CA2148697A1 - Building or construction element - Google Patents

Abstract

A modular building element (10) for road or bridge repair, rehabilitation or construction comprises a cast concrete deck (13) with integral end diaphragms (14). A girder (12) such as a round timber (20) is shear coupled to the underside (16) of the deck (13) and spans between the diaphragms (14).

Description

~- WO 94/10389 PCT/AU93/00575 `-~ 214~697 BUILDING OR CQ~ST~U~TION ELEM~NT
Field of the In~ention The invention pertains to a building or construction element which in a preferred fo~m is a combined girder and deck which can be used in the repair, rehabilitation or construction of roads and bridges and as building element in other structural applications. More particularly, the com~ined girder and deck comprise a module which is fabricated, in part, from cast concrete.
-Background of the Invention It is well appreciated that one of the major problemsfacing road authorities and local councils is the maintenance and replacement of a large population of aging timber bridges. One of the reasons for such a large number of timber structures lies in the fact that Australia, for example, was blessed with ~ast supplies of durable and strong hardwood timber. However, a point has been reached in Australia and elsewhere, where large sawn timber is not available in sufficient quanties to continue to economically maintain these structures in the traditional manner. It is well ~nown that the supply of large diameter logs is quickly diminishing as old growth ; forests disappear. Consequently the cost of timber has risen sharply. Over the past ten years, the cost of good quality large sawn hardwood tim~er has risen ~y about a factor of four.
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From an environmental point of view, alternative methods and materials are needed to replace aging timbers or reduce the need for such timbers.
Because timber is dimensionally unstable (~hat is as , the moisture content varies it swells or shrinks by as much as ten percent perpendicular to the grain) and is f also biologically unstable if exposed to the elements, it .' has to date been considered as a temporary material in ~ 35 outdoor construction. Thus timber structures have been ~ECEIVF5D 0 ~ ~R ~99 21~8697 ,, -- 1/1 --repaired in the traditional manner which involves replacing members as they degrade.
Also, because natural round timber is irregular in its natural form, it is sawn to produce a more uniform product. Up to sixty percent of the timber is lost a~ the mill and a material of inferior strength is produced because some load carrying fibres are severed and knots are exposed.
The invention, in one application, replaces large sawn timber with reinforced concrete and combines this in the preferred embodiment with natural round timber which is in reasonable supply and can be obtained from plantations and regrowth forests.
Object and Summary of the In~ention It is an object of the invention to provide a modular - load carrying member which combines a girder and a deck into a single structure.
- The invention aims to produce a substantially dimensionally stable and accurate load carrying member or building element which is capable of~accommodating a dimensionally unstable girder as the main load carrying member, but is equally suited to accommodating a dimensionally stable girder.
The present invention consists in a structural module comprising:
a cast concrete portion; and a girder;
the cast concrete portion comprising a reinforced deck having a reinforced load bearing diaphragm at opposite ends;
the girder extending between the diaphragms and being shear coupled to the deck whereby forces induced in the girder are transferred to the diaphragms via shear ,J' ~ ' transfer between the girder and the deck.
In a preferred embodiment, the module combines a cast ~ !

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RECEIYED O 6 S~ 1994 concrete deck and end diaphragms with a round timber.
Preferably the module, when in use, is adapted to protect the girder from the elements, in particular water, which could degrade the girder where it is of timber.
In a preferred embodiment ~he module is formed by a cast reinforced concrete deck and end diaphragms with a round timber cast in an inverted position on a flat bed.
This upside down method of casting provides for denser and consequently more durable concrete at the wearing surfa~- and allows a tread or non skid pattern to be cast into the surface.
The module in its simplest form can provide a complete bridge or building element.
The modules may be coupled together to form large elements while being fully demountable if required (eg if bolted or stressed toyether) and may be reused.
The modules may be made contiguous by gluing or casting insitu with concrete between modules or by some other means.

