GIRDER FOR CONCRETE BRIDGES WITH AN INCORPORATED CONCRETE OVERHANG AND VERTICAL STAY-IN-PLACE FORM AND METHOD FOR USING SAME

Abstract

During bridge construction, a form at the upper, outer edge of a bridge's outer girder, upper flange retains concrete slurry poured on the bridge's deck. The girder is cast with extended upper flanges, and the form is precast integrally with the flange. The improved girder may eliminate the need for a construction worker walkway.

Claims

1. A girder for use in building a bridge, comprising: said girder having a height, a width, and a span; wherein said girder is comprised of a top flange with a deck and an underside, a bottom flange, and a web; wherein said top flange is connected opposite of said deck at or near a center of a width of said top flange to a first end of said web; wherein said bottom flange is connected at or near a center of a width of said bottom flange to a second end of said web; wherein said web first end is opposite of said web second end; wherein said top flange's width is at least twice as great as said bottom flange's width; a form; wherein said girder and said form are manufactured from concrete; wherein said form is manufactured as an integral part of said top flange; wherein said form is located on said deck and adjacent to a first edge of said top flange, such that said form extends upwardly above said deck; and said form has an inner edge against which slurry concrete can be poured such that said concrete fills over said deck; a drip groove in said top flange underside near said first edge and generally under said form; and wherein said drip groove extends for about the entire span of said girder.

2. A girder for use in building a bridge, comprising: said girder having a height, a width, and a span; wherein said girder is comprised of a top flange with a deck, a bottom flange, and a web; wherein said top flange is connected opposite of said deck at or near a center of a width of said top flange to a first end of said web; wherein said bottom flange is connected at or near a center of a width of said bottom flange to a second end of said web; wherein said web first end is opposite of said web second end; wherein said top flange's width is at least twice as great as said bottom flange's width; and wherein said girder is manufactured from concrete.

3. The girder of claim 2, further comprising: a form; wherein said form is manufactured from concrete, and is manufactured as an integral part of said top flange; wherein said form is located on said deck and adjacent to a first edge of said top flange, such that said form extends upwardly above said deck; and said form has an inner edge against which slurry concrete can be poured such that said concrete fills over said deck.

4. A girder for use in building a bridge, comprising: said girder having a height, a width, and a span; wherein said girder is comprised of a top flange with a deck and an underside, a bottom flange, and a web; wherein said top flange is connected opposite of said deck to a first end of said web; wherein said bottom flange is connected to a second end of said web; wherein said web first end is opposite of said web second end; a form; wherein said girder and said form are manufactured from concrete; wherein said form is manufactured as an integral part of said top flange; wherein said form is located on said deck and adjacent to a first edge of said top flange, such that said form extends upwardly above said deck; and said form has an inner edge against which slurry concrete can be poured such that said concrete fills over said deck.

5. The girder of claim 4, wherein said top flange's width is in the range of one and a half (1.5) times to two and a half (2.5) times as wide as said bottom flange's width.

6. The girder of claim 4, further comprising: a drip groove in said top flange underside near said first edge and generally under said form; and wherein said drip groove extends for about the entire span of said girder.

7. The girder of claim 6, wherein said drip groove is formed in said flange during casting of said flange.

8. The girder of claim 7, wherein when said drip groove is formed by: placing a line of an easily removable material in a flange mold along said span; pouring slurry concrete into said mold to form said girder and said flange; allowing said slurry concrete to cure; and removing said removable material.

9. A method of building a bridge, comprising: attaching a first outer girder, having a first integrated form on a first top flange, to a first upper side of said bridge and adjacent to a first outer side of said bridge, wherein said first integrated form is positioned adjacent to said first outer side of said bridge; attaching a second outer girder, having a second integrated form on a second top flange, to a second upper side of said bridge and adjacent to a second outer side of said bridge, wherein said second integrated form is positioned adjacent to said second outer side of said bridge; said first outer girder, first integrated form, second outer girder, and second integrated form each being comprised of concrete; the first and second integrated forms each having rebar protruding from a form top of said integrated forms, said rebar being sized and shaped to be capable of having a single slope traffic rail formed about it; attaching an interior girder to a third upper side of said bridge and between said first and second outer girders; placing one or more deck panels such that they span any spaces between girders from said first outer girder to said second outer girder; pouring slurry concrete on said deck panel, said first outer girder, and said second outer girder, and between said first form and said second form, the first and second forms each retaining the slurry concrete between them without use of a removable slurry concrete retainer on the bridge's sides; curing the slurry concrete in place; and completing bridge construction without removing the first and second retainer barriers.

