WO2019090374A1

WO2019090374A1 - Method for producing a bridge support of a prestressed concrete bridge

Info

Publication number: WO2019090374A1
Application number: PCT/AT2018/060266
Authority: WO
Inventors: Johann Kollegger; Sebastian Maier; Stephan FASCHING; Tobias Huber
Original assignee: Kollegger Gmbh
Priority date: 2017-11-07
Filing date: 2018-11-06
Publication date: 2019-05-16

Abstract

The method for producing a prestressed bridge support (1) of hollow-box-shaped cross section from prefabricated segments (3) comprises the following work steps: - producing a first segment (3) from slabs (7) of reinforced concrete, wherein the slabs (7) have ribs (8) which are designed to be normal to the centre plane of the slabs (7); - producing at least one transverse frame (20) in the first segment (3) by the force-fitting and flexurally rigid connection of the ribs (8) in frame corners (26); - producing further segments (3) in the same way; - moving the segments (3) to an installation site (11); - assembling the segments (3) to form a bridge support (1); - bringing the bridge support (1) into the final position (12) and - applying layers (9) of reinforced concrete to the slabs (7) of the segments (3).

Description

Method for producing a bridge girder of a prestressed concrete bridge

The invention relates to a method for producing a bridge girder of a prestressed concrete bridge and to bridge girders produced by this method.

Prestressed concrete bridges were typically made with the final concrete sections.

The construction of in situ concrete bridges according to the cantilever method is described in US 2,963,764. The bridge girder is made starting from a pier on both sides in sections. Usually, two sections with the final cross-sectional dimensions are concreted in one week.

The construction of a bridge with prefabricated reinforced concrete segments is described in US 5,577,284. The trough-shaped segments have the final cross-sectional dimensions and are placed on trusses with a crane. When all trough-shaped segments are mounted, tendons are installed and tense within the concrete section of the segments. The tensioning of the tendons causes a load-bearing bridge carrier to be formed from the individual segments.

The erection of a bridge of prefabricated segments made of ultra high strength concrete slabs is described in CN 205152771 U. To make a segment, two wall panels, the bottom panel, and the top panel in the corners of the segment are bonded together with in-situ concrete. After joining the segments frame structures are formed in the segment joints lying within the hollow box. The bridge girder has a low dead weight, because the wall plates are made of ultra-high strength concrete and therefore can be made very thin. A disadvantage of the construction described in CN 205152771 U is that the bridge girder is manufactured with the final cross-sectional dimensions. In the case of CN 205152771 U, transverse frames are formed in the segment joints. This requires making the cross frame after joining the segments to a bridge girder. This procedure is more complicated than a production of the frame in the production of the segments and thus represents a further disadvantage of the CN 205152771 U dar.

A disadvantage of the construction of a bridge with the final cross-sectional dimensions is that in the construction conditions already affects the entire weight of the bridge girder. This can lead to the fact that the cross-sectional dimensions of the final bridge structure must be chosen due to the stresses in the construction conditions. It can also be disadvantageous that the supports of the bridge girder in the condition of construction must be designed for the entire dead weight of the bridge girder. In order to reduce the dead weight of the bridge girder in the construction state, also construction methods for bridges have been developed in which after the preparation of the bridge girder a cross-sectional complement is performed with in-situ concrete.

The construction of a bridge of thin-walled prefabricated beams with a trough-shaped cross-section is described in the publication "Building bridges using the balanced lift method" by Johann Kollegger et al., In the journal "Structural Concrete", Vol. 15, 2014, pages 281-291. The trough-shaped cross-section consists of two wall plates and a bottom plate. In the vicinity of the upper edges of the wall panels reinforcing bars are welded to the lattice girders arranged in the wall panels. The connection of the wall panels by the reinforcing bars contributes to a stiffening of the trough-shaped cross-section. In addition, a bandage, which also consists of reinforcing bars, is welded onto these reinforcing bars. The thin-walled precast beams are mounted in a vertical position according to the method described in DE 10 2006 039551 and brought by a folding operation in a horizontal position. Subsequently, a filled concrete is introduced into the precast beams with trogförmigem cross-section and the deck plate is made with a composite formwork car.

