, for example, pierced steel sheets with strict position of each rod or cable, pieces of wood, pieces of concrete; in other applications these elements may also be an integral part of the (4) fixing elements, as shown for example, in FIG. 20.

[0126] There may be an assembly line, for example, as schematically shown in FIG. 15, in which auxiliary means (7) can be used. Several sequences of assembly of empty segments can be implemented (3). All this so that the empty segments (3) are completely prepared to be placed in the next span.

[0127] Depending on the structure (1) designed, the empty segments may include prestressing ducts (10), interface structures or inserts (12), or other elements that are part of the final structure (1) that can be incorporated in the prefabrication, as, for example, the prefabricated anchoring blocks (29), prefabricated elements (33) (see FIG. 29), among others.

[0128] The empty segments (3) must be made with the same or very similar geometry to that which ensures the correct execution of the final structure (1) and the fixing elements (4) must ensure the stability of the empty segments (3) during transport and placement. The fixing elements must be compatible with the moulds (13), in this case the formwork, which are not included in them, and, as is the case of this example, include the inner formwork (13) as shown in FIG. 14.

[0129] If each empty segment (3) has a sole position for placement in the shoring (6), it may be appropriate to mark the empty segments (3), for example, by numbering them.

[0130] The fixing element segments (4) may also be provided with collective safety equipment, e.g. guards, platform, or safety belts fixing elements, which may be useful for carrying out the work safely.

[0131] In the case of the fixing elements (4) incorporating elements that trespass the filling material (8), in this case concrete, as it happens, for example, in the fixing element (4) in FIG. 13, it may be necessary to use some insulating parts (25) of plastic, for example, which prevent the fixing element (4) from aggregating to the concrete when it consolidates.

[0132] In some cases, the empty segments (3) fabrication process can be more productive and with greater quality control, if the assembling of the empty segments (3) is carried out in the prefabrication area (5) on a platform, with an L1 extension, which can hold simultaneously and continuously all the empty segments (3) pertaining to the same execution phase.

Phase B—

[0133] Transport, placement and fixing of the empty segments (3) in the scaffolding (6);

[0134] This phase is explained based on FIGS. 14, 15, 16, 17, 18 and 21.

[0135] According to FIG. 15, after being fabricated, the empty segments (3) are transported to the works front line by means of transport (17) that can be by land or water, as shown schematically in FIGS. 15, 16, 17 and 18. This operation takes place after the shoring system (6) is properly positioned in view of the current stage of construction.

[0136] Note that an empty segment (3) has dimensions and weight suitable for easy transport to the shoring system, for example a scaffolding, and for easy lifting and placement in the scaffolding (these elements may weigh several times less than an element of prefabricated concrete, (i.e. than the corresponding structure segment (1)).

[0137] As shown in FIG. 16, the supply of empty segments (3) can be made by means of land transport (17) along the deck, it can be done by lower land means (see FIG. 18), or can be done by lower water means (17), as shown in FIG. 17.

[0138] The design of the fixing elements (4) must take account the empty segments (3) type of supply to be carried out in the works. It may be appropriate, for example, to use more complete fixing elements (4), similar to those in FIG. 10 in the case the supply of empty segments (3) is to be carried out bellow the deck.

[0139] In the case of using overhead scaffolding (6), the plan view dimensions of the empty segments (3) must be made compatible with the support elements (20) of the scaffolding (6) (shown in FIG. 16). In some cases, it may be advantageous to ensure that the empty segments (3) are introduced as a rotation in the 90° plant view, as it is common in construction with prefabricated segments, and well-known in the state of the art solutions.

[0140] The placement of the empty segments (3) in the final position can be made by auxiliary means similar to the auxiliary means (7) of the prefabrication area, or it may be performed by auxiliary means (19) incorporated in the scaffolding (6).

[0141] As can be seen in FIG. 14, the existence of interface fixing devices (16) that can ensure a fast and accurate placement of the empty segments (3) can greatly facilitate the operation of positioning and eventual fixing of the empty segments (3) in the final position in scaffolding (6). These interface fixing devices (16) may have several locations, which may be in the scaffolding (6), in the inner or outer moulds (13), in the fixing elements (4), or in some of these elements, or in all.