10. The method of claim 9 wherein said bridge is completed without attaching a walkway retainer bracket to said bridge.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0039] FIG. 1 is a front, perspective view of a girder with an integrated form.

[0040] FIG. 2 is a front view of a girder with an integrated form illustrating a first stage in preparing a roadway.

[0041] FIG. 3 is a front view of a girder illustrating a second stage in preparing a roadway.

[0042] FIG. 4 is a top view of a girder with an integrated form.

[0043] FIG. 5 is a front view of a girder illustrating a third stage in preparing a roadway.

[0044] FIG. 6 is a front view of a girder illustrating a fourth stage in preparing a roadway.

[0045] FIG. 7 is a front view of a bridge with girders illustrating a fifth stage in preparing a roadway.

[0046] FIG. 8 is a front view of a girder and illustrates the form cast with a box type girder.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

[0047]

TABLE-US-00001 Ref. Element 10 Outer Girder 12 Inner Girder 14 Top Flange 16 Bottom Flange 18 Deck Panel 20 Integrated Form 22 Pier Cap 24 Inner Girder Top Flange 26 Inner Girder Bottom Flange 28 Rail Support Rebar 30 Drip Groove 32 Slab 34 Rebar 36 Form Inner Edge 38 Bearing Pad 40 Threaded Hole 42 Top Flange Deck 44 Pocket 46 Web 48 Apertures 50 Bedding Strip 52 Threaded Center Marker 54 Top Flange Underside 56 Bottom Flange Topside 58 Bottom Flange Underside 60 Connector Bar 62 Form Top 64 Paving Machine Rail 66 Girder Center Line (“CL Girder”) 68 Single Slope Traffic Rail (“SSTR”) 70 Field Bend Bar 72 Inner Girder Top Flange 74 Inner Girder Bottom Flange 76 Form Outer Edge 78 Top Flange Edge 80 82 84 86 88 90 92 94 96 98 100 Concrete 102 Traffic Rail 104 Safety Rail 106 Bridge 108 Bridge Deck 110 Pier Cap 112 Pier Column 114 116 118 120 122 124 126 Y-Y Girder Height Axis X-X Girder Width Axis Z-Z Girder Length Axis

[0048] Referring to the figures, FIG. 1 is a front, perspective view of a girder 10 in an “I” beam embodiment. The girder 10 is designed to be one (1) of the two (2) outer girders of a bridge. The girder 10, when in the I beam configuration, is generally configured with a height along the Y-Y axis, a width along the X-X axis and a span or length along the Z-Z axis. An I-beam girder 10, has a top flange 14 that extends from the Y-Y axis outwardly, generally parallel with, the X-X axis. Likewise, it has a bottom flange 16 that extends from the Y-Y axis outwardly, generally parallel with, along the X-X axis. A web 46 extends along the Y-Y axis. The top flange 14 is connected, at or near the center of the width of the top flange 14 (along the X-X axis), to a first end of the web 46a. The bottom flange 16 is connected, at or near the center of the width of the bottom flange 16 (along the X-X axis), to a second end of the web 46b. Thus, the top flange 14 and the bottom flange 16 are connected to opposing ends of the web 46 (as viewed from the front). This configuration creates the “I” shape for which this embodiment of girders is known.

[0049] The girder 10 and integrated form 20, as described herein, are manufactured from concrete 100. As is known and used herein, “manufactured from concrete” does not mean 100% concrete 100 because the girder 10 will include rebar 34 that helps increase the structural integrity of the girder 10, and is used for add-on features such as railings and center-line 66 markers.