A support with a trough-shaped cross section is also shown in FIG. 13 of WO 2016 037 864. The wall plates of the carrier are formed by the two plates of a double wall. In the vicinity of the upper edges of the wall plate, a connecting element, which consists of a steel profile with an angular cross-section, arranged. This connecting element serves to receive the concreting pressure during the introduction of the filling concrete into the carrier consisting of thin-walled plates. In addition, this connecting element serves to stiffen the trough-shaped cross section during the transport and assembly operations.

Box-shaped cross-sections are much better suited for absorbing bending and torsional loads than trough-shaped cross sections. Therefore, in FIG. 14 of WO 2016 037 864 a box-shaped cross-section is also shown which has two webs of double walls, a bottom plate and a cover plate. A bending load due to its own weight can be absorbed much better by this box-shaped cross-section than by a trough-shaped cross-section. A disadvantage of the cross section shown in FIG. 14 of WO 2016 037 864, however, is that the two wall panels of a double wall are connected to one another only by lattice girders arranged parallel to the lower and upper edges of the double wall. The lattice girders serve as connecting elements between the two wall panels and are dimensioned so that they can accommodate the concreting pressure arising during the filling of the concrete in the cavity between the two wall panels. The fasteners are usually also sized for stresses that occur when lifting and moving a double wall. However, the cross section shown in FIG. 14 of WO 2016 037 864 is not in capable of absorbing shear stresses in the lands formed by, for example, applying a layer of reinforced concrete to the floor slab or to the cover slab. It is also disadvantageous in the cross section shown in FIG. 14 of WO 2016/037864 that the upper reinforcement for a layer of reinforced concrete applied to the floor slab must be passed through the inner wall slabs of the double walls, which results in a considerable increase Expenses for making holes or slots in the inner wall panels of the double walls is connected.

A cross section corresponding to FIG. 14 of WO 2016 037 864 is also shown in FIG. 1 of the publication "Bridge girders out of hollow wall elements and ultra-thin precast elements", 10th International PhD Symposium in Civil Engineering, Quebec, Canada, 2014 of Sara Foremniak is formed between the lower edges of the double walls, a rib which is connected to the bottom plate, formed between the upper edges of the top plate a rib which is connected to the cover plate, the wall plates of the double walls are only on the In the figures of this publication it can be seen that the wall panels of a double wall are interconnected by connecting means formed in one segment as a lattice girder and in a segment other than steel shafts, lattice girders and steel shafts are common connection means in a double wall, whose function is the inclusion of concreting pressure s is during the filling of the concrete in the arranged between the inner and the outer wall plate cavity. The cross-section shown in this publication is incapable of absorbing shear stresses in the lands caused, for example, by the application of a layer of reinforced concrete to the floor slab or deck slab.

A disadvantage of the segments shown in this publication is also that the lower edges of the inner wall panels are arranged in the bottom plate. This results in a considerable effort for performing an upper reinforcement of a layer of reinforced concrete on the bottom plate through the inner wall panels in the cavities between the inner and outer wall panels.

Further examples of segment bridges in which a cross-sectional completion takes place in the final position are described in KR 10140525 Bl, in JP 20061159730 A and in JP 2005023684 A. The KR 10140525 Bl shows a method in which is formed by the connection of prefabricated wall elements, a segment with trough-shaped cross section on a mounting station. The individual segments become one with two end blocks containing the tendon anchors and cross frames in the segment joints One-field carrier joined together. In the final position, the cross-sectional supplement is made by producing a cover plate from a precast slab with a concrete layer.