[0142] The fixing elements (4) may also include interface fixing devices (16) between them and seals (30) or other interface materials to ensure an airtight closing of the moulds (13) (as shown in FIG. 14).

[0143] Depending on the design criteria, the empty segments (3) may, for example, have no connection between them (see FIG. 16), in which case, in works front line there is no work with steel reinforcement material (9).

[0144] Empty segments (3) with steel reinforcement (9) which penetrate into the adjacent empty segment (as shown in view B-B of FIG. 14) may alternatively be designed.

[0145] It is also possible to adopt, for example, a solution, shown in FIG. 19, with occasional introduction of overlapping reinforcement elements or overlaps (21) in situ, in the interfaces of the empty segments (3) or with other complementary located elements to be placed in situ that are deemed necessary (for example, seals or other). If that is the option, special solutions can be adopted of overlapping reinforcement elements of overlap or overlaps (21) of the empty segments (3), for example, threaded overlapping reinforcement elements or overlaps (21).

[0146] Alternatively, the overlapping reinforcement elements or overlaps (21) may travel with the empty segments (3) without being fixed, and it is possible to slide them when the empty segments (3) are already in their final position.

[0147] There may also be a design of fixing elements (4) and moulds (13) providing for the placement of closing moulds elements (24) in situ, schematically shown in FIG. 21. These closing moulds (24) may also be useful to facilitate the placement of overlapping reinforcement elements or overlaps (21).

[0148] Depending on the design of the fixing elements (4), after placement of the empty segments (3) part of the moulds can be introduced (13), for example, the inner moulds, which in the case of the fixing elements having a design similar to that shown in FIG. 14 is not necessary (since, in this case, the moulds are fully included in the fixing elements). The fixing elements (4) could also include only a part of the moulds (13), as shown in the example of FIG. 9.

[0149] Finally, after all the empty segments have been placed (3) in the shoring system (6) and any additional works have been executed in situ as previously mentioned, in the case of the structure (1) being designed with prestressing, with the respective cables having an extension above the empty segments (3), then ducts (10) connecting elements must also be placed in situ, and the prestressing cables (11) must also be introduced in an in situ operation at the works front line, similarly to what happens in traditional construction with prefabricated segments.

[0150] The shoring system (6) may be prepared for the installation of lifting equipment (19) that allows the placement of prestressing coils under the deck. The installation of the prestressing cables is performed after the prestressing ducts sealing (10).

Phase C—

[0151] Concreting of the structural element (1);

[0152] The operation of pouring the filling material (8), which in this example coincides with the concreting operation of the deck, may have very variable durations, and usually means several hours for the example being described. In this operation, a number of specialized operators will pour and vibrate the liquid concrete in all the empty segments (13) located between two consecutive construction joints (18), i.e. of a portion of the structure (1) to be constructed. Normally, as the extension to be executed in each cycle has, for example, dimension L (indicated in FIG. 15), this means that the sum of the lengths of empty segments (13) used in that span will also have, for example, the same L1 extension. It is possible to apply the method to other extensions of concreting.

[0153] The shoring system (6) which can be, for example and as already mentioned, self-launching scaffolding, can be equipped with elements that allow the creation of concreting circuits along the stretch to be constructed, for optimization of this process.

[0154] Note that the operation in question, in the example shown, is identical to the normal concreting operation of the in situ construction methodology, without any influence of ‘segmentation’ of the deck in that process, which is continuous and follows the normal rules of the state of the art for in situ concreting.

[0155] The same application principles apply if the filling material (8) is not concrete, but should also take into account the particularities of the material involved.

[0156] It should be noted that the filling of the empty segments (3), if there is more than one, does not imply the existence of the filling material discontinuities in the interface areas between empty segments (3).

[0157] If concrete accelerating admixtures (31) are incorporated in the fixing elements (4) or in the shoring systems (6) the curing periods may be shortened.

Phase D—

[0158] Curing period;

[0159] In the example shown, with structures in prestressed reinforced concrete, the curing period can mean dozens of hours and must be defined case by case, according to the rules of the state of the art for structures concreted in situ, and depending on the particular characteristics of the deck (or other structural member), for example, type of concrete, inclusion of prestressing or not, necessary resistance to the prestressing application and other common state of the art specifications that are applicable.

