WO2014200361A1

WO2014200361A1 - Bridge construction kit set and method

Info

Publication number: WO2014200361A1
Application number: PCT/NZ2014/000111
Authority: WO
Inventors: Kelly Wright; Stephen Nigel SWANN
Original assignee: Kelly Wright; Swann Stephen Nigel
Priority date: 2013-06-11
Filing date: 2014-06-10
Publication date: 2014-12-18
Also published as: WO2014200361A4

Abstract

In one aspect the invention provides a method of constructing a bridge used to span an obstacle which includes the initial step of locating a first set of foundation blocks on one side of an obstacle, and then locating a second set of foundation blocks on the opposite side of the obstacle. Next an array of spanning panels are connected together to form a deck, and then the first end of the deck is connected to the first set of foundation blocks and the second end of the deck is connected to the second set of foundation blocks. Once these connections are made a settable material is poured over the deck.

Description

BRIDGE CONSTRUCTION KIT SET AND METHOD

Field of the Invention

This invention relates to a bridge construction method in addition to a kit set of parts used to construct a bridge.

Background of the Invention

Bridges are constructed to span a variety of obstacles, and in many situations a bridge will need to support the weight of vehicles with a robust construction. In various applications there is a need to construct a bridge over small watercourses in isolated locations where it is difficult to deliver construction materials or where heavy construction machinery cannot easily be deployed. The overall cost of the construction process and the time taken to construct a bridge is also important.

In rural and farming environments it is common for a farmer to wish to drive a variety of vehicles over a stream accessed by a basic farm track. In these situations large trucks carrying long lengths of structural steel or reinforced concrete beams may not be able to gain access to the site were a bridge is required. It may also be difficult to deploy heavy machinery such as lifting cranes or excavators at these sites. A common approach used in these situations is to excavate the stream and install a culvert, then backfill the excavated spoil over the culvert to form a bridge.

However the construction process required for culvert based bridges damages the surrounding ecosystem, and in a particular destroys the section of stream bed in which the culvert is installed. Furthermore, downstream sections of the watercourse are polluted by any excavation spoil allowed to fall into the stream. The diameter of the culvert used can also be dictated by the capacity of the vehicle used to deliver the culvert to site and any lifting equipment required to install the culvert. In inaccessible regions it may only be possible to install sections of culvert which can be lifted into place by hand.

Culvert-based bridges can also be relatively expensive to construct, requiring excavation work in addition to the cost of the culvert itself.

These forms of bridges are only useful in respect of small watercourses and cannot be used to span other forms of obstacles such as ravines or steep dips and hollows in the land.

It would therefore be of advantage to have improvements over the prior art which addressed the above issues or at least provided the public with an alternative choice.

In particular, it would be of advantage to have an improved method of constructing a bridge and a kit set of parts used to construct a bridge which could be deployed in remote locations without requiring good road access or heavy lifting equipment. An improved method of construction and a kit set of parts which could be used to form a bridge inexpensively and quickly, and which could also span obstacles other than small watercourses would be of advantage. A method of construction and an associated kit set of parts which minimise damage to the local ecosystem and the environment of a

watercourse would also be of advantage.

Disclosure of the Invention

According to one aspect of the present invention there is provided a method of constructing a bridge used to span an obstacle characterised by the steps of:

• locating a first set of foundation blocks on one side of an obstacle, and

• locating a second set of foundation blocks on the opposite side of the obstacle, and

• connecting together an array of spanning panels to form a deck, and • connecting a first end of the deck to the first set of foundation blocks and connecting a second end of the deck to the second set of foundation blocks, and

• pouring a settable material over the deck.

According to a further aspect of the invention there is provided a bridge construction kit set which includes a plurality of spanning panels arranged for connection together to form a deck, and a plurality of foundation blocks arranged to connect to the deck to form a bridge.

The present invention is arranged to facilitate the construction of a bridge over an obstacle. Aspects of the invention include both a method of construction used to form a bridge in addition to a set of parts or

components employed within this construction method. Reference in general throughout this specification will primarily be made to the invention providing a method of construction. However, those skilled in the art will also appreciate that the invention also encompasses the provision of a kit set of parts used in this method of construction.

The bridge constructed by the invention can also be used to span a variety of obstacles. Again reference will be made throughout this specification to the bridge constructed being used to span small watercourses such as streams. Those skilled in the art will appreciate that other obstacles may be spanned by a bridge provided by the invention and reference to the above in isolation should in no way be seen as limiting.