JP 20061159730 A shows a method in which two wall panels are set up to make a segment, a reinforced concrete floor panel is formed between the lower edges of the wall panel, and the upper edges of the wall panels are connected by a cross member. After joining the segments to form a bridge girder, a concrete slab is formed in the final layer.

JP 2005023684 shows a method for producing a bridge with the clock shift method. On an assembly site, the bottom plate, then the wall panels, then transverse frames are produced with oblique pressure struts and finally arranged between the wall panels part of the cover plate in each construction section first. After hardening of the concrete in the last produced segment of the entire bridge body is moved in the longitudinal direction so far that the assembly space for the production of the next segment is free. After the entire bridge girder has been moved to the final position, the cantilevered parts of the cover plates are produced on the projecting parts of the transverse frames.

A disadvantage of the method described in KR 10140525 Bl, in JP 2006169730 and in JP 2005023684 is that only a small part of the entire cross section is produced by the Ortbetonergänzung in the final position of the bridge girder.

It is therefore an object of the present invention to provide a bridge girder with hollow box-shaped cross-section, in which the ratio of the weight of the bridge girder in the construction state to the weight of the bridge girder in the final state is smaller than in the known embodiments, which has more favorable cross-sectional values than the known bridge girder with trough-shaped cross-sections and capable of absorbing stresses from the application of a layer of reinforced concrete on the floor slab or on the cover slab.

The present invention solves this problem by providing a method for producing a bridge carrier according to claim 1 and by bridge carrier produced according to this method according to claim 22. Advantageous developments of the invention are defined in the subclaims.

An inventive method for producing a prestressed bridge girder with a hollow box-shaped cross section of prefabricated segments is characterized in that for the production of a segment, at least two wall panels having a preferably rectangular shape in a section through the median plane are made of reinforced concrete,

each wall panel having at least one rib, which is formed substantially normal to the median plane of the wall panel, is non-positively connected,

the at least two wall panels are placed on a mounting station so as to be spaced from one another in a sectional plane normal to the longitudinal axis of the segment, and that the ribs are arranged in sectional planes which are at an angle α between 45 ° and 135 ° with the longitudinal axis of the segment; preferably 90 °.

a reinforced concrete floor slab having at least one rib frictionally connected to the floor slab is formed between the lower edges of the wall slabs, the at least one rib being disposed in the floor slab such that the at least one rib of the floor slab and the ribs the wall panels are in one plane,

- The wall panels are connected to the bottom plate by connecting the arranged in the wall plates ribs with the at least one arranged in the bottom plate rib non-positively and rigidly;

- A reinforced concrete cover plate having at least one rib, which is frictionally connected to the cover plate, is formed between the upper edges of the wall plates, wherein the at least one rib in the cover plate is arranged so that the at least one rib of the cover plate and the ribs the wall panels lie in one plane;

- The wall panels are connected to the cover plate by a connector of the arranged in the wall panels ribs with the at least one arranged in the cover plate rib non-positively and rigidly and at least one transverse frame is formed by this connection;

- at least one further segment is produced in the same way;

- The at least two segments are moved to an installation location;

- The at least two segments are assembled at the installation site to a bridge girder;

- The bridge girder is brought into the final position and

- In the final position of the bridge girder in at least one segment on at least two plates, preferably on all plates, preferably in all segments, a layer of reinforced concrete is applied.

Using the method according to the invention, bridge girders can be produced which have a much lower weight in the construction state than in the final state. The construction method according to the invention is particularly advantageous if the course of the bending moments in the bridge girder in the construction state during the manufacture of the bridge girder differs from the course of the bending moments in the final state, as is the case for example with the clock sliding method or the bridge folding method. One with the According to the method of the invention produced bridge girder may, for example, in the construction state have a weight that is only one fifth of the weight of the bridge girder in the final state. This allows significant savings in the number of tendons and supports in the construction state.