[0050] The view of this figure illustrates a three dimensional view of the top flange deck 42 and integrated form 20. The integrated from 20 extends upwardly (in the direction of the Y-Y axis) from a first edge of the top flange deck 42a, such that the form 20 extends upwardly above said deck 42. It is anticipated that the integrated from 20 will be attached adjacent to the first edge of the top flange deck 42a for generally the entire length of the girder 10 along the Z-Z axis, however certain application may require that the integrated from 20 be shortened or that there be gaps. The form 20 is located, sized and shaped so it is capable of retaining slurry concrete 100 poured on the deck 42 of the flange 12 and inward toward the other side of the bridge 106 relative to the form 20. The form 20 has rebar 34 located within the form 20 and some rebar 34 extending out of the upper side of the form 20.

[0051] When a pair of girders 10 are paired on opposing edges of a bridge deck 108 with the first integrated form 20a of the first girder 10a and the second integrated form 20b of the second girder 10b at the furthest opposing sides of the bridge deck 108, the first integrated form 20a and the second integrated form 20b create a two (2) sided barrier that holds the slurry concrete 100 in place on the top flange decks 42 and the deck panel 18.

[0052] FIG. 2 is a front view of a girder 10. In this embodiment, the girder 10 is an “I” beam style beam where the longer length of the central web 46 runs up and down along the Y-Y axis, and the flanges (14 and 16) extend horizontally to the side, or outwardly from the web 46 along the X-X axis. The girder 10 is installed on a bearing pad 38 at the top of a pier cap 110. The girder 10 is designed to be one (1) of the two (2) outer girders of a bridge.

[0053] This figure shows the integrated form 20, outer rebar 34a and inner rebar 34b. It also illustrates the continuous drip groove 30. The drip groove 30 is sized and shaped to cause water running down and under flange to drip off of flange at the drip groove rather than running down the remainder of the girder. The drip groove 30 is a channel molded or cut into the top flange underside 54 near the top flange edge 78 and generally under the form 20. The drip groove 30 extends for about the entire span of the girder 10.

[0054] The outer girder 10 has an extended top flange 14 (in comparison to conventional top flanges and the top flange 24 of the inner girders 12). Viewed from the front of the girder 10, this figure shows the vertical axis Y-Y that extends up the center of the web 46.

[0055] The threaded holes 40 interspersed along the girder center line 66 of the top flange deck 42 may be used to connect a threaded insert (not shown) to the top flange deck 42. This figure also illustrates an alternative embodiment in which, rather than installing rebar 34 in the beam form 20 that extends above the beam form 20 for use in building a traffic rail 102, a pocket 44 is formed in the top of the beam form 20. A safety rail 104, or structural portion of a safety rail 104 may be inserted in the pocket 44. Or, other structural components, such as posts (not shown), can be inserted into the pocket 44 for use in building a rail 104.

[0056] A threaded anchor hole 40 may be in the deck 42 of the top flange 14. The threaded hole 40 is generally along the Y axis that runs along the center of the web 46. The threaded hole 40 is sized to receive a threaded center marker 52. A concrete deck paving machine rail 64 is attached to the threaded center marker 52, and will be used to act as a marker of the Girder Center Line (“CL Girder”) 66 when pouring the concrete slab 32, as well as for determination of depth of the cast-in-place slab 32.

[0057] This figure illustrates a first example in a method of preparing a bridge 106 where the outer girder has been attached at the top of a bearing pad 38 where the bearing pad 38 is attached at the top of a pier cap 110.

[0058] FIG. 3 is a front view of a girder 10 illustrating a second stage in preparing a roadway bridge. A deck panel 18 has been installed and its second edge 18b attached on the inner edge 10a of the improved girder 10. The deck panel 18 extends to and its first edge 18a is attached on a second edge 12b of an inner girder 12.

