Granted Patent B2

US 12,398,520 · App. 17/402,667 · Granted Aug 26, 2025

Inventor: Mohamed J. Said (Lewes, DE)

E01D2/00C04B14/06C04B14/062C04B14/28C04B18/141C04B20/0048E01D19/125E01D21/00E01D2101/262E01D2101/264E01D2101/266

Abstract

Claims (140)

1. A beam for use in construction of a long span bridge structure comprising:

a reinforcing member formed of a plurality of aligned modular elements and having a geometric configuration selected from a group consisting of: a “U” tub beam with composite deck system; and a decked I-beam; and

each of said plurality of aligned modular elements each further comprises a prestressed beam cast from a ultra-high performance concrete (UHPC) mix as a unitary body;

said UHPC is configuration to have:

an initial compressive strength, f′ci=10.0 ksi;

a compressive strength at service, f′c=17.4 ksi;

a modulus of elasticity of concrete, Ec=6500 ksi;

a residual rupture stress, frr=0.75 ksi; and

a concrete unit weight, wc=0.155 kcf;

said ultra-high performance concrete mixture further comprises:

cement at about 24.5% by weight;

silica flume at about 4.5% by weight;

limestone powder at about 7.6% by weight;

slag at about 13.0% by weight;

masonry sand at about 39% by weight;

water at about 4% by weight;

ice at about 4% by weight;

a shrinkage reducing admixture at less than 2% by weight; and

a workability retaining admixture at less than 0.5% by weight;

said UHPC mix further comprises a plurality of discontinuous fibers distributed randomly throughout a concrete matrix, said plurality of discontinuous fibers formed of a material selected from the group consisting of: steel; polypropylene; nylon; polyvinyl alcohol; polyolefin; polyethylene; polyester; acrylic; aramid; carbon; silica glass; basalt glass; glass fiber-reinforced polymer; and basalt fiber-reinforced polymer; and

said plurality of aligned modular elements are connected by an epoxy grout adhering as element joints and post-tensioned to form the reinforcing member.

2. The beam of claim 1 , wherein said plurality of discontinuous fibers each form a reinforcing strand further comprising:

a diameter of between about 0.5-inch and about 2.0-inches; and

a length of between about ½ inch to about 5 inches.

3. A beam, for use in construction of a long span bridge structure comprising:

a reinforcing member formed of a plurality of aligned modular elements and having a geometric configuration selected from a group consisting of: a “U” tub beam with composite deck system; and a decked I-beam; and

each of said plurality of aligned modular elements each further comprises a prestressed beam cast from a UHPC mix as a unitary body;

said UHPC is configuration to have:

an initial compressive strength, f′ ci =10.0 ksi;

a compressive strength at service, f′ c =17.4 ksi;

a modulus of elasticity of concrete, E c =6500 ksi;

a residual rupture stress, f rr =0.75 ksi; and

a concrete unit weight, w c =0.155 kcf;

said UHPC mix further comprises a plurality of discontinuous fibers distributed randomly throughout a concrete matrix, said plurality of discontinuous fibers formed of a material selected from the group consisting of: steel; polypropylene; nylon; polyvinyl alcohol; polyolefin; polyethylene; polyester; acrylic; aramid; carbon; silica glass; basalt glass; glass fiber-reinforced polymer; and basalt fiber-reinforced polymer; and

said plurality of aligned modular elements are connected by an epoxy grout adhering as element joints and post-tensioned to form the reinforcing member, wherein said cement is selected from a group consisting of: Portland cement; and blended cements including mineral admixtures or blends calcium aluminate cements, calcium sulfoaluminate cements, alkali-activated binders, supersulfated slag cements;

wherein the UHPC mix further comprises a mixture of:

cement;

silica flume;

limestone;

slag;

masonry sand;

water;

ice;

a shrinkage reducing admixture; and

a workability retaining admixture;