In an advantageous embodiment of the method according to the invention segments are joined together at the installation site to pieces of a bridge girder. Subsequently, the sections of the bridge girder are brought into the final position and connected to each other. The low weight of the segments made by the method according to the invention is particularly advantageous in the transport, lifting and assembly operations at the installation site and in the building operations required to bring the bridge girder to its final position.

In the production of the segments, it may be advantageous to frictionally connect the lower edges of the wall panels with the bottom plate. In a variant with double walls, it may be advantageous to frictionally connect the lower edges of the outer wall panels of the double walls with the bottom plate. This allows a transmission of shear forces between the plates along the frictionally connected edges.

In the manufacture of the segments, it may be advantageous to frictionally connect the upper edges of the wall panels with the cover plate. In a variant with double walls, it may be advantageous to non-positively connect the upper edges of the inner wall panels of the double walls with the cover plate. This allows a transmission of shear forces between the plates along the frictionally connected edges.

The joining of the segments to a bridge girder or to a section of a bridge girder can advantageously take place by the tensioning of tendons arranged in the longitudinal direction of the segments. It will be particularly advantageous if more than two segments are joined together by the tensioning of tendons.

It has already been explained that in the method according to the invention, the weight of the bridge girder in the construction state is much lower than in the final state. In the final position of the bridge girder, layers of reinforced concrete can be applied to the bottom plates and / or the wall plates and / or the cover plates of the segments to increase the area, the moment of inertia and the resistance moment of the girder. This cross-sectional complement enhances the static properties of the bridge girder in the final position, and thereby becomes able to remove loads from traffic.

It will be particularly advantageous if the layers of reinforced concrete are applied to the top of the bottom plates and the tops of the cover plates of the segments. The layers of reinforced concrete can be beneficial on the inside or the Outside of the wall panels of the segments are applied. Advantageously, the wall panels are prefabricated in a match-cast method and / or the bottom panel and the cover panel are concreted in the manufacture of a segment in a match-cast method.

Advantageously, the joints between the segments in the assembly of the segments as Vergussfugen with a width of 1mm to 100mm, preferably 10 to 30mm produced.

Advantageously, the faces of the segments are milled and the joints between the segments in the assembly of the segments made as dry joints.

Advantageously, at least two plates of a segment, preferably all plates of a segment having a thickness of between 25 mm and 250 mm, preferably 50 mm to 150 mm, are produced.

To provide bridge girders with variable height or varying width, the segments are made so that the height and / or width within the segments is variable. The production of segments with variable height requires the production of wall panels, which have a trapezoidal shape in the view.

Advantageously, the ribs are made of T-shaped steel girders and the webs of the T-shaped steel girders are partially embedded in the concrete when concreting the slabs.

In an advantageous embodiment of the method according to the invention, the T-shaped steel beams are produced with webs of trapezoidal sheet or corrugated metal.

Advantageously, in the webs of the T-shaped steel carrier recesses, which extend up to the web edges which are not connected to the flange, arranged.

In an advantageous embodiment of the method according to the invention, the ribs are made of truss girders made of steel and the lower chords of the truss girders when concreting the slabs embedded in the concrete.

To save the cost of manufacturing the steel fins, it may be advantageous to make the reinforced concrete fins.

In an embodiment of the method according to the invention with double walls, the outer wall panels of the double walls are formed to the underside of the segments in order not to arrange the joints extending at the bottom of the bridge in the longitudinal direction between the outer wall panels and the bottom plate on the outer sides of the webs. The lower edges of the inner wall panels have a distance, which is between 0mm and 50mm smaller than the thickness of a layer of reinforced concrete, which is applied to the bottom plate, to the top of the thin-walled base plate in the construction state. The outer sides of the outer wall panels are affected by environmental factors such as changing moisture conditions claimed higher than the arranged in the hollow box outer sides of the inner wall panels. Therefore, the concrete cover can be made smaller in the outer sides of the inner wall panels than in the outer wall panels. This results in that the thickness of the inner wall panels can be made smaller than the thickness of the outer wall panels, which is advantageous in terms of the production of light segments as possible. The ribs in the double walls can be advantageously formed from steel sheets, trapezoidal sheets, corrugated sheets, steel profiles, T-shaped steel beams, truss structures or lattice girders. Also, the production of ribs of concrete between the inner and the outer wall plate of a double wall is possible.