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,~wos4/l0389 21~869~ PCr/AU93/onS75 Brief Description of the Dra~Ying Figures Figure 1 is a partial side elevation of a module according to the teachings of the present invention. This view shows only a left half of a module.
Figure 2 is a partial side elevation of a module utilising a round timber beam and 5 shear connectors between the beam and the concrete deck. A right half is shown.
Figure 3 is a cross-section through lines 3-3 of Figure 2, but where the module is inverted showing its orientation with respect to a casting bed.
Figure 4 is a cross-section through a module resting in a cas~ing bed.
Figure S is a cross-section through a module in which a steel I-beam is used.
Figure 6 is a cross-section through a module illustrating the use of a round timber and shear connector.
Figure 7 is a cross-section through a double width module in which a hollow reinforced cast concrete beam is itself a~fixed to the deck surface.
Figure 8 is a cross-section through a double width or larger module in which steel I-15 beams are used in place of round timbers.
Figure 9 is a schematic cross~sec~ion through a module illustrating the location of reinforcements and a method of using bolts or studs as shear connectors.
Figure 10 is an alternate method of attachment of a round or square timber beam to the deck.
Figure 11 is 2 longitudinal cross-section through a portion of a module illustrating the location of reinforcement members and illustrating the interconnection between beam ; and deck.
- Figure 12 is a detail illustrating a method of shear connecting a beam or girder to a deck.
; 25 Figure 13 is a detail of a pier or support onto which modules have been stacked.
Figure 14 is a side elevation of a portion of a bridge, the right hand of which has - been repaired and the left hand of whirh is awaiting repair.
Figure 15 is a front elevation, partially sectioned, of an existing timber bridge which has been repaired according to the teachings of the present inven~ion.
Figure 16 illustrates how modules may be formed in altemate embodiments.
Figure 17 illus~rates a multi-lane roadway which has been repaired according to the teachings of the present invention.
. Figure 18 is a schematic side elevation illustrating upright casting and pre-stressing of a module utilising a round timber with square trimmed ends. ~, Figure 19 is a cross-sectional view of an end of the module depicted in Pigure 18.
Figure 20 is a cross-section through lines 20-20 of Figure 19.
Figure 21 is a cross-section of a module utilising a box beam. The bGx beam is fabricated from laminated timber sides and is anchored into the cast deck.
Figure 22 is a side elevation of the module depicted in Figure 21.
Figure 23 is a cross-section of the detail encircled in Figure 21.

