Pre-Fabricated Link Slab - Ultra High Performance Concrete

Abstract

Disclosed invention comprises innovations related to the fabrication process and the associated design of Prefabricated Link Slabs made using Ultra High-Performance Concrete (UHPC) for bridges hereinafter referred as PLS-UHPC. This disclosure is regarding methods of designing, manufacturing, and installing PLS-UHPC as connections between bridge spans. The invention includes the concept of installing PLS-UHPC which will provide numerous benefits such as faster construction in the field, and better maintenance of established systems.

Claims

1-7. (canceled)

8. A method of manufacturing a prefabricated link slab, the method including: determining a size and shape of the prefabricated link slab; first, in a controlled factory environment, setting reinforcing bars; and second, in the controlled factory environment, pouring Ultra High-Performance Concrete (UHPC) including over at least a portion of the reinforcing bars; third, in the controlled factory environment, curing the UHPC to form a prismatic portion of the prefabricated link slab.

9. The method of claim 8, wherein the determining of the size and shape of the prefabricated link slab is performed based on geometry and one or more structural aspects of connecting spans of a bridge.

10. The method of claim 9, further comprising: assembling a form based on the determined size and shape of the prefabricated link slab, wherein the setting of the reinforcing bars is at least partially within the form and corresponds to the one or more structural aspects of the connecting spans; and the pouring of the UHPC is into the form.

11. The method of claim 10, wherein the setting of the reinforcing bars includes setting the reinforcing bars to extend completely through the prismatic portion and protrude from at least two sides of the prismatic portion.

12. The method of claim 10, wherein the setting of the reinforcing bars includes setting the reinforcing bars not to extend completely through the prismatic portion and to protrude from at least two sides of the prismatic portion.

13. The method of claim 8, further comprising: embedding at least a portion of a debonding layer into at least a portion of the prefabricated link slab.

14. The method of claim 13, wherein the embedding of the at least a portion of the debonding layer comprises embedding the at least a portion of the debonding layer into a bottom of the prefabricated link slab.

15. A method of manufacturing a prefabricated link slab, the method including; on-site, measuring geometry and one or more structural aspects of connecting spans of a bridge; determining a size and shape of the prefabricated link slab to connect the spans of the bridge based on the geometry and one or more structural aspects; assembling a form for the prefabricated link slab based on the determined size and shape of the prefabricated link slab; first, a controlled factory environment, setting reinforcing bars corresponding to the one or more structural aspects of the connecting spans; second, in the controlled factory environment, pouring Ultra High-Performance Concrete (UHPC) into the form including over at least a portion of the reinforcing bars, third, in the controlled factory environment, curing the UHPC into the prefabricated link slab, and on-site, installing the prefabricated link slab to connect the spans of the bridge.

16. The method of claim 15, wherein the spans of the bridge form a bridge deck.

17. The method of claim 15, wherein the measuring, determining, assembling, setting, pouring, curing, and installing are repeated a plurality of times such that a plurality of prefabricated link slabs are provided, and the plurality of link slabs are installed in a plurality of stages.

18. A prefabricated link slab, comprising: a prismatic portion of the prefabricated link slab, the prismatic portion being formed of factory cured Ultra High-Performance Concrete (UHPC); and factory-set reinforcing bars projecting from one or more sides of the prismatic portion of the prefabricated link slab.

Description

DESCRIPTION OF DRAWINGS

[0013] All descriptions herein with reference to the figures are not limiting, and can be understood as features of varying details of the presented embodiment. The features, components, elements and/or aspects of the illustrations can be reorganized, re-sequenced and/or interchanged with other materials without effectively departing from the disclosed invention. The geometry of the components is exemplary and can be altered without effectively affecting or limiting the disclosed invention.

[0014] The drawings and associated descriptions of the preferred embodiment of the invention shall be treated as an example and is intended for making the invention readily apparent to those with ordinary skill in the art. The presentation of the preferred embodiment of the invention shall not be regarded as limiting since the invention is capable of other embodiments and can be practiced or carried out in multiple ways.

[0015] FIG. 1 is a representation of a three-dimensional digital model of the preferred first embodiment of the present invention prior to its incorporation into a bridge deck or any other applicable structure.

[0016] FIG. 2 is a sectional view of the preferred first embodiment of the invention as part of a bridge superstructure, taken perpendicular to the center lines of bearings at an intermediate support used in conjunction with the construction of new or replacement decks of adjacent spans.