[0059] The width (as measured along the X-X axis) of the top flange 14 is wider than the width (as measured along the X-X axis) of the bottom flange 16. The wider top flange 14 is intended to allow a safety walkway to be installed along the outer edges of the bridge 106 without the need for the support brackets (not shown) that are used on conventional bridges in order to support the walkway (not shown) off the outer edge of the bridge 106. The top flange 14 may be in the range of one and a half (1.5) times as wide as the bottom flange 16 to two and a half (2.5) times as wide as the bottom flange 16. Thus, within that range, the top flange 14 may be twice as wide, approximately twice as wide, or at least twice as wide, as the bottom flange 16. Likewise, the top flange 14 may be one and a half (1.5) times as wide, approximately one and a half (1.5) times as wide, or at least one and a half (1.5) times as wide, as the bottom flange 16. However, there is a maximum width of the top flange 14 based upon the diminishing benefits of the wider top flange 14 and increasing forces down on the top flange 14 due to weight on it increasing as the top flange and

[0060] In one embodiment, some of the dimensions of the girder 10 may be as follows:

[0061] The width of the top flange 14 along the X-X axis is 72 inches. The width of the bottom flange 16 along the X-X axis is 32 inches. The top flange edge 78 is 3½ inches thick (along the Y-Y axis), while the top flange underside 58 is 3½ inches thick where it connects to the top flange edge 78 and thickens to 7 inches thick where it connects to the web 46. The web 46 is 7 inches thick (along the X-X axis). The bottom flange 16 is 8¾ inches thick (along the Y-Y axis) at its bottom flange edge 80, while it thickens to 16½ inches thick where it connects to the web 46. The 36 inch width of the top flange 14 as measured from the girder centerline 66 to the form outer edge 76 is 20 inches longer than the 16 inch width of the bottom flange 16 measured from the girder centerline 66 to the bottom flange edge 80. The form inner edge 36 of form 20 extends upward (along the Y-Y axis) from the top flange deck 42, 12 inches. The form 20 is 6 inches wide (along the X-X axis) where it is integrated into the top flange 14 at one of the top flange edges 78. The form outer edge 76 extends upward from the deck 42 at the top flange edge 78, 8½ inches. For the next 1½ inches of rise of the form 20, the width of the form 20 gradually narrows such that at 10 inches in height of the form 20, the width of the form 20 is 4½ inches. The width of form 20 at the very top is 4½ inches. On the top flange underside 54 is a continuous drip groove 30 that is 3 inches from the top flange edge 78. The continuous drip groove 30 is three quarters of an inch and cut or molded into the top flange underside 54 for the entire length or span (along the Z-Z axis) of the outer girder 10.

[0062] FIG. 4 is a top view of an embodiment of a girder 10 and illustrating the top flange deck along a portion of the girder's 10 span or length along the Z-Z axis. The girder's 10 span extends from one pier column 112a to the next pair column 112b. The threaded holes 40 are spaced along the CL girder 66 and will accept threaded center markers 52 for use by the builders and mapping work along the girder 10. The integrated form 20 is at one top flange edge 78. The apertures 48 are interspersed along the top of the form 20 near the center of the form top 62.

[0063] FIG. 5 is a front view of a girder 10 illustrating a third stage in preparing a bridge deck 108. Slurry concrete 100 for a slab 32 is poured over the deck panel 18 and girder 10. The slurry concrete 100 is held in place, during its slurry stage, by the beam form 20. In this embodiment, a threaded center marker 52 supports a paving machine rail 64 near the CL girder 66. A safety rail 104 has been inserted into aperture 48.

[0064] FIG. 6 is a front view of a girder 10 illustrating a fourth stage in preparing a bridge deck 108. A safety rail 104 has been installed, and the bridge deck 108 and cast-in-place (“CIP”) slab 32 finished. Rebar 34 is often used as support in the top flange 14 as is common in concrete structures, and can extend upwardly from within the retainer barrier or form 20. The field bend bar 70 is a reinforcing bar bent to a prescribed shape such as a truss bar, straight bar with end hook, stirrup, or column tie. Concrete 100 is poured and molded about the field bend bar 70 in order to make the single slope traffic rail (“SSTR”) 68.

[0065] FIG. 7 illustrates an outer girder 10 with an integrated form 20, at a fifth stage in preparing a bridge deck 108. Generally, a bridge 106 is comprised of, in part, two (2) opposing outer girders 10, and may have any number of inner girders 12, depending upon the width of the bridge 106 and its weight bearing requirements.