In the final position of the bridge girder still concreting work for the introduction of the concrete in the double walls and for the application of layers of reinforced concrete on the floor panels and / or the cover plates and / or the wall panels must be performed. In support of this work, it is advantageous if a carriage for the transport of material and labor in the longitudinal direction of the bridge girder can be moved on the bridge girder. On the upper frame corners support structures can be formed. On the support structures, which can be carried out, for example, similar to the support structures described in WO 2016 187 634, Verschublager be mounted. On the Verschublagern a similar as in WO 2016 187 634 designed carriage can be moved in the longitudinal direction of the bridge.

The frame corners can be advantageously made of sheets and profiles made of steel, which is favorable for the production of a quick connection of the ribs of the double walls with the ribs of the bottom plate and the cover plate. The frame corners can also be made of a pourable building material such as concrete or a grout, if the manufacturing cost of a segment to be reduced and the assembly speed of minor importance.

In order to accelerate the building process, it may be advantageous to at least partially, ideally completely, place the reinforcement arranged in the layers of reinforced concrete at the installation site and / or the installation site. Advantageously, the majority of this reinforcement is laid at the assembly site and at the installation this reinforcement is supplemented by an additional reinforcement at the segment joints.

In an advantageous embodiment of the method according to the invention, the transverse frames have a distance from each other which is at least 0.5 m and at most 10 m and preferably between 1.0 m and 3.0 m. An inventive, longitudinally prestressed bridge girder with hollow-box-shaped cross section of prefabricated segments is characterized in that the bridge girder comprises transverse frames, wherein the transverse frames have a distance from one another which is at least 0.5 m and at most 10.0 m and preferably between 1.0 m and 3 , 0m is located.

In the following the invention will be described with reference to non-limiting exemplary embodiments illustrated in the drawings. In each case show in schematic representations:

1 shows a section through a bridge carrier with trogförmigem cross section, the tensions due to dead weight and the stresses due to a combination of dead weight and bias voltage.

Figure 2 is a section through a bridge girder, the webs are formed by double walls, the tensions due to dead weight and the stresses due to a combination of dead weight and bias.

3 shows a section through a bridge carrier produced by the method according to the invention, the stresses due to its own weight and the stresses due to a combination of dead weight and preload;

4 is a view of two wall panels according to a first embodiment of the invention;

Fig. 5 is a view of four wall panels according to a first embodiment of the invention;

Fig. 6 is a view of four wall plates and a bottom plate of an embodiment according to the invention;

7 is a view of a segment according to a first embodiment of the invention;

8 is a view during the insertion of a bridge carrier of a first embodiment of the invention;

9 shows a view after the insertion of the bridge carrier of a first embodiment according to the invention;

Fig. 10 is a section along the line XX of Fig. 8 and Fig. 9; Figure 11 is a section corresponding to Figure 10 after applying a layer of reinforced concrete on the bottom plate.

Figure 12 is a section corresponding to Figure 11 after the application of a layer of reinforced concrete on the cover plate.

Figure 13 is a section corresponding to Figure 12 after the application of layers of reinforced concrete on the wall panels.

FIG. 14 shows a section corresponding to FIG. 13 after assembly of the pressure struts and the production of the cantilever plates; FIG.

15 shows a view during the production of portions of a bridge girder according to a second embodiment of the invention;

Fig. 16 is a section along the line XVI-XVI of Fig. 15;

FIG. 17 shows detail A of FIG. 16; FIG.