[0017] FIG. 3 is a more detailed description of FIG. 2

[0018] FIG. 4 is a sectional view of the preferred first embodiment of the invention as part of a bridge superstructure, taken perpendicular to the center lines of bearings at an intermediate support when used as the replacement of an existing bridge deck joint.

[0019] FIG. 5 is a more detailed description of FIG. 4.

[0020] FIG. 6 is a plan view of the bridge deck incorporating the preferred first embodiment of the invention in conjunction with the construction of new or replacement decks of adjacent spans when the entire width of the deck is constructed in three stages. The presentation of a three-stage construction sequence is exemplary, the applicability of this invention in a plurality of stages and sequences are implied. Only the relevant part of the bridge deck near an intermediate support is presented.

[0021] FIG. 7 is a plan view of a bridge deck incorporating the preferred first embodiments of the invention to replace an existing deck joint with between decks of adjacent spans of an existing bridge when the entire width of the deck is constructed in three stages. The presentation of a three-stage construction sequence is exemplary, the applicability of this invention in a plurality of stages and sequences are implied. Only the relevant part of the bridge deck near an intermediate support is presented.

[0022] FIG. 8 is a sectional view of the bridge superstructure at location S1:S1 shown in FIG. 6 and FIG. 7.

[0023] FIG. 9 is a sectional view of the bridge superstructure at location S2: S2 shown in FIG. 6 and FIG. 7.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

[0024] This invention is the concept of and method for designing and fabricating PLS-UHPC in a factory environment and installing it on a new or existing structure. This invention eliminates all major shortcomings of the prior art identified in this disclosure.

[0025] The size, shape, and structural design of the PLS-UHPCs exhibited in this disclosure is exemplary and this invention is inclusive all appropriate modification to these aspects necessitated by a specific application of this invention.

[0026] The strength, toughness, functionality, crack resistance, and corrosion resistance of PLS-UHPCs are far superior to cast-in-place LS-CC and cast-in-place LS-ECC.

[0027] PLS-UHPCs are not only better quality and relatively defect free, but can also be installed faster and at a lower cost compared to Cast-In-Place LS-UHP.

[0028] The size, shape, other structural aspects of PLS-UHPCs are to be designed for each specific application based on the geometry and the structural aspects of the connecting spans of any specific bridge.

Description of the Preferred First Embodiment

[0029] FIG. 1 is a representation of a three-dimensional digital model of the preferred first embodiment of the present invention prior to its incorporation into a bridge deck or any other applicable structure.

[0030] (1) The prismatic portion of the Prefabricated Link Slab. This central part of the Prefabricated Link Slab is made using Ultra High-Performance Concrete (PLS-UHPC) as per this invention and manufactured under a controlled environment under strict Quality Control and Quality Assurance procedures. This production method and environmental controls enable the use of materials with significantly better physical properties and durability characteristics and eliminates all negatives identified in the prior art in this disclosure.

[0031] (2) is a debonding layer attached to the bottom of (1) for strain isolation of a portion of (1) from the supporting concrete deck.

[0032] (5) is reinforcing bars for (1) that are projecting from the sides. The interior portion of (5) is not visible in this model.

[0033] FIG. 2 is a sectional view (1) PLS-UHPC as part of a bridge superstructure, taken perpendicular to the center lines of bearings at an intermediate support used in conjunction with the construction of new or replacement decks of adjacent spans of a bridge.

[0034] Refer to FIG. 1 for descriptions of (1), (2) and (5)

[0035] (6) are conventional new concrete bridge decks constructed using the state of the art bridge construction practices.

[0036] (7) Steel Girder Web, (8) Steel Girder Top Flange, (9) Steel Girder Bottom Flange are parts of a conventional steel bridge superstructure shown in this figure. A similar setup is implied for a superstructure with concrete girders.

[0037] (10) Bridge Bearings supporting steel or concrete girders are routinely used in the state-of-the-art practice in bridge construction.

[0038] (11) Pedestals, (12) Bridge Seat are parts of bridge substructure and are routinely used in the state-of-the-art practice in bridge construction.

[0039] FIG. 3 is a more detailed view of the same section shown in FIG. 2.

[0040] See FIG. 1 and FIG. 2 for descriptions of (1), (2), (3), (5), (6), (7), (8), (9), (10), (11) and (12)

[0041] (1rs) roughened surfaces of (1) that are intended to bond with (6).

[0042] (5i) is the internal reinforcing bars that are not protruding out of (1).