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Figure 24 illustrates modules according to the teachings of the present invention utilising constructing a floor, wall and ceiling of a building structure.
Figure 25 is a side elevation of a module illustrating how small timbers can be gnpped by a jaws-like apparatus which is embedded in the deck.
5 Figure 26 is a cross-section of, for example, a repaired bridge pier. Adjacentmodules are joined to one another by a horizontal fastener. The modules rest on a support which is itself fabricated from reinforced cast concrete into which is embedded a round timber. The modules are af~lxed to this support by a vertical rod wh~ch is embedded in the support.
Figure 27 is a cross-seetional detail of the support depicted in Figure 26.
Description of a Preferred Embodiment and Other Embodiments of the Invention - As will be apparent from the following description, a preferred embodiment of the invention uses the outstanding strength and durability qualitites of hardwood and some 15 treated softwood timbers and Australian hardwood timbers in cornbination with reinforced concrete to produce a composite, hi,,h strength, structural member which has applications in bridges, wharves, roof structures and has tilt up walls or tilt up structural columns.
The product is necessarily modular. In the preferred embodiment, the combination of materials allows the concrete to protect the timber from moisture and resulting 20 degradation. While the use of round timbers is shown in some of the exarnples, it would be understood that square or rectangular timbers, kiln dried timber or laminated timber, may be used as well. 9 In some embodiments, the modules are cast in an upside down position. This allows for irregularities of round timbers to be easily accommodated. Utilising this method, the , 25 timber, steel or concrete girder is lowered into or suspended into the slab portion of the module with suitable shear connections into the inverted slab which later becomes the running surface. The nature of the casting must be capable of easily accommodating the irregular dimensions of natural round timber girder so that the full strength of the round - timber is realised. The module should at the same time be capable of protecting the girder 30 from moisture which could degrade the girder in the case of timber. Typically, the slab is only about l50mm thicl~ and is easy to cast in an upside-down manner on the ground.
Any pattern for skid resistance rnay be incorporated into the top surface; It will be observed that the high shrinkage characteristics of timber and Australian hardwoods are accommodated in the method of shear and load transfer.
35 A typical length of a module for bridge applications may be about 10 metres long.
, This will suit the vast majority of timber bridges. The module has a large reserve strength :; and would be suitable for even longer lengths.
Modules may be bolted, dowelled, glued or stressed together in the transverse -' direction. They may be then bolted together, as will be described, through the .,, rWO 94/10389 2 1~ 8 6 9 7 diaphragms of each to keep joints tight in the direction of traffic. Provision for holding down bolts is also made. It will be appreciated that various combinations of module cross-section, width and length will allow for the full range of bridge widths and spans to be accommodated.
S Where round timbers are specified in the specification, timbers of about 500mm in diameter are envisaged. Smaller or larger timbers may also be used. 500mm diameter timber is in pIentiful supply and involves little waste at the mill. This also allows for the reuse of sound timber girders in the production of modules. The method also allows for the use of hitherto unacceptable species of hardwood such as spotted gum and blackbutt 10 which are in plentiful supply. These timbers are suitable for preservation ~eatment.
Given the fact that timber prices are on the increase, it is believed that modules can be manufactured and installed at the same cost as repairing a timber bridge structure in the traditional manner. Given the premise that decking needs to be replaced about every 15 years, employment of the invention will allow many timber bridges to be recycled at the 15 end of their 15-year life cycle.
As shown in Figures 1 and 2 a module 10 according to the present invention comprises a reinforced concrete portion 11 and a girder 12. The girder 12 may be steel, timber or concrete or cornbinations of these. The cast reinforced concrete portion 11 further comprises a deck surface 13 and a diaphragm 14 at each end. It will be 20 appreciated that Figures 1 and 2 are abbreviated representations, each being generally symmetrical about the vertical axis I~Ya. The deck 13 has a top surface or road surface 15 and an underside 16. ,~, As shown more particularly in Figure 2 (and Figure 6) a round timber 20 may be cast into the underside 16 of the deck 13. Preferably, the ends of the round timber 20 are 25 at least partially embedded into the diaphragm 14. In order to provide a shear connection between the round timber 20 and the deck 13, shear connectors 21 are embedded in the timber 20 and also cast into the deck 13. The shear connectors shear couple the girder to the deck. The shear connectors 21 may be in the form of plates, bolts, bars or studs and are preferably steel. In corrosive environments, it may be advantageous to use stainless 30 steel or plastic shear connectors. As shown in Figure 2 steel reinforcement 25 is advantageously located both~within the deck 13 and within the diaphragm 14. Figure 1 further illustrates how transverse through ducts 26 provide openings through which dowells or reinforcement may be located for transversely stressing laterally adjacent j~
modules.
35 Figure 3 illustrates (upside down) a module located in a casting bed. Modules are preferably cast upside down. Ill this example, the height of the module "h" is abou~
800mm and the width of the module "w" is about 1200mm. The bottom faces 99 of each diaphragm are preferably flat. The thickness of the deck is about l~Omm. A 500mm ~, diameter hardwood girder 20 is used.