FIG. 18 shows the detail B of FIG. 16; FIG.

19 is a detail corresponding to FIG. 17 after the application of a layer of reinforced concrete on the floor slab and after the assembly of precast slabs;

Fig. 20 is a section along the line XX-XX of Fig. 19;

21 is a view during production of a segment according to a third embodiment of the invention;

Fig. 22 is a view during assembly of a portion of a bridge girder according to the third embodiment of the present invention;

FIG. 23 shows a section through a bridge girder after the application of layers of reinforced concrete; FIG.

FIG. 24 shows a section according to the line XXIV-XXIV of FIG. 22; FIG.

Fig. 25 is a section along the line XXV-XXV of Fig. 23;

Fig. 26 is a view during manufacture of a segment according to a fourth embodiment of the invention;

FIG. 27 shows a section during the production of a bridge carrier according to the fourth embodiment of the invention; FIG.

FIG. 28 is a view of two double walls according to a fifth embodiment of the invention; FIG. FIG. 29 is a view of four double walls according to the fifth embodiment of the present invention; FIG.

Fig. 30 is a view of four double walls and a bottom plate according to the fifth embodiment of the invention;

FIG. 31 is a view of a segment according to the fifth embodiment of the present invention; FIG.

FIG. 32 is a view during insertion of a bridge carrier according to the fifth embodiment of the present invention; FIG.

33 is a view after the insertion of the bridge carrier according to the fifth embodiment of the invention;

Fig. 34 is a section along the line XXXIV- XXXIV of Fig. 32 and Fig. 33;

Figure 35 is a section corresponding to Figure 34 after the application of a layer of reinforced concrete on the bottom plate.

FIG. 36 shows a section corresponding to FIG. 35 after the application of a layer of reinforced concrete on the cover plate; FIG.

FIG. 37 shows a section corresponding to FIG. 36 after the filling of concrete into the double walls; FIG.

FIG. 38 shows a section corresponding to FIG. 37 after assembly of the pressure struts and the production of the cantilever plates; FIG.

39 is a view during the production of parts of a bridge girder according to a sixth embodiment of the invention;

Fig. 40 is a section along the line XL-XL of Fig. 39;

FIG. 41 shows detail C of FIG. 40; FIG.

Fig. 42 shows the detail D of Fig. 40;

Fig. 43 is a detail corresponding to Fig. 41 after the application of a layer of reinforced concrete on the floor slab;

Fig. 44 is a section taken along the line XLIV-XLIV of Fig. 43;

FIG. 45 is a view during manufacture of a bridge carrier according to a seventh embodiment of the present invention; FIG. FIG. 46 shows a view corresponding to FIG. 45 after the positioning of a section at the installation location; FIG.

FIG. 47 shows a view corresponding to FIG. 46 during the displacement of a further section of the bridge girder from the assembly site to the installation location; FIG.

Fig. 48 is a section along the line XLVI I l-XLVI 11 of Fig. 45 and

Fig. 49 shows the detail E of Fig. 47, wherein the section between the wall panels of the double walls has been performed.

Reference will first be made below to FIGS. 1 to 3, in which the static load-bearing behavior of different cross-sections for a bridge girder 1 is examined. The three cross sections illustrated in FIGS. 1 to 3 have a height of 2.0 m and a width of 1.0 m.

Fig. 1 shows a trough-shaped cross section of a bridge girder 1, as shown in Fig. 13 in WO 2016 037 864. The thickness of the wall panels 4 is 50mm. The thickness of the bottom plate 5 is equal to 200mm. The area of this cross-section is 0.380m ² , the moment of inertia 0.144m ⁴ , the moment of resistance at the top of the wall plates 4 -0.101m ³ , the moment of resistance at the bottom of the bottom plate 0.251m ³ and the radius of gyration 0.616m. The center of gravity is 0.574m from the bottom of the bottom plate 5. In the bottom plate 5, 5, two tendons 15 are arranged in the vicinity of the wall plates 4 at a distance of 0.15 m from the bottom of the bottom plate. A positioning of the tendons 15 in the vicinity of the wall panels 4 is favorable because in this way deflection forces and anchoring forces of the tendons 15 can be introduced into the wall panels 4 with only slight bending stresses of the bottom plate 5.

