Lightweight fabricated composite bridge deck

Abstract

The application discloses a light prefabricated combined bridge deck panel and belongs to the technical field of steel structure bridges, comprising a foamed aluminum prefabricated panel assembly, a steel bridge deck panel assembly, a waterproof bonding layer and an abrasion layer; wherein the foamed aluminum prefabricated panel assembly is arranged on the upper end of the steel bridge deck panel assembly, the waterproof bonding layer is arranged on the upper end of the foamed aluminum prefabricated panel assembly, and the abrasion layer is arranged on the upper end of the waterproof bonding layer. By using foamed aluminum, the weight of the combined bridge deck panel is reduced, the self weight is reduced by 50% compared with the traditional combined bridge deck panel, the rigidity and impact resistance of the foamed aluminum panel are improved by arranging the corrugated steel mesh, the foamed aluminum prefabricated panel assembly can be used to directly bear the vehicle load, the foamed aluminum prefabricated panel assembly is prefabricated in blocks in a factory, the transportation and installation weight is light, the on-site installation is quick and convenient, the male keys and the female keys are arranged around the foamed aluminum panel, dry connection between the foamed aluminum panels is realized, no other additional measures are needed, and the fatigue problem of the orthotropic bridge deck panel is effectively solved.

Description

Technical Field

[0001] This invention relates to the field of steel structure bridge technology, specifically to a lightweight prefabricated composite bridge deck. Background Technology

[0002] Currently, steel structure bridges are a common type of structure in medium- and long-span bridges. Steel beams are increasingly used in bridge construction due to their light weight, easy quality control, and high degree of prefabrication. The bridge deck of steel structure bridges typically uses orthotropic plates, which consist of a top plate, longitudinal ribs, and transverse ribs, with the longitudinal and transverse ribs perpendicular to each other. For vehicular bridges, U-ribs are usually chosen as longitudinal ribs to improve deck stiffness. Because orthotropic plates have numerous intersecting longitudinal and transverse welds, their structural details are complex. The stresses and secondary stresses generated by wheel loads on various components and at intersections are highly complex, leading to significant fatigue problems in orthotropic bridge decks. Statistics show that fatigue cracking of steel bridge decks has become one of the biggest defects in steel bridges.

[0003] The causes of fatigue defects can generally be attributed to insufficient stiffness of the bridge deck, which is significantly affected by localized vehicle impact loads. This problem has not yet been completely solved, and concrete or composite bridge decks are often used to avoid the need for orthotropic steel bridge decks. However, the self-weight of concrete or composite bridge decks is 2 to 3 times that of orthotropic slabs, increasing the structural weight, hindering the expansion of bridges to larger spans, increasing structural stress and cost, and creating difficulties for beam segment transportation and hoisting.

[0004] Currently, there are also solutions using thin-layer UHPC composite bridge decks, but the on-site casting and curing process for UHPC has high requirements and is expensive. On-site casting and curing cannot meet the requirements for rapid traffic opening, nor can it meet the rapid construction requirements of current prefabricated bridges.

[0005] Aluminum foam is lightweight, has high specific stiffness, high damping and shock absorption performance, and high impact energy absorption rate, but it has low elastic modulus and poor load-bearing capacity, making it unsuitable for directly bearing vehicle loads.

[0006] The above problems urgently need to be solved. To address this, a lightweight prefabricated composite bridge deck is proposed. Summary of the Invention

[0007] The technical problem to be solved by this invention is: how to solve the fatigue problem of orthotropic bridge decks, and the problems of heavy weight and poor assembly performance of concrete bridge decks and traditional composite bridge decks, and to provide a lightweight prefabricated composite bridge deck.

[0008] The present invention solves the above-mentioned technical problems through the following technical solution: The present invention includes a precast aluminum foam panel assembly, a steel bridge deck assembly, a waterproof adhesive layer, and a wear-resistant layer; from bottom to top, the components are a steel bridge deck assembly, a precast aluminum foam panel assembly, a waterproof adhesive layer, and a wear-resistant layer.