The invention employs a plurality of foundation blocks, with a first set of foundation blocks to be located on one side of a stream and a second set of foundation blocks to be located on the opposite side of the stream. These foundation blocks therefore demarcate each of the ends of the bridge to be formed.

In some optional embodiments the foundation blocks may be sited on top of additional ground works or support piles. For example, in some cases a foundation block may be sited on top of an engineered driven pile or similar component. In a preferred embodiment the first and second set of foundation blocks may be located on opposite sides of a stream by being dug into each bank at the normal waterline of the stream. Those skilled in the art will appreciate that foundation blocks may be entirely or partially buried in each bank in such embodiments.

In a preferred embodiment each of the first and second set of foundation blocks can be deployed end to end or side to side in a line, with the length of this line approximating the width of the bridge to be formed.

In a preferred embodiment a foundation block may be formed from a precast settable material such as concrete. Precast settable materials provide flexibility in terms of the form or shape of the resulting foundation block which can be achieved and may also include additional materials such as reinforcing fibres or reinforcing metal rods. Individual precast foundation blocks can also be formed of a size and weight which allows blocks to be easily transported and lifted into place.

Reference in general will also be made throughout this specification to a foundation block being formed from a precast concrete block with a modular form, with sets of substantially identical foundation blocks being used in conjunction with the invention. However those skilled in the art will appreciate that other forms of materials in addition to variations in the sizes and shapes of foundation blocks used may be employed in various additional embodiments of the invention.

In a preferred embodiment each foundation block may include at least one lifting projection. Such projections may form loops, hooks or other

equivalent structures which allow a foundation block to be engaged and lifted easily. In a further preferred embodiment a lifting projection may form a handle, loop or staple shaped projection which can be engaged by a hook or lifting strop.

In a preferred embodiment a lifting projection may be formed by a steel reinforcing bar bent into the form of a staple which is set into the precast body of the foundation block. In a further preferred embodiment the terminal ends of the steel staple used may extend at least half way through the width or depth of the block to strongly engage this component with the body of the block.

In a preferred embodiment each foundation block may define at least one channel used to receive a settable material. Preferably a channel defined in a foundation block may be sited adjacent to the block's connection with a further element of the bridge such as the bridge deck or an adjacent foundation block. Settable materials poured into a channel may therefore be used to assist in connecting the foundation block with an adjacent

foundation block or a section of the bridge deck.

In a further preferred embodiment a foundation block may define a continuous central channel which extends at least through each end face of the block and along the top face of the block. This single continuous central channel can therefore provide a connection to two adjacent foundation blocks in addition to a section of the bridge deck once filled with a settable material.

In a preferred embodiment the top face of a foundation block may also define a locating recess which is arranged to contact components used to form a portion of the deck. This recess can therefore be used to locate a section of the deck in contact with the foundation block prior to a settable material being pored over the deck and preferably into any channel or channels formed by the foundation block.

As referenced above the construction method provided by the invention requires a settable material to be pored over the deck formed for the bridge. Reference in general throughout this specification will also be made to concrete being used as this settable material. However those skilled in the art will appreciate that any equivalent or similar settable materials may be substituted for concrete, and reference to the use of concrete throughout this specification should in no way be seen as limiting.

The invention employs an array of spanning panels which are connected together to form the bridge deck. The ends of the deck formed are

connected to each of the first and second sets of foundation blocks during construction. A spanning panel provided by the invention may have a regular or modular shape, allowing panels to be mass produced at relatively low cost.

In a preferred embodiment a spanning panel may have a substantially curved form or shape, allowing the deck formed by these panels to define an arch used to span a stream or equivalent obstacle. In such embodiments the deck formed by the spanning panels will rise from the first set of foundation blocks to curve to the centre of the bridge and then drop back to connect to the second set of foundation blocks.

In a preferred embodiment a spanning panel may have a substantially rectangular form or shape. Rectangular panels make efficient use of materials and can easily be connected together with edges that meet squarely with neighbouring panels.

Those skilled in the art will appreciate that the dimensions of spanning panels may be varied in a number of embodiments depending on the characteristics of the bridge required. For example, in some alternative embodiments a single spanning panel may extend the entire width or length of the deck, whereas in other preferred embodiments the bridge deck may be formed by a rectangular array of a plurality of spanning panels making up both the length and the width of the deck.