wherein said cement is selected from a group consisting of: Portland cement; and blended cements including mineral admixtures or blends calcium aluminate cements, calcium sulfoaluminate cements, alkali-activated binders, supersulfated slag cements;

wherein said ultra-high performance concrete mixture further comprises:

cement at about 24.5% by weight;

silica flume at about 4.5% by weight;

limestone powder at about 7.6% by weight;

slag at about 13.0% by weight;

masonry sand at about 39% by weight;

water at about 4% by weight;

ice at about 4% by weight;

a shrinkage reducing admixture at less than 2% by weight; and

a workability retaining admixture at less than 0.5% by weight.

4. The beam of claim 3 , wherein said cement is selected from a group consisting of: Portland cement; and blended cements including mineral admixtures or blends calcium aluminate cements, calcium sulfoaluminate cements, alkali-activated binders, supersulfated slag cements, and wherein said ultra-high performance concrete mixture further comprises:

cement at about 24.5% by weight;

silica flume at about 4.5% by weight;

limestone powder at about 7.6% by weight;

slag at about 13.0% by weight;

masonry sand at about 39% by weight;

water at about 4% by weight;

ice at about 4% by weight;

a shrinkage reducing admixture at less than 2% by weight; and

a workability retaining admixture at less than 0.5% by weight;

wherein said cement is selected from a group consisting of: Portland cement; and blended cements including mineral admixtures or blends calcium aluminate cements, calcium sulfoaluminate cements, alkali-activated binders, supersulfated slag cements.

5. A method of erecting a long span bridge beam comprising:

a. obtaining a plurality of segmented modular elements each comprising:

a geometric configuration selected from a group consisting of: a “U” tub beam with composite deck system; and a decked I-beam; and

each of said plurality of aligned modular elements each further comprises a prestressed beam cast from a UHPC mix as a unitary body;

said UHPC is configuration to have:

an initial compressive strength, f′ci=10.0 ksi;

a compressive strength at service, f′c=17.4 ksi;

a modulus of elasticity of concrete, Ec=6500 ksi;

a residual rupture stress, frr=0.75 ksi; and

a concrete unit weight, wc=0.155 kcf;

said UHPC mix further comprises a plurality of discontinuous fibers distributed randomly throughout a concrete matrix, said plurality of discontinuous fibers formed of a material selected from the group consisting of: steel; polypropylene; nylon; polyvinyl alcohol; polyolefin; polyethylene; polyester; acrylic; aramid; carbon; silica glass; basalt glass; glass fiber-reinforced polymer; and basalt fiber-reinforced polymer; and

said plurality of aligned modular elements are connected by an epoxy grout adhering as element joints and post-tensioned to form the reinforcing member;

b. moving the plurality of segmented modular elements to an erection location by rail or truck and unloaded to a staging location;

c. aligning the plurality of segmented modular elements at the project site;

d. attaching adjacent modular elements by applying an epoxy grout at each joint between each successive joint and applying compression about each joint to assure curing of the epoxy to the joint;

e. once all elements are assembled into a long span beam, inserting post-tensioning strands through the beam in a manner that post-tensioning forces are applied to the assembled beam; and

f. erecting the assembled beam into a final position.

6. The method of claim 5 , further comprising:

g. installing a UHPC stay-in-place form to create a topping form; and

h. casting a bridge deck onto the topping form.

