Steel-UHPC Composite Capping Beam for Lighter Bridge Hoisting

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Solution Overview

Problem

Existing capping beam structures face challenges such as high weight, complex construction processes, and structural defects at steel-concrete transitions, particularly in large cantilever applications, limiting their efficiency and cost-effectiveness in urban bridge construction.

Innovation Solution

A composite capping beam design combining a steel beam with an ultra-high-performance concrete (UHPC) plate, featuring a variable section structure, seamless fixation, and strategic use of lower extension sections and shear connectors to enhance stability and reduce weight, allowing for prefabrication and efficient assembly.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Stability of the object's composition

If a fully prefabricated prestressed concrete capping beam is used, then the beam height is large and the structure is stable, but the hoisting weight exceeds 500 tons requiring multi-stage hoisting and batched assembly which complicates construction

Engineering Contradiction:

Improvestructural stabilityVSAvoidconstruction complexity

Core Design Contradiction:

Stability of the object's compositionVSDevice complexity

Solution Approach 1:

The capping beam is divided into steel beam segments and UHPC plate segments that can be manufactured separately and assembled together. The steel beam includes web plates and bottom plates that form a lattice structure, while the UHPC plate is poured into the formed cavity. This segmentation allows each component to be optimized independently and assembled with simpler procedures compared to monolithic concrete construction.

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The invention uses a composite structure combining steel materials and ultra-high-performance concrete (UHPC) materials. The steel beam provides tensile strength and structural framework, while the UHPC plate provides compressive strength and fills the cavity. This composite approach leverages the complementary properties of both materials to achieve both structural stability and reduced weight, avoiding the need for multi-stage hoisting while maintaining structural integrity.

Inventive Principle:

Principle #40Composite materials

2Weight of stationary object

If a fully prefabricated steel capping beam is used, then the hoisting weight is small and the beam height is reduced, but the cost is high and the steel-concrete transition joint has complex stress distribution that may become a structural defect

Engineering Contradiction:

Improvehoisting weightVSAvoidmanufacturing cost

Core Design Contradiction:

Weight of stationary objectVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

3Adaptability or versatility

If on-site pouring is used for huge beam body construction, then the beam can be customized for unique bridge requirements, but multiple complicated procedures including support erection, steel mesh binding, pouring and curing, and multi-times prestress tensioning are required

Engineering Contradiction:

Improvedesign adaptabilityVSAvoidconstruction procedure complexity

Core Design Contradiction:

Adaptability or versatilityVSDevice complexity

Solution Approach 1:

Inventive Principle:

Principle #1Segmentation

Solution Approach 2:

The steel beam structure with its lattice framework is prepared in advance, creating the cavity formwork before the UHPC pouring process. This preliminary preparation of the steel structure serves dual purposes: providing the structural framework and creating the mold for concrete pouring, thereby eliminating the need for separate formwork erection and simplifying the construction sequence.

Inventive Principle:

Principle #10Preliminary action

4Area of stationary object

If a large cantilever capping beam structure is adopted to utilize urban space, then space under the bridge is fully used and land is saved, but the beam weight and height increase which complicates construction

Engineering Contradiction:

Improvespace utilizationVSAvoidbeam weight

Core Design Contradiction:

Area of stationary objectVSWeight of stationary object

Solution Approach 1:

Inventive Principle:

Principle #40Composite materials

Data Source

PatentUS12612748B2Composite capping beam with steel beam and ultra-high-performance concrete plate and construction method therefor

Publication Date: 2026.04.28 HUNAN UNIV

AI summary

Disclosed is a composite capping beam with a steel beam and an ultra-high-performance concrete plate. The composite capping beam includes a steel beam and an ultra-high-performance concrete (UHPC) plate, where the steel beam includes a bottom plate and web plates, the web plates are arranged at two sides of the bottom plate in a longitudinal bridge direction, bottoms of the web plates extend downwards to be provided with lower extension sections, and the UHPC plate is clamped in a cavity defined by the lower extension sections and the bottom plate. The present disclosure further provides a construction method for the composite capping beam with a steel beam and an ultra-high-performance concrete plate. The composite capping beam with a steel beam and an ultra-high-performance concrete plate according to the present disclosure is small in hoisting weight and economical.