Reference in general throughout this specification will also be made to spanning panels being formed with a substantially rectangular curved form. However those skilled in the art will appreciate that other shapes and arrangements of spanning panels may also be employed in alternative embodiments and reference to the above in isolation throughout this specification should in no way be seen as limiting.

In a preferred embodiment a spanning panel may be formed from steel sheet material. Steel is a strong and durable construction material which can provide a robust strong bridge.

In a preferred embodiment spanning panels may be arrayed together and connected together at their adjacent edges to form the bridge deck. Those skilled in the art will appreciate that a variety of connection schemes may be employed to engage adjacent spanning panels together - from screws, bolts or welds by way of example. Reference in general throughout this

specification will also be made to spanning panels being bolted together, but those skilled in the art will appreciate that alternative connections schemes are also envisioned.

In a preferred embodiment the perimeter of each spanning panel may define an upturned lip where adjacent panels are bolted or otherwise connected together by or at this lip. The lip formed at the perimeter of each panel will therefore enclose a volume, allowing each panel to act as a tray capable of receiving a volume of concrete to be pored over the deck.

In a preferred embodiment a bridge constructed using the invention may also integrate at least one side flange element. A side flange may be formed from a section of material with a complimentary form or shape to the profile of the deck to be formed, and can be engaged with the exposed perimeter edge of one or more spanning panels which define one side of the resulting deck. Once connected to one or more spanning panels a side flange may extend upwards above the spanning panels to present a further barrier to any concrete pored over the deck.

In a further preferred embodiment a plurality of side flange elements may be connected along both sides of the deck along the length of the deck. These side flanges therefore partially enclose a volume spanning the width of the deck and can be used to retain concrete pored over the deck.

Those skilled in the art will appreciate that in some instances a single side flange element may span the entire length of one side the deck, whereas in other embodiments of plurality of side flange elements may be connected to one side of the deck to form the barrier required.

Furthermore, those skilled in the art will appreciate that a variety of connection schemes may be employed to engage spanning panels with side flanges - from screws, bolts or welds by way of example. Reference in general throughout this specification will also be made to spanning panels and side flanges being bolted together, but those skilled in the art will appreciate that alternative connections schemes are also envisioned.

In a preferred embodiment a reinforcing structure may be applied on to the upper surface of the deck prior to concrete being pored over the deck. This reinforcing structure can improve the overall strength of the resulting deck and bridge when concrete is pored over and around it.

In a further preferred embodiment of the invention a reinforcing structure may be formed from a layer of reinforcing steel mesh. Reinforcing steel mesh is well known in the construction industry and is commonly integrated into poured concrete structures.

Reference in general throughout this specification will also be made to the bridge formed incorporating a layer of steel reinforcing mesh applied above or on top of the spanning panels. However those skilled in the art will appreciate that in other embodiments different forms of reinforcing

structures may be employed. In yet other embodiments where a lightweight and low-cost bridge construction is required, a reinforcing structure may not necessarily be employed with the invention.

In a preferred embodiment the steel mesh applied above the spanning panels may be tied or otherwise connected to each set of foundation blocks prior to concrete being pored over the deck. In such embodiments a range of connection schemes may be used to engage this reinforcing structure to the foundation blocks. For example, in one further preferred embodiment a steel rod may be threaded through each foundation block's lifting projection or staple with this rod running the length of the set of foundation blocks. The terminal edge of the steel mesh can then be tied off to this steel rod, with concrete pored over deck being allowed to flow over the connected mesh and rod to strongly engage the deck with each set of foundation blocks.

In a preferred embodiment a pair of side retaining walls may be constructed to bracket or abut the edges of the deck prior to concrete being pored over the deck. In such embodiments the side retaining walls may preferably be formed from wooden posts and planking, and may perform in a concrete boxing role to prevent any overspill of concrete reaching the stream being bridged. Furthermore, these side walls may also extend upwards above the surface of the deck to form or define a guard rail for the bridge.

In a preferred embodiment the outer surface of the side retaining walls may be covered in a decorative cladding material. For example, in some

embodiments an outer skin which resembles stone or brick work (for example) may be applied to retaining walls formed from wooden materials.

In a further preferred embodiment once the concrete poured over deck has set the foundation blocks and ends the deck may be covered by filler material. The filler material can be used to form a gently sloping ramp onto the apex of the deck. In such embodiments the side retaining walls

referenced above can also function to prevent filler material being pushed into a stream and causing pollution effects.