[0160] Depending on the conditions of the location of the works and the technical requirements, additional operations may be needed to ensure a proper curing, for example, watering the elements in consolidation.

[0161] In the case of filling material (8) is not concrete, the time of consolidation should be defined accordingly.

Phase E—

[0162] Prestressing of the structure (if any) and removal of scaffolding;

[0163] In the case where the structure (1) is, for example, prestressed, including elements of the prestressing type (10) and (11) or others, before the removal of the scaffolding takes place, the cables, or other prestressing elements, must be tensioned according to the tensioning plan provided for, and it can be a partial or total tensioning.

[0164] Then follows the removal of scaffolding of the structure (1), which is no more than disengaging the shoring system (6) from the weight of the part of the structure (1) being executed. This operation can be performed, for example, by manual or mechanical means, and can be done, for example, through a sequence of small localized operations, or through a single global operation with mechanical means designed for this purpose and known in the state of the art. This task may benefit from, for example, the use of an automatic control system of scaffolding deformations (6) depending on their structural response.

[0165] Normally, this operation is followed by the transposition of the shoring system (6) to the next portion of the structure (1), in this example to the next span of the structure (1) to be constructed. Where the shoring system (6) is self-launching scaffolding, this operation is the forward operation.

Phase F—

[0166] Removal of the Fixing Elements (4) and transport to prefabrication area (5).

[0167] At the same time, before or after the transposition of the shoring system (6) to a new position, a team of operators starts removing the fixing elements (4), which, for example, include the inner moulds (13).

[0168] If the fixing elements (4) have elements that trespass the filling material (8) as is the case of the fixing elements in FIG. 14, the fixing elements (4) must be separated into two or more parts.

[0169] Still based on FIG. 14, the fixing elements, which in this example include the inner moulds (13) (for example, inner formwork) may, as mentioned, for example, include adjusting devices (15) that may facilitate their dismantling and removal.

[0170] This removal will also be easier if, as shown in FIG. 9, the fixing elements (4) also include sliding devices (26) (for example, wheels) or/and if they include, for example, gripping systems (27), or if they include both.

[0171] In the case of the example shown, the construction of a prestressed reinforced concrete deck, carried out with empty segments (3) with fixing elements (4) including inner moulds (13) as, for example, retractable systems illustrated in FIG. 14, the fixing systems (4) may, for example, be removed from the interior of the box girder already constructed in the opening of the section (18) located at the works front line.

[0172] External auxiliary equipment (7), for example, or, also for example, auxiliary equipment (19) of the shoring system itself (6), may be used to facilitate the removal of the fixing elements (4) and placement in a means of transport (17) (with characteristics compatible with the type of supply previously defined) that will take them to the prefabrication area (5) where they will be used for the prefabrication of a new series of empty segments (3), thus starting a new cycle.

[0173] To increase productivity, it may be convenient to have a plurality of fixing elements sets (4) for each position. In such a way that, while a set of empty segments (3), including the respective fixing elements (4), is being used at the works front line, for the construction of the current stretch, another set (or more than one) of fixing elements (4) is in the prefabrication area (5) so that, at the same time, the next stretch is already being prefabricated, or several of the next stretches, if so defined.

[0174] In the case of using this process in overhead self-launching scaffolding, for example, a special pier segment (28) can be previously executed that, in addition to the components of an empty segment (3), can have incorporated, for example, a pre-slab and a frame of the shoring system (6). This special pier segment (28) may alternatively, and also for example, be a conventional prefabricated segment, already with filling material. In this case, this is the segment corresponding to ‘segment 0’.

[0175] In these special pier segments (28), the fixing element (4) can be different and need not have connections to the scaffolding, as can be seen in FIG. 22. The fixing element (4) may, for example, be provided with connections to allow opening so as to facilitate disassembling at the end of the deck stretch construction (1).

[0176] The construction process in accordance with the present invention can be applied in various types of shoring systems (6) (lower self-launching scaffolding, ground scaffolding, or others) simply by making the adaptations resulting from the characteristics of the shoring systems, with impact on the choice of means of transport (17) and in the design of the fixing elements (4), and may also influence the design of auxiliary equipment (19) of shoring systems (6). It is good project practice to develop the project with a simultaneous selection of the type of shoring system (6) to be adopted.