7. A method of erecting a long span bridge beam comprising:

a. obtaining a plurality of segmented modular elements each comprising:

a geometric configuration selected from a group consisting of: a “U” tub beam with composite deck system; and a decked I-beam; and

each of said plurality of aligned modular elements each further comprises a prestressed beam cast from a UHPC mix as a unitary body;

said UHPC is configuration to have:

an initial compressive strength, f′ci=10.0 ksi;

a compressive strength at service, f′c=17.4 ksi;

a modulus of elasticity of concrete, Ec=6500 ksi;

a residual rupture stress, frr=0.75 ksi; and

a concrete unit weight, wc=0.155 kcf;

said UHPC mix further comprises a plurality of discontinuous fibers distributed randomly throughout a concrete matrix, said plurality of discontinuous fibers formed of a material selected from the group consisting of: steel; polypropylene; nylon; polyvinyl alcohol; polyolefin; polyethylene; polyester; acrylic; aramid; carbon; silica glass; basalt glass; glass fiber-reinforced polymer; and basalt fiber-reinforced polymer;

said plurality of discontinuous fibers each form a reinforcing strand further comprising:

a diameter of between about 0.5-inch and about 2.0-inches; and

a length of between about ½ inch to about 5 inches; and

said plurality of aligned modular elements are connected by an epoxy grout adhering as element joints and post-tensioned to form the reinforcing member;

b. moving the plurality of segmented modular elements to an erection location by rail or truck and unloaded to a staging location;

c. aligning the plurality of segmented modular elements at the project site;

d. attaching adjacent modular elements by applying an epoxy grout at each joint between each successive joint and applying compression about each joint to assure curing of the epoxy to the joint;

e. once all elements are assembled into a long span beam, inserting post-tensioning strands through the beam in a manner that post-tensioning forces are applied to the assembled beam; and

f. erecting the assembled beam into a final position.

8. The method of claim 7 , further comprising:

g. installing a UHPC stay-in-place form to create a topping form; and

h. casting a bridge deck onto the topping form.

9. A method of erecting a long span bridge beam comprising:

a. obtaining a plurality of segmented modular elements of claim 5 wherein said ultra-high performance concrete mixture further comprises:

a reinforcing member formed of a plurality of aligned modular elements and having a geometric configuration selected from a group consisting of: a “U” tub beam with composite deck system; and a decked I-beam; and

each of said plurality of aligned modular elements each further comprises a prestressed beam cast from a UHPC mix as a unitary body;

said UHPC is configuration to have:

an initial compressive strength, f′ ci =10.0 ksi;

a compressive strength at service, f′ c =17.4 ksi;

a modulus of elasticity of concrete, E c =6500 ksi;

a residual rupture stress, f rr =0.75 ksi; and

a concrete unit weight, w c =0.155 kcf;

said UHPC mix further comprises a plurality of discontinuous fibers distributed randomly throughout a concrete matrix, said plurality of discontinuous fibers formed of a material selected from the group consisting of: steel; polypropylene; nylon; polyvinyl alcohol; polyolefin; polyethylene; polyester; acrylic; aramid; carbon; silica glass; basalt glass; glass fiber-reinforced polymer; and basalt fiber-reinforced polymer; and

said plurality of aligned modular elements are connected by an epoxy grout adhering as element joints and post-tensioned to form the reinforcing member;

wherein the UHPC mix further comprises a mixture of

cement at about 24.5% by weight;

silica flume at about 4.5% by weight;

limestone powder at about 7.6% by weight;

slag at about 13.0% by weight;

masonry sand at about 39% by weight;

water at about 4% by weight;

ice at about 4% by weight;

a shrinkage reducing admixture at less than 2% by weight; and

a workability retaining admixture at less than 0.5% by weight;

b. moving the plurality of segmented modular elements to an erection location by rail or truck and unloaded to a staging location;

c. aligning the plurality of segmented modular elements at the project site;

d. attaching adjacent modular elements by applying an epoxy grout at each joint between each successive joint and applying compression about each joint to assure curing of the epoxy to the joint;

e. once all elements are assembled into a long span beam, inserting post-tensioning strands through the beam in a manner that post-tensioning forces are applied to the assembled beam; and

f. erecting the assembled beam into a final position.

10. The method of claim 9 , further comprising:

g. installing a UHPC stay-in-place form to create a topping form; and

h. casting a bridge deck onto the topping form.

Assignments (1)

Continuity (3)

References Cited (22)