Brief description of the drawings

Additional and further aspects of the present invention will be apparent to the reader from the following description of embodiments, given in by way of example only, with reference to the accompanying drawings in which :

• Figure 1 shows a perspective view of a partially constructed bridge formed in accordance with a preferred embodiment of the present invention, and

• Figure 2 shows an exploded perspective view of the bridge of figure 1 when fully constructed but prior to backfilling of excavation spoil over the ends of the bridge deck, and

• Figure 3 shows an enlarged view of the first set of foundation blocks shown with respect to figure 2, and

• Figure 4 shows an end cross-section view of a foundation block used to construct the bridge shown with respect to figures 1 and 2.

Further aspects of the invention will become apparent from the following description of the invention which is given by way of example only of particular embodiments.

Best modes for carrying out the invention Figure 1 shows a perspective view of a partially constructed bridge formed in accordance with a preferred embodiment of the present invention.

Figure 1 illustrates the initial construction phases implemented by the invention in a preferred embodiment. As can be seen from this figure a first set of concrete foundation blocks 1 are located on one side of a stream (not shown) and a second set of foundation blocks 2 are located on the opposite side of the stream. These foundation blocks 1, 2 are dug into the bank of the stream at the normal waterline of the stream. Each set of foundation blocks are laid end to end in a line which defines the width of the bridge to be formed.

Figure 1 also shows the provision of an array of spanning panels 3 connected together to form a deck 4 for the bridge. Each spanning panel 3 has a curved rectangular form where the perimeter of each of the panels defines an upturned lip 5. Each adjacent spanning panel is connected to its neighbours by a number of bolts projecting through the contacting edge lips. This perimeter lip also encloses a volume on the upper surface of each panel arranged to trap and retain concrete poured on to the deck in a later step in the construction method.

In the situation shown in figure 1 a side retaining wall 6 has been

constructed to bracket the far edge of the deck prior to concrete being pored over the deck. This side retaining wall has been constructed from wooden posts and planks.

Figure 2 shows an exploded perspective view of the bridge of figure 1 when fully constructed but prior to backfilling of excavation spoil and filler material over the ends of the deck bridge.

A number of side flange elements 7 are connected along the side of the deck extending the length of the deck.

Figure 2 also illustrates how a reinforcing structure formed by a layer of steel mesh 8 is applied over the connected spanning panels. This mesh layer is applied once the deck is formed and positioned between each set of foundation blocks. Once the steel mesh layer is in place concrete 9 is pored over the deck to bond the various elements of the bridge together. The upturned lips 5 of each spanning panel trap a volume of concrete while the side flanges 7 and retaining sidewalls 6 increase the height of the concrete layer above these lips and cover the steel mesh 8 under at a layer of concrete.

After the concrete has set excavation spoil (not shown) from seating the foundation blocks is pushed back over the foundation blocks and the ends of the bridge to form a gently sloping ramp to the apex of the deck. If the spoil available does not form an effective ramp additional filler material is also applied over the ends of the deck. The side retaining walls 6 work to prevent any of the filler material from falling into the stream and causing pollution problems.

Figure 3 shows an enlarged area of figure 2 illustrating features of the foundation blocks used and their connections to the remaining components of the bridge. Figure 4 also shows an end cross-section view of one of these foundation blocks.

These figures show a pair of lifting projections formed by looped steel staples 10 embedded in each block during casting. As can be seen from figure 4 the ends of each staple project down over half way through the body of each foundation block.

Each foundation block defines a continuous central channel 11 which extends along each end wall 12 and across its top face 13. This channel is filled by the concrete poured over the deck and bonds adjacent foundation blocks and the deck together. As can be seen from figure 3 concrete poured into the channel forms a vertical cylinder 14 in the void defined between each foundation block while the upper section of the channel is filled by the edge of the deck's upper concrete layer 15.

Figures 3 and 4 also show how aised steel rod 16 is threaded through each of the staples 10 projecting from these foundation blocks. This rod provides an element which runs the length of the set of foundation blocks, allowing wire ties to be used to connect the reinforcing mesh layer 8 of the deck directly to the foundation blocks. As can be seen from these figures a locating recess 17 is formed in each foundation block to receive the terminal edge of the deck's spanning panels. The rod 16 is tied off to the steel mesh 8 and then concrete is pored over the deck to lock together these elements of the bridge.