[0066] In this figure, an outer beam, or girder 10, and an inner beam, or girder 12, are shown. The inner beam 12 is an I-beam type girder of conventional construction with the width of section of the inner girder top flange 24 being generally equal to the width of section of the inner girder bottom flange 26. In contrast, the improved beam 10 has a width of section of the top flange 14 that is large than the width of section of the bottom flange 16. The bottom flanges (16 and 26) of both beams (10 and 12) would be attached at the top of a pier cap 22. A deck panel 18 is placed at adjacent ends (10a and 12b) and on top of the beams (10 and 12) across the gap between the inner beam second end 12b and the outer girder first end 10a. At the outer edge 10b of the outer beam 10 is an integrated form 20. Concrete 100 can be poured over the deck panel 18 and top flange 14, and the outer girder's 10 vertical side integrated form 20 will hold the concrete 100 (in its slurry stage) in place. The integrated form 20 acts as a retainer barrier and extends upwardly from the top, outer flange 14b. Slurry concrete 100 poured over the deck panel 18 and top flange 14 is retained by the form 20, or retainer barrier, and becomes the slab 32. The integrated form 20 may have rail support rebar 28 in the integrated form 20 that extends upwardly from inside the integrated form 20 to outside the integrated form 20. This rebar 28 will be used to structurally reinforce the traffic rail (not shown).

[0067] The outer top flange 14 and integrated form 20 are preferably made as a precast unitary, concrete unit with rebar 28 extending from the form 20.

[0068] In an illustrative bridge construction, an edge slurry concrete retainer form is thirty feet (30′) long. Construction workers who must have a place from which to work. This work is done at the elevated dangerous edge of the bridge and while the workers are standing on a temporary construction walkway attached to the edge of the bridge. Conventionally, safety brackets and walkways are installed on the edge of the bridge. The conventional overhang formwork typically requires support brackets to support construction worker walkways. Installing and removing such brackets and safety walkways is a dangerous and labor intensive process where construction workers must work at the dangerous edge of the bridge, as well as when they are removing the concrete retainer form.

[0069] In an embodiment, the improved form is pre cast integrally with the upper flange. This eliminates much time consuming and dangerous work on the bridge. In an embodiment, the form is cast in place on the bridge. In this embodiment, the bridge panel or flange is delivered with upwardly protruding rebar and the retainer barrier is formed by pouring slurry into a retainer barrier form incorporating the flange's rebar.

[0070] In an alternative embodiment, the retainer barrier is pre cast as a separate unit and sealed to the deck or flange after they are installed at the bridge site, taking advantage of protruding rebar to secure the retainer barrier to the bridge.

[0071] An anticipated method of building a bridge in which includes attaching a first outer girder, having a first integrated form on a first top flange, to a first upper side of the bridge and adjacent to a first outer side of the bridge, wherein the first integrated form is positioned adjacent to the first outer side of the bridge. Attaching a second outer girder, having a second integrated form on a second top flange, to a second upper side of said bridge and adjacent to a second outer side of said bridge, wherein said second integrated form is positioned adjacent to said second outer side of said bridge. Depending upon the intended width of the bridge, interior girders may be placed on the upper side of the bridge between the outer girders. As described previously, the girders and integrated forms are each made of concrete. The integrated forms each have rebar protruding from the form top of the integrated forms. The rebar is sized and shaped to be capable of having a single slope traffic rail formed about it. Deck panels are placed such that they span from the first outer girder to any interior girders, and to the second outer girder. Slurry concrete 100 is poured over the deck panels, the interior girders, and the first and second outer girders, and between the first form and the second form. The first and second forms each retain the slurry concrete 100 between them without the use of a removable slurry concrete retainer on the bridge's sides. The slurry concrete is cured in place. And, the bridge construction is completed without removing the first and second retainer barriers. The bridge is completed without attaching a walkway retainer brackets and temporary walkway to the bridge.

[0072] FIG. 8 illustrates the form 10 cast with a box type girder 10. Where any girder or I-beam type girder is described or used herein, it is anticipated that other girder types such as a U beam or box beam could also be used with necessary provisions for the different shapes of the girder 10. As illustrated in this figure, the top flange 14 and bottom flange 16 are arranged the same relative to each other as illustrated herein with “I” type girders 10. Likewise, the form 20 is integrated into the girder 10 on the top flange deck 32 at or near the top flange edge 78. The form still operates to hold liquid concrete slurry 100 in place while it dries and hardens.