[0009] The precast aluminum foam panel assembly includes aluminum foam panel units, corrugated steel mesh, and positioning bolts. The corrugated steel mesh is embedded in the aluminum foam panel and includes multiple crisscrossing reinforcing bars. Each reinforcing bar includes two corrugated steel bars arranged side by side at a set clear distance, which is equal to the diameter of the bolt of the positioning bolt. Multiple positioning bolts are respectively located at each trough of the corrugated steel mesh and are welded to the four surrounding corrugated steel bars to form a whole.

[0010] Furthermore, for a single corrugated steel bar, including multiple alternating web members and chord members, the angle between the web members and chord members is α, the value of α is in the range of 30° to 60°, the wavelength of the corrugated steel bar is W, the value of W is in the range of 250mm to 400mm, the wave height L of the corrugated steel bar is 150mm to 200mm, the single corrugated steel bar is placed at an angle in the vertical plane, the angle between it and the vertical plane is β, the value of β is in the range of 30° to 45°, and the nominal diameter of the corrugated steel bar is 10mm to 14mm.

[0011] Furthermore, the foamed aluminum board is made of closed-cell foamed aluminum with a porosity of 60% to 68%. A corrugated steel mesh is pre-installed in the shaping template, and then closed-cell foamed aluminum is poured in, forming a precast foamed aluminum board assembly with the corrugated steel mesh and positioning connecting bolts.

[0012] Furthermore, the aluminum foam board is provided with convex and concave keys around its perimeter, and adjacent aluminum foam boards are connected by convex and concave keys.

[0013] Furthermore, the steel bridge deck assembly includes a steel bridge deck top plate and multiple steel stiffening plates, with the multiple steel stiffening plates disposed at the lower end of the steel bridge deck top plate and positioned and connected to the steel bridge deck top plate by positioning bolts.

[0014] Furthermore, the steel stiffening plate is in the shape of a "1", with two adjacent steel stiffening plates arranged in parallel and the spacing between the corrugated steel bars is the same, and they are staggered with each corrugated steel bar.

[0015] Furthermore, the foamed aluminum board is a square board with a side length that is an integer multiple of the wavelength of the corrugated steel bar.

[0016] Furthermore, the material of the waterproof adhesive layer is acrylic.

[0017] Furthermore, the load-bearing capacity of the precast aluminum foam panel assembly is calculated using the following formula:

[0018]

[0019] Where a and b are the length and width of the wheel contact bridge surface, h is the total thickness of the wear layer and the waterproof adhesive layer, and σ cyE represents the vertical compressive strength of the aluminum foam board, E represents the elastic modulus of the corrugated steel bar, and I represents the bending stiffness of a single corrugated steel bar.

[0020] Compared with existing technologies, this invention has the following advantages: This lightweight prefabricated composite bridge deck reduces weight by using aluminum foam, achieving a 50% weight reduction compared to traditional composite bridge decks. The use of corrugated steel mesh enhances the rigidity of the aluminum foam panels, allowing them to directly bear vehicle loads. The prefabricated bridge deck components are manufactured in sections at the factory, resulting in lightweight transport and installation, and quick and convenient on-site installation. Raised and recessed keys around the perimeter of the aluminum foam panels enable dry connections between them, eliminating the need for additional measures and effectively solving the fatigue problem of orthotropic bridge decks. Simultaneously, this composite bridge deck offers advantages such as reduced driving noise, improved comfort, and enhanced durability. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of the overall structure of the lightweight prefabricated composite bridge deck in an embodiment of the present invention;

[0022] Figure 2 This is a schematic diagram illustrating the fit between the corrugated steel mesh and the high-strength bolts in an embodiment of the present invention;

[0023] Figure 3 This is a schematic diagram illustrating the fit between the corrugated steel bar and the high-strength bolt in an embodiment of the present invention;

[0024] Figure 4 This is a schematic diagram of a single corrugated steel bar in an embodiment of the present invention;

[0025] Figure 5 This is a schematic diagram of the structure of the aluminum foam board in an embodiment of the present invention;

[0026] Figure 6 This is a schematic diagram of the structure of the precast aluminum foam panel assembly in an embodiment of the present invention.