In the preceding description and the following claims the word "comprise" or equivalent variations thereof is used in an inclusive sense to specify the presence of the stated feature or features. This term does not preclude the presence or addition of further features in various embodiments.

It is to be understood that the present invention is not limited to the embodiments described herein and further and additional embodiments within the spirit and scope of the invention will be apparent to the skilled reader from the examples illustrated with reference to the drawings. In particular, the invention may reside in any combination of features described herein, or may reside in alternative embodiments or combinations of these features with known equivalents to given features. Modifications and variations of the example embodiments of the invention discussed above will be apparent to those skilled in the art and may be made without departure of the scope of the invention as defined in the appended claims.

Claims

What we claim is:

1. A method of constructing a bridge used to span an obstacle

characterised by the steps of:

i. locating a first set of foundation blocks on one side of an

obstacle, and

ii. locating a second set of foundation blocks on the opposite side of the obstacle, and

iii. connecting together an array of spanning panels to form a deck, and

iv. connecting a first end of the deck to the first set of foundation blocks and connecting a second end of the deck to the second set of foundation blocks, and

v. pouring a settable material over the deck.

2. A method of constructing a bridge as claimed in claim 1 wherein

concrete is the settable material poured over the deck.

3. A method of constructing a bridge as claimed in claim 2 wherein each of the first and second sets of foundation blocks are deployed end to end in a line where the length of this line approximates the width of the bridge to be formed.

4. A method of constructing a bridge as claimed in claim 2 or claim 3

wherein at least one side flange is engaged with the exposed

perimeter edge of one or more spanning panels which define one side of the deck.

5. A method of constructing a bridge as claimed in claim 4 wherein said at least one side flange extends upwards above the spanning panels to present a barrier to concrete pored over the deck.

6. A method of constructing a bridge as claimed in claim 4 or claim 5

wherein a plurality of side flange elements are connected along both sides of the deck along the length of the deck.

7. A method of constructing a bridge as claimed in any one of claims 2 to 6 wherein a reinforcing structure is applied on to the upper surface of the deck prior to concrete being pored over the deck.

8. A method of constructing a bridge as claimed in claim 7 wherein the reinforcing structure is formed from a steel mesh.

9. A method of constructing a bridge as claimed in claim 8 wherein the steel mesh applied above the spanning panels is connected to each set of foundation blocks prior to concrete being pored over the deck.

10. A method of constructing a bridge as claimed in any one of claims 2 to 9 wherein a pair of side retaining walls are constructed to bracket the edges of the deck prior to concrete being pored over the deck.

11. A method of constructing a bridge as claimed in claim 10 wherein the side walls extend upwards above the surface of the deck to form a guard rail.

12. A method of constructing a bridge as claimed in any one of claims 2 to 11 wherein the deck is covered by filler material to form a ramp onto the apex of the deck after concrete is poured over the deck.

13. A bridge construction kit set which includes a plurality of spanning panels arranged for connection together to form a deck, and a plurality of foundation blocks arranged to connect to the deck to form a bridge.

14. A bridge construction kit set as claimed in claim 13 wherein a

foundation block is formed from a precast concrete.

15. A bridge construction kit set as claimed in claim 14 wherein a

foundation block includes reinforcing materials.

16. A bridge construction kit set as claimed in any one of claims 13 to 15 wherein a foundation block includes at least one lifting projection.

17. A bridge construction kit set as claimed in claim 16 wherein a lifting projection is formed by a steel reinforcing bar bent into the form of a staple set into the foundation block.

18. A bridge construction kit set as claimed in claim 16 or claim 17

wherein the terminal ends of the lifting projection extend at least half way through the block.

19. A bridge construction kit set as claimed in any one of claims 13 to 18 wherein each foundation block defines a continuous central channel which extends at least through each end face of the block and along the top face of the block.

20. A bridge construction kit set as claimed in any one of claims 13 to 19 wherein the top face of a foundation block defines a locating recess.

21. A bridge construction kit set as claimed in any one of claims 13 to 20 wherein a spanning panel has a substantially curved rectangular shape.

22. A bridge construction kit set as claimed in any one of claims 13 to 21 wherein a spanning panel is formed from steel sheet material.

23. A bridge construction kit set as claimed in any one of claims 13 to 22 wherein the perimeter of each spanning panel defines an upturned lip.