WO 94110389 2 14 8 6 9 7 PCr/AU93/00~

Figure 4 shows match casting. In this method, the module is cast, then moved sideways, then rotated through angle "an.
Figure S illustrates an alternate embodiment in which a steel I-beam 30 is used as a girder. As illustrated, the I-beam or girder extends fxom the underside 16 of the deck 13 5 to the bottom 28 of the diaphragms 14. A number of shear connectors 29, such as bolts or integral studs extend into and are c~;t into the deck slab 13. In a typical appllcation, each of the diaphragms 14 will rest on elastomeric pads 27.
As shown in Figure 6, it may be advantageous to provide drip catchers 3 l along each lateral edge of the deck 13. The drip catchers help keep the gi~er dry by diverting 10 dripping water away from whichever girder is used. Figure 6 illustrates a simple shear connector 21 in the form of a rectangular steel plate. It will be understood that a wide variety of shear connectors may be used to facilitate the transfer of bending loads from ~e -deck into the girder.
Figure 7 illustrates an alternate embodiment of the invention which diverges in some 15 respects from the embodiments depicted in Figures 1-6. As shown in Figure 7, two girders 40 are affixed, owing to the use of shear connectors 41, into the deck slab 13 of a module 10. In this instance, the module lO is a double width module and utilises two girders 40. More than two girders may be used. Rather than being flat, the lateral edges of the module 42 are stepped to allow an overlapping with an adjacent module or 20 structure. In the example shown in Figure 7, a hollow concrete girder 40 is employed.
As shown in Figure 8, the same principles depicted in Pigure 7 may be applied to a module in which a steel I-beam 45 is used in place of ti41ber or concrete girders.
~'! Figure 9 illustrates a round dmber 20 which may be partially embedded into a deck 13. In this example, a bolt S0 rather than a rectangular plate is used as a shear connector.
25 Reinforcement 25 is provided in the deck and in the diaphragm (reinforcement not shown). In fact two or more bolts 50 may be used to facilitate the shear connection -between the deck 13 and the girder.
-Figure lO illustrates another method of shear connection. Here a bracket 60 is interposed between the timber girder 20 and the deck 13. Bolts 61 pass through the 30 bracket 60 and into the timber girder 20. The bracket 60 is embedded in the cast concrete deck 13 or may be attached to it by bolts or studs (not shown). The bracket may take any number of specific forms.
Figure l l illustrates how a bracket 60 may be employed in a generally UC~
.'configuration. The bracket or channel has parallel sides 62 which extend into parallel -35 slots hrmed in the timber girder 20. In this instance, two layers of reinforcement 63 are provided in the cast deck 13. Purther, the diaphragm 14 is also reinforced with steel rods 64 which are wrapped around transverse reinforcements 65. Note that in this embodiment, a lateral fillet 66 is used to interconnect the diaphragm 14 and the deck 13 in the comers between the declc and diaphragm. A steel reinforcement 67 passes through the 40 interior of the fillet ~6 and extends from the diaphragm 14 into the declc 13.
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Figure 12 illustrates a bracket 60 in which two pairs of adjacent bolts 69 pass through the bracket 66 into the timber girder 20. A plurality of such bracket and bolt arrangements are used along the length of the timber girder 2û.
Figure 13 illustrates some details of a typical assembly at a timber bridge pier. The existing wales 7Q associated with a pile 71 are used to suppor~ a new crosshead 72 which may be made from larninated treated pine. The new crosshead may be bolted together.
The new crosshead then supports one or more of the modules of the present invention 10.
These may be supported above elastomeric pads 73, if required.
Figure 14 illustrates how a bridge may be repaired, in sections. As shown in Figur~
10 14, the original corbel 80 is cut in half and one half of the original eorbel 81 is removed.
If required, a new spacer or crosshead 82 is provided above the existing wales. This prepares one half of the bridge pier 83 to accept a module 10 of the present invention.
The module 10 is then laid on top of the crosshead or spacer 82 so that a diaphragm 14 rests on the spacer or crosshead 82. The other half of the bridge pier section may then be 15 repaired in this same fashion. Bolts can be used to hold the adjacent diaphragms 14 together.
Figure 15 illustrates a multi-lane construction in which two di~ferent module types are used for the purpose of illustration. On the left of Figure 15 a three unit module 90 is used. Each module 90 includes three round timbers 20. The deck 13 may be cast with an 20 integral curb 91 which is preferably 200 x 200mm square. On the right side of the road illustrated in Figure 15, three separate modules 92 are utilised. Only one of the modules 93 incorporates an integral curb 91.
Another embodiment is depicted in Figure 16. Here, the interior lateral edges ofeach of the adjacent two modules are configured similarly to the stepped arrangement 25 depicted in Figure 7. An intermediate slab 9S extends between the two mo~ules 96.
Guard rails 97 are affixed directly or indirectly to the modules 96. In the example of Figure 16, the width of the road bed is defined by the width of the two modules together ~,vith the width of the intermediate slab.
Figure 17 illustrates that a plurality of single width modules 100 may be used to 30 transversely span a road bed. Intermediate slabs 101 interconnect adjacent modules 100.
The stepped lateral edges 102 Qf each module allow the intermediate slab 101 to lie flush with the upper or road surfaces 103 of each module 100.
An alternate method for module construction is suggested by Figure 18. Utillsingthis method, the module is cast upright rather than inverted (as shown in Figures 3 and 4).
35 This method allows the round timber 20 to be pre-stressed. This is accomplished by supporting the timber 20, at or near the middle so that the ends of the timber 200 sag below the level of the middle portion 201. This allows the ends to be adjus~bly raised or lowaed so as to achieve a degree of curvature in the timber 20. Any suitable apparatus 202 may be used to support the ends 200. For example, hydraulic or mechaniGIl jacldng 40 devices are suitable for this purpose. Depending on such parameters as the length and 2 1 ~ 8 6 9 7 PCl /AU93/00~