[0027] The numbers in the diagram represent:

[0028] 1. Foamed aluminum precast panel assembly; 11. Foamed aluminum board; 111. Convex key; 112. Concave key; 12. Corrugated steel mesh; 13. High-strength bolts;

[0029] 2. Steel bridge deck assembly; 21. Steel bridge deck top plate; 22. Steel stiffening plate;

[0030] 3. Waterproof adhesive layer;

[0031] 4. Wear layer. Detailed Implementation

[0032] The embodiments of the present invention are described in detail below. These embodiments are implemented based on the technical solution of the present invention, and provide detailed implementation methods and specific operation processes. However, the scope of protection of the present invention is not limited to the following embodiments.

[0033] like Figures 1 to 6 As shown, this embodiment provides a technical solution: a lightweight prefabricated composite bridge deck, including a foamed aluminum precast panel assembly 1, a steel bridge deck assembly 2, a waterproof adhesive layer 3, and a wear-resistant layer 4. The foamed aluminum precast panel assembly 1 is placed on top of the steel bridge deck assembly 2, the waterproof adhesive layer 3 is placed on top of the foamed aluminum precast panel assembly 1, and the wear-resistant layer 4 is placed on top of the waterproof adhesive layer 3.

[0034] The precast aluminum foam panel assembly 1 includes an aluminum foam panel 11, a corrugated steel mesh 12, and high-strength bolts 13 (i.e., the positioning connection bolts of the present invention).

[0035] The corrugated steel mesh 12 is made of ribbed steel bars in a predetermined waveform. Two corrugated steel bars are arranged side by side at a certain clear distance to form a bundle of bars, which is equal to the diameter of the bolt 13. The bundle of bars are placed in a crisscross pattern to form the steel mesh. The high-strength bolt 13 is placed at the trough of the steel mesh and welded to the surrounding four steel bars to form a whole.

[0036] The wavelength of the corrugated steel bar is W, with a value ranging from 250mm to 400mm. The angle between the web member and the chord member is α, with a value ranging from 30° to 60°. The wave height L is 150mm to 200mm. A single corrugated steel bar is placed at an angle in the vertical plane, with an angle of β between it and the vertical plane, with a value ranging from 30° to 45°. The nominal diameter of the corrugated steel bar is 10mm to 14mm.

[0037] The aluminum foam board 11 is made of closed-cell aluminum foam with a porosity of 60% to 68%. It is provided with convex keys 111 and concave keys 112 around its perimeter. A corrugated steel mesh 12 is pre-installed in the shaping template, and then aluminum foam is poured in to form a pre-fabricated aluminum foam board assembly 1 with the corrugated steel mesh 12.

[0038] The steel bridge deck component 2 includes a steel bridge deck top plate 21 and a steel stiffening plate 22, which are connected by welding. The steel stiffening plate is in the shape of an "I".

[0039] The load-bearing capacity P of the precast aluminum foam panel assembly 1 is calculated using the following formula, requiring P ≥ 50kN. The calculation formula is as follows:

[0040]

[0041] Where a and b are the length and width of the wheel contact bridge surface, h is the total thickness of the wear layer 4 and the waterproof adhesive layer 3, and σ cyE represents the vertical compressive strength of the aluminum foam board 11, E represents the elastic modulus of the corrugated steel bar, and I represents the bending stiffness of a single corrugated steel bar.

[0042] The steel bridge deck assembly 2 is connected to the precast aluminum foam panel assembly 1 by high-strength bolts 13, and is installed in sections on the upper surface of the steel bridge deck assembly.

[0043] In this embodiment, the spacing 22 of the steel stiffening plates is the same as the spacing of the corrugated steel bar troughs.

[0044] In this embodiment, the aluminum foam board 1 is a square board, and the side length is taken as an integer multiple of the wavelength of the corrugated steel bar for easy installation and handling.

[0045] In summary, the lightweight prefabricated composite bridge deck of the above embodiments reduces the weight of the composite bridge deck by 50% compared to traditional composite bridge decks through the use of aluminum foam. The rigidity of the aluminum foam board is increased by incorporating corrugated steel mesh, allowing it to directly bear vehicle loads. The prefabricated bridge deck components are manufactured in sections at the factory, resulting in lightweight transportation and installation, and quick and convenient on-site installation. Raised and recessed keys around the perimeter of the aluminum foam board enable dry connections between the boards, eliminating the need for additional measures and effectively solving the fatigue problem of orthotropic bridge decks. Simultaneously, this composite bridge deck offers advantages such as reduced driving noise, improved comfort, and enhanced durability.