[0073] Unless otherwise specifically noted, articles depicted in the drawings not necessarily drawn to scale, however the drawings are illustrative and do indicate relative size and relative positioning or placement.

[0074] Throughout this disclosure, the reference numeral refers to the element generically or collectively. If an element has secondary elements, such as multiple sides, edges, or the like, then the first of such secondary elements is designated as “a,” the second of such secondary elements is designated as “b,” and so on. So, for clarification and as an example only, if a Widget is designated as 20, then the class of Widgets may be referred to collectively as Widgets 20 and any one of which may be referred to generically as a Widget 20, while a Widget First Edge would be designated 20a, while Widget Third Edge would be designated 20c.

[0075] When the terms “substantially,” “approximately,” “about,” or “generally” are used herein to modify a numeric value, range of numeric values, or list numeric values, the term modifies each of the numerals. Unless otherwise indicated, all numbers expressing quantities, units, percentages, and the like used in the present specification and associated claims are to be understood as being modified in all instances by the terms “approximately,” “about,” and “generally.” As used herein, the term “approximately” encompasses +/−5 of each numerical value. For example, if the numerical value is “approximately 80,” then it can be 80+/−5, equivalent to 75 to 85. As used herein, the term “about” encompasses +/−10 of each numerical value. For example, if the numerical value is “about 80,” then it can be 80+/−10, equivalent to 70 to 90. As used herein, the term “generally” encompasses +/−15 of each numerical value. For example, if the numerical value is “about 80,” then it can be 80%+/−15, equivalent to 65 to 95. Accordingly, unless indicated to the contrary, the numerical parameters (regardless of the units) set forth in the following specification and attached claims are approximations that may vary depending upon the desired properties sought to be obtained by the exemplary embodiments described herein. In some ranges, it is possible that some of the lower limits (as modified) may be greater than some of the upper limits (as modified), but one skilled in the art will recognize that the selected subset will require the selection of an upper limit in excess of the selected lower limit.

[0076] At the very least, and not limiting the application of the doctrine of equivalents to the scope of the claim, each numerical parameter should at least be construed in light of the number of reported significant digits and by applying ordinary rounding techniques.

[0077] The terms “inhibiting” or “reducing” or any variation of these terms refer to any measurable decrease, or complete inhibition, of a desired result. The terms “promote” or “increase” or any variation of these terms includes any measurable increase, or completion, of a desired result.

[0078] The term “effective,” as that term is used in the specification and/or claims, means adequate to accomplish a desired, expected, or intended result.

[0079] The terms “a” or “an” when used in conjunction with the term “comprising” in the claims and/or the specification may mean “one,” but it is also consistent with the meaning of “one or more,” “at least one,” and “one or more than one.”

[0080] The term “each” refers to each member of a set, or each member of a subset of a set.

[0081] The terms “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “have” and “has”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are inclusive or open-ended and do not exclude additional, unrecited elements or method steps.

[0082] In interpreting the claims appended hereto, it is not intended that any of the appended claims or claim elements invoke 35 U.S.C. 112(f) unless the words “means for” or “step for” are explicitly used in the particular claim.

[0083] It should be understood that, although exemplary embodiments are illustrated in the figures and description, the principles of the present disclosure may be implemented using any number of techniques, whether currently known or not. The present disclosure should in no way be limited to the exemplary implementations and techniques illustrated in the drawings and description herein. Thus, although the invention has been described with reference to specific embodiments, this description is not meant to be construed in a limited sense. Various embodiments may include some, none, or all of the enumerated advantages. Various modifications of the disclosed embodiments, as well as alternative embodiments of the inventions will become apparent to persons skilled in the art upon the reference to the description of the invention. It is, therefore, contemplated that the appended claims will cover such modifications that fall within the scope of the invention. Modifications, additions, or omissions may be made to the systems, apparatuses, and methods described herein without departing from the scope of the disclosure. For example, the operations of the systems and apparatuses disclosed herein may be performed by more, fewer, or other components in the methods described may include more, fewer, or other steps. Additionally, steps may be performed in any suitable order.