Composite Bridge Girder Grid Assembly via Cement Grouting
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Solution Overview
Problem
Current bridge construction methods face challenges in simplifying the production of girder grids and roadway slab elements, leading to complex and costly processes, especially in welding and transporting large, bulky components, which increases production costs and disrupts traffic routes.
Innovation Solution
A construction method where a girder grid is formed on-site by assembling longitudinal and transverse beams with cement-based grouting, followed by the addition of in-situ concrete to connect the components, allowing for prefabrication of smaller, easily transportable parts and eliminating the need for extensive formwork and weather-sensitive welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If large and bulky girder grids are transported to the construction site, then the bridge can be assembled quickly, but the production costs increase and traffic routes are disrupted
Solution Approach 1:
The girder grid is divided into individual longitudinal girders and transverse girders that can be manufactured separately and transported independently to the construction site, where they are assembled on-site. This segmentation reduces transport complexity and costs while maintaining assembly efficiency.
Solution Approach 2:
The construction process moves from transporting complete three-dimensional girder grids to transporting one-dimensional beam elements that are assembled into the grid structure on-site, reducing spatial requirements and transport costs.
2Strength
If welding is used to connect girders, then strong connections are achieved, but the process becomes weather-sensitive and time-consuming
Solution Approach 1:
The welding process is replaced with a casting process using cement-based grout to connect the girders. This substitution eliminates weather sensitivity and reduces construction time while maintaining connection strength through the rigid cement matrix.
Solution Approach 2:
The connection method changes from thermal welding to chemical cementation, altering the fundamental parameters of the joining process to eliminate temperature dependence and weather sensitivity.
3Stability of the object's composition
If extensive formwork is used for concrete construction, then structural integrity is ensured, but the complexity and cost of production increase
Solution Approach 1:
The cement-based grout serves its own formwork function by being contained within the girder assembly gaps themselves, eliminating the need for separate external formwork structures. The grout fills and defines the connection zones without requiring additional shaping equipment.
4Productivity
If prefabricated parts with large dimensions are used, then fewer components need to be assembled, but transport becomes more difficult and costly
Solution Approach 1:
The bridge superstructure is segmented into standardized, smaller-dimensional girder elements that are easier to manufacture and transport, while the modular nature allows for efficient on-site assembly into the complete bridge structure.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces production costs, minimizes traffic disruptions, and enables the construction of bridges with medium spans up to 50 meters, as it simplifies the assembly process, reduces material usage, and allows for high-quality connections under various weather conditions.
Implementation Method 1
at least the side members and the cross members are connected to one another by a cement-based casting
Implementation Method 2
assembling longitudinal and transverse beams with cement-based grouting
Implementation Method 3
allowing for prefabrication of smaller, easily transportable parts and eliminating the need for extensive formwork
Data Source
Figure 1
Figure 2a~2b
Figure 3
AI summary
The method involves connecting longitudinal carriers (1) and cross beams (2) to a support grid by grouting, and hardening the grouting. Prefabricated plate elements (4) are positioned on flanks, and are fixed on the support grid by filling of in-situ concrete (5). The support grid is prepared outside of its installation position, and is subsequently placed in the installation position. The cross beams are assembled on upper sides of the longitudinal carriers. The in-situ concrete is applied up to height of upper sides of the cross beams. An independent claim is also included for a system for preparing a steel-concrete composite structure.