[0046] Although embodiments of the present invention have been shown and described above, it is understood that the above embodiments are exemplary and should not be construed as limiting the present invention. Those skilled in the art can make changes, modifications, substitutions and variations to the above embodiments within the scope of the present invention.

Claims

1. A lightweight prefabricated composite bridge deck panel, characterized by, The application relates to a foam aluminum prefabricated plate assembly, a steel bridge deck plate assembly, a waterproof adhesive layer and an abrasion layer; from bottom to top, the components are sequentially arranged as the steel bridge deck plate assembly, the foam aluminum prefabricated plate assembly, the waterproof adhesive layer and the abrasion layer. The foam aluminum prefabricated plate assembly comprises a foam aluminum plate, a corrugated steel bar mesh and positioning connecting bolts; the corrugated steel bar mesh is arranged in the foam aluminum plate; the corrugated steel bar mesh comprises a plurality of longitudinal and transverse intersecting bundle steels; one bundle steel comprises two corrugated steels arranged side by side at a set spacing, the set spacing is equal to the diameter of the screw rod of the positioning connecting bolt, and a plurality of positioning connecting bolts are arranged at each wave trough of the corrugated steel bar mesh respectively and are welded with the surrounding four corrugated steels to form an integral whole. The foam aluminum plate is made of closed-cell foam aluminum and has a porosity of 60%-68%; the corrugated steel bar mesh is arranged in a shaping mold in advance, and then the closed-cell foam aluminum is poured to form the foam aluminum prefabricated plate assembly together with the corrugated steel bar mesh and the positioning connecting bolts.

2. The light-weight prefabricated composite bridge deck panel according to claim 1, characterized in that: For a single corrugated reinforcement, including a plurality of web members and chord members connected alternately, the included angle between the web members and the chord members is , The value range of the included angle is 30°-60°, the wavelength of the corrugated reinforcement is W, the value range of W is 250mm-400mm, the wave height L of the corrugated reinforcement is 150mm-200mm, the single corrugated reinforcement is placed obliquely in a vertical plane, and the included angle between the single corrugated reinforcement and the vertical plane is , The value range of the included angle is 30°-45°, and the nominal diameter of the corrugated reinforcement is 10mm-14mm.

3. The light-weight prefabricated composite bridge deck panel according to claim 2, characterized in that: The foam aluminum plate is provided with a convex key and a concave key around the periphery, and two adjacent foam aluminum plates are connected through the convex key and the concave key.

4. The light-weight prefabricated composite bridge deck panel according to claim 3, characterized in that: The steel bridge deck plate assembly comprises a steel bridge deck top plate and a plurality of steel stiffening plates; the steel stiffening plates are arranged at the lower end of the steel bridge deck top plate; and the positioning connecting bolts are connected with the steel bridge deck top plate.

5. The light weight fabricated composite bridge deck slab as claimed in claim 2 wherein: The steel stiffening plate is in a 1-shaped structure; two adjacent steel stiffening plates are arranged in parallel and have the same spacing as that between two adjacent wave troughs of the corrugated steel bar and are arranged in a staggered mode with the wave troughs.

6. The light weight fabricated composite bridge deck slab as claimed in claim 5 wherein: The foam aluminum plate is a square plate, and the side length is an integral multiple of the wavelength of the corrugated steel bar.

7. The light weight fabricated composite bridge deck slab as claimed in claim 6 wherein: The material of the waterproof adhesive layer is acrylic.

8. The light weight fabricated composite bridge deck slab as claimed in claim 1 wherein: The bearing capacity of the foam aluminum prefabricated plate assembly is calculated according to the following formula:

9. The light weight fabricated composite bridge deck slab as claimed in claim 2 wherein: ​ ； wherein, , is the length and width of the wheel contact with the bridge surface, is the total thickness of the wearing course and the waterproof bonding course, is the vertical compressive strength of the foam aluminum plate, is the elastic modulus of the corrugated reinforcement, is the moment of inertia of a single corrugated reinforcement section about the neutral axis.

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