[0177] The application of the construction process in accordance with the present invention to reinforced concrete structures without prestressing (10) and (11) is in everything identical to that presented in this text, without the tasks/actions and elements related to the prestressing.

[0178] In the construction of concrete structures, several structural systems, with several horizontal shapes can be executed by this method (see FIGS. 1 and 6), sloping structures (see FIG. 3), arched structures, see FIG. 2, vertical structures of piers (see FIG. 4), vertical structures of other elements with other shapes, for example, of concrete building cores (see FIG. 5), or other structures with other shapes in which it is possible to divide the structure to be built (1) into one or more reference segments (2) corresponding to the empty segments (3) (see FIG. 7).

[0179] Likewise, the construction process according to the present invention can be used in the construction of structures (1) of reinforced (and/or prestressed) concrete with different cross-sections, as for example the A-A cutaway section of FIG. 15, the section of FIG. 9, the cross-sections of FIGS. 11 and 12, the cross-sections of FIGS. 22 to 28, or the generic cross-section shown in FIG. 8, where the empty segments (3) assume configurations corresponding to the reference segments (2) of the structure (1) to be constructed.

[0180] In some cases, as in the example of FIG. 11, the empty segment (3) may incorporate a fixing element (4) with the structural capacity to cover the span, in which case dispensing the shoring system (6).

[0181] This method without shoring system (6) can also be applied in elements such as shown in FIG. 12, wherein either because they are vertical elements, or because they are elements with a span compatible with the resistance of the fixing element (4), it becomes feasible to execute empty segments (3) which fit sequentially into each other, whereby the fixing elements (4) are dimensioned accordingly.

[0182] The application of the construction process in accordance with the present invention to structures (1) executed with other materials, for example, glass, ceramic, plastic or with hydraulic binders other than those used in reinforced concrete, is also possible provided the structure (1) to be constructed is divisible into one or more structure segments (2) and can justify and reveal advantages if this structure (1) is composite, either including steel reinforcement materials (9) or interface structures or inserts (12), and may also include or not, active reinforcement elements (11) and active reinforcement ducts (10), if necessary, and in which there are advantages to pouring the filling material (8) in situ in a place other than the place of prefabrication of the empty segments.

[0183] For example, this type of solution can be used to construct library or warehouse shelving made of plastic, with steel reinforcements (11) and/or rigid inserts (12), in plastic reservoirs with steel reinforcements (9) and/or active reinforcement (11), or glass structures with a wide span to be executed in situ, and that include steel reinforcements (9) and/or inserts (12), or, more generally, composite structures in which it is advantageous to pour the filling material (8) in situ.

Lisbon, Jan. 31, 2017.

LIST OF REFERENCE INDICES

[0184] 1. Structure, to be constructed [0185] 2. Reference segment, of structure to be constructed [0186] 3. Empty segment [0187] 4. Fixing elements [0188] 5. Prefabrication area [0189] 6. Shoring system (scaffolding) [0190] 7. Auxiliary equipment (for cargo handling in the prefabrication area) [0191] 8. Filling material [0192] 9. Steel reinforcement elements [0193] 10. Prestressing ducts [0194] 11. Active reinforcement elements (prestressing cables) [0195] 12. Interface structure or ‘insert’ [0196] 13. Mould (for example formwork) [0197] 14. Handling device and/or positioning of the formwork [0198] 15. Mechanically adjustable elements (spindles, jacks, etc.) [0199] 16. Interface fixing devices (fixing devices or positioners, or positioner fixing devices) [0200] 17. Means of transport [0201] 18. Construction joint [0202] 19. Scaffolding auxiliary means (means of transport of loads) [0203] 20. Support elements of the shoring system [0204] 21. Overlapping elements or steel reinforcement overlaps [0205] 22. Rigid elements (of the fixing elements) [0206] 23. Position elements of steel reinforcement elements [0207] 24. Mould closing elements [0208] 25. Isolation Devices (trespass of filling material, negatives in the filling material) [0209] 26. Sliding devices [0210] 27. Gripping devices [0211] 28. Special pier segments [0212] 29. Prefabricated anchoring blocks [0213] 30. Seals or interface elements between segments [0214] 31. Concrete accelerating system (for example, by steam) [0215] 32. Reaction rigid elements for tensioning [0216] 33. Prefabricated elements