diameter of the timber 20, the dimensions of the module 10 and the degree of pre-stressing desired, the adjustable supports 202 are used to introduce a predetermined extent of bending in the timber 20. In essence, this represents a generally symmetrical sagging of the timber 20, which sagging is maintained by the central support 203 and the outer 5 adjustable supports 202. The cast reinforced concre~e portion 2W is then formed around the pre-stressed timber 20. By pre-stressing the timber 20, the module sags less when supported by its diaphragms 205 and deflects less in the ver~cal direction when loaded from above. It will be appreciated that depending on the extent of the sag of the ends 200, the finished module 10 may be intentionally formed with a degree of "hog" or over 10 vertical curvature.
Figure 19 illustrates a cross-section through an end of a module, for example of the type illustrated in Figure 18. In this example, a round timber 20 is trimmed so that its end 210 is square or rectangular in cross-section. In addition, a top surface 211 is also trimmed to be flat and flush with a lower surface 212 of a rib 213 which extends down 15 from the lower surface 214 of the deck 215. The square or rectangular trimmed end 210 preferably extends about l50mm into the diaphragm 216 and is in this example about 300mm square in cross-section. The protNding rib 213 spaces the timber 20 away from the deck 215 and also allows line contact to occur between the flat trimmed upper surface ~- 211 of the timber 20 and the slab which comprises the deck 215 and rib 213. Fillets 220 20 are provided between the deck 215 and diaphragm 216. They both strengthen theintersection between deck and diaphragm and also allow reinforcement members 221 to pass, on the diagonal, from the diaphragm 216 into the d~ck structure 215. In this -~ example, shear coupling is accomplished with nails, bolts, rods or studs 222 which are embedded into the timber 20 and extend into and are cast into the rib 213 and deck 215.
~ 25 Preferably, the shear coupling elements 222 extend into the steel reinforcement mesh ;i which forms part of the deck structure. The shear coupling elements 222 do not need to be oriented vertically with respect to the deck surface. They may be inclined to better accommodate the stresses and timber shrinkage of a particular application.
Figure 20 illustrates the orientation of the timber 20 relative to the rib 213 which ,~ 30 extends the full length of the module 10 between the diaphragms 216. This figure also illustrates the fillets 220 which may be located in the corners between the deck 215 and diaphragms 216.
Figure 21 illustrates a module 250 which utilises two girders 251. Each girder 251 - is built in the forrn of a box beam. The box beam further comprises sides 252 fabricated - 35 from laminated timber veneer or other engineering timbers. The bottom 253 in this example is fabricated from adjacent lengths of solid timber, square in cross-section. The built-up sides 252 of each box beam 251 are anchored into the reinforced deck 254 by a series of connectors 255, illustrated in more detail in Figure 23.