[0043] (6r) is reinforcements routinely used in the state of the art practice of constructing (6) bridge decks.

[0044] FIG. 4 is a sectional view of the preferred first embodiment of the invention as part of a bridge superstructure, taken perpendicular to the center lines of bearings at an intermediate support when PLS-UHPC is used as the replacement of an existing bridge deck joint.

[0045] See FIG. 1 and FIG. 2 for descriptions of (1), (2), (3), (5), (6), (7), (8), (9), (10), (11) and (12)

[0046] (6E) are existing, concrete bridge decks. Only portions of the existing decks need to be removed and replaced during the installation of (1).

[0047] (4) is the closure concrete pour between the (1) and the (6E) in a joint replacement application where existing deck joints are replaced with (1)

[0048] FIG. 5 is a more detailed view of the same section shown in FIG. 2.

[0049] See FIG. 1 and FIG. 2 for descriptions of (1), (2), (3), (5), (6), (7), (8), (9), (10), (11) and (12) See FIG. 4 for descriptions of (1rs), (4), (6E), (5i) and (6r)

[0050] FIG. 6 is a plan view of the bridge deck incorporating the preferred first embodiment of the invention in conjunction with the construction of new or replacement decks of adjacent spans when the entire width of the deck is constructed in three stages. Only the relevant part of the bridge deck near an intermediate support is presented.

[0051] Refer to FIG. 1 and FIG. 2 for description for (1)

[0052] See FIG. 2 for descriptions of (7)

[0053] Refer to FIG. 8 for section S1:S1

[0054] Refer to FIG. 9 for section S2:S2

[0055] (6a), (6b) and (6c) are segments of (6) constructed in 3 stages. Number of stages and order of construction is exemplary.

[0056] (6ac) is the closure concrete pour between segments (6a) and (6b).

[0057] (6bc) is the closure concrete pour between segments (6b) and (6c).

[0058] (601) is concrete barrier which is a part of conventional bridge superstructure shown in this figure. Bridge Railing Systems is an alternate for concrete barriers and

[0059] FIG. 7 is a plan view of the bridge deck incorporating the preferred first embodiment of the invention in conjunction with the construction of replacement decks joint with PLS-UH PC in three stages. Only the relevant part of the bridge deck near an intermediate support is presented.

[0060] Refer to FIG. 1 and FIG. 2 for description for (1)

[0061] See FIG. 2 for descriptions of (7)

[0062] See FIG. 6 for descriptions of (601)

[0063] Refer to FIG. 8 for section S1:S1

[0064] Refer to FIG. 9 for section S2:S2

[0065] FIG. 8 is the view of section S1:S1 as shown on FIG. 6 and FIG. 7.

[0066] See FIG. 1 and FIG. 2 for descriptions of (1), (7), (8), and (12)

[0067] See FIG. 6 for descriptions of (601)

[0068] FIG. 4 for descriptions of (4)

[0069] (6h) are concrete fill between (6) and (8) used in the state-of-the-art practice in bridge deck construction.

[0070] FIG. 9 is the view of section S2:S2 as shown on FIGS. 6 and 7

[0071] See FIG. 1 and FIG. 2 for descriptions of (1), (2), (7), (8), and (12)

[0072] See FIG. 6 for descriptions of (601)

[0073] FIG. 4 for descriptions of (4)

[0074] (6h) are concrete fill between (6) and (8) used in the state of the art practice in bridge deck construction.

Design Method

[0075] PLS-UHPC's are designed based on the bridge type, geometry, superstructure type, and the design load.

[0076] The prismatic portion of the PLS-UHPC will be custom designed. The objective of the design is to limit maximum tensile strain at service limit states not to exceed 50% the maximum tensile strain capable of sustaining post crack tensile strength which is equal to or greater than the pre-crack tensile strength. The sustained post crack behavior of UHPC is utilized to achieve this design objective.

Fabrication Method

[0077] (1) The prismatic portion of the Prefabricated Link Slab can be fabricated using a plurality of fabrication procedures appropriate for production of precast components without effectively departing from the disclosed invention. A plurality of material choices and processes are anticipated for attaching (2) the debonding layer to (1) the prismatic portion of the Prefabricated Link Slab and shall be considered inclusive in the present invention.

[0078] A plurality of methods is anticipated for developing (1rs) the roughened surfaces of (1) the prismatic portion of the Prefabricated Link Slab and shall be considered inclusive in the present invention.