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Figure 22 illustrates how a series of yoke-like connectors 255 extend down the length of the girder 251, some of the connectors or anchors 256 being completelyembedded in the cast concrete structure.
As shown in Figure 23, each of the connectors 255 may comprise a yoke 257 which 5 is partially embedded. The legs 258 of the yoke are interconnected by a fastener 259 which passes through the side 252 of the girder 251.
Figure 24 illustrates an e~cample of a building construction utilising the modules of the present invention. As illustrated, a floor 260, a wall 270 and a roof 28f0 may all be fabricated utilising cast concrete deck-like surfaces with integral diaphragms, a bearn 10 extending between the opposed diaphragms of each module.
Figure 25 illustrates an alternate embodiment for anchoring or shear coupling the sides of a girder to the reinforced deck. ~n this example, an anchor or shear coupler 290 comprises opposed plate-like elements 291 each having nails or teeth 292 aligned along an interior surface. The opposed jaws or sides 291 of the anchor 290 are set into f~he girder 15 or girder portion using bolts 300 which pass through the sides 290. The upper por~ion of the anchor or shear coupler is itself embedded in the reinforced and cast concrete deck.
Figure 26 illustrates how two modules may be maintained in position by a specially adapted support 320 which is affixed to a pier 321. As shown by Figure 26, each module comprises one or more longitudinal bores 322 which are used to interconnect modulf~s 20 which are end-to-end with respect to one another. A fastener 323 is inserted through the aligned bores 3æ and prevents adjac~nt diaphragms from separating. Transverse bores 323 are also provided for the purpose of aligning and fastening laterally adjacent modules.
One or more vertical bores 324 may also be provided. The vertical bore 325 allows a fastener 326 to be passed through it for the purpose of anchoring the module with respefct to a convenient support. One such support 320 is illustrated in Figure 26. The support comprises a reinforced and cast concrete deck 325 into which is set a round timber section f 326. The timber section 326 is secured by any number of shear couplers 327 which are at least partially embedded in the reinforced concrete deck 325. The round timber 326 is then supported by and anchored to a pier 321 in any one of a number of convenient ways.
As shown in Figure 27, the vertical fastener 326 carries a ferTule 330 at a lower end. The ferrule is embedded into the reinforced concrete deck 325 of the support 320.
While the invenftion has been disclosed with reference to particular materials and : details of construction, these should be understood as having been provided, particularly where indicated, as oxamples rnd no~ as limitabons to the scope or spirit of the invention.
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Claims (16)

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1. A structural module comprising:
a cast concrete portion; and a girder;
the cast concrete portion comprising a reinforced deck having a reinforced load bearing diaphragm at opposite ends;
the girder extending between the diaphragms and being shear coupled to the deck whereby forces induced in the girder are transferred to the diaphragms via shear transfer between the girder and the deck.

2. The module of claim 1, wherein the diaphragms are integral with the deck and have flat bottom faces.

3. The module of either of claims 1 or 2, wherein the girder is shear coupled to the deck by a plurality of shear connectors, spaced along the girder and extending into both the girder and an underside of the deck.

4. The module of any one of claims 1-3, wherein the girder is a timber.

5. The module of either of claims 3 or 4, wherein the shear connectors are steel plates.

6. The module of either of claims 4 or 5, wherein the shear connectors comprise one or more bolts or studs.

7. The module of any one of claims 1-3, further comprising one or more additional girders extending between the diaphragms and shear coupled to the deck.

8. The module of any one of claims 1-7, wherein a lateral edge of a module comprises a stepped portion adapted to receive an intermediate slab and support the intermediate slab generally flush with a top surface of the module.

9. The module of any one of claims 1-8, wherein the deck is provided with one or more transverse passages which are adapted to allow a fastener to pass completely therethrough.

10. The module of any one of claims 1-9, wherein the girder is pre-stressed in a vertical plane.

11. The module of claim 10, wherein the module incorporates an over vertical curvature such that when the module is supported by the diaphragms, a centre portion of the module is higher than either end.

12. The module of any one of claims 1-11, wherein the girder is a timber girder having its top surface trimmed flat.

13. The module of claim 12, wherein the ends of the timber girder are trimmed square and are embedded into the diaphragms.

14. The module of any one of claims 1-13, wherein the deck further comprises a lower surface from which extends a rib, the rib extending between the diaphragms and having a flat lower surface adapted to make line contact with the girder.

15. A module, substantially as hereinbefore described with reference to the drawing figures.

16. A method of making a structural module as claimed in any one of the preceding claims wherein the concrete portion is cast such that the surface of the deck is the lowermost surface of the casting.