The weight of the trough-shaped cross section is 9.5 kN / m when the weight is assumed to be 25 kN / m ³ . For a single-span bridge girder 1 with articulated mounting at the end points, a length of 40 m and the trough-shaped cross section according to FIG. 1, a bending moment of 1900 kNm results due to dead weight in the middle of the field. The tensions due to dead weight in mid-field of the bridge girder 1 are -18.8MPa at the top and +7.6MPa at the bottom. A prestressing force of 1750 kN applied with the two tendons 15 is required in order to ensure that the cross-section in the middle of the field of the bridge girder 1 has no tensile stresses due to its own weight.

Fig. 1 shows that the stress due to the effects of dead weight and bias at the bottom is zero and at the top of a compressive stress of 15.8 MPa is present.

Fig. 2 shows a cross section with four wall panels 4, a bottom plate 5 and a cover plate 6 as shown in FIG. 14 of WO 2016 037 864. Die Dicke des. The thickness of Wall panels 4 is 50mm. The thicknesses of the bottom plate 5 and the cover plate 6 are equal to 100mm. The area of this cross-section is 0.56m ² , the moment of inertia 0.278m ⁴ , the moment of resistance at the top of the top plate 6 -0.278m ³ , the moment of resistance at the bottom of the bottom plate 5 0.278m ³ and the radius of gyration 0.704m. The focus is in half the height of the cross section. At a distance of 0.15 m from the bottom of the bottom plate 5, two tendons 15 are arranged between the wall panels 4. A positioning of the tendons 15 between the wall panels 4 is beneficial because in this way deflection forces and anchoring forces of the tendons 15 can be introduced directly into the wall panels 4 via not shown in FIG. 2 anchor blocks. The coupling of the ducts to the joints 16 between the segments 3 is connected in the example shown in FIG. 2, however, with considerable expenses, because the ducts are between the wall panels 4 and are not accessible. A coupling of the cladding could be done for example by arranged in the wall panels 4 recesses.

The weight of the cross section shown in Fig. 2 is 14.0 kN / m when the weight of the building material is assumed to be 25 kN / m ³ . For a single-span bridge girder 1 with articulated mounting at the end points, a length of 40 m and a cross section according to FIG. 2, a bending moment of 2800 kNm results due to its own weight in the middle of the field. The tensions due to deadweight in the middle of the bridge girder 1 are -10, lMPa at the top and 10, lMPa at the bottom. A prestressing force of 2080 kN applied with the two tendons 15 is required in order to ensure that the cross section in the middle of the field of the bridge girder 1 has no tensile stresses due to its own weight.

Fig. 2 shows that the stress due to the effects of dead weight and bias at the bottom is zero and at the top a compressive stress of -7.4 MPa is present.

Fig. 3 shows a cross section produced by the method according to the invention with two wall plates 4, a bottom plate 5 and a cover plate 6. The thickness of the wall plates 4 is 50mm. The thicknesses of the bottom plate 5 and the cover plate 6 are equal to 100mm. The area of the cross-section is 0.38 m ² , the moment of inertia is 0.229 m ⁴ , the moment of resistance at the top of the cover plate 6 is -0.229 m ³ , the moment of resistance at the bottom of the bottom plate 5 is 0.229 m ³ and the inertia radius is 0.777 m. The focus is in half the height of the cross section. At a distance of 0.15 m from the bottom of the bottom plate 5, two tendons 15 are arranged.

The weight of the cross section shown in Fig. 3 is 9.5 kN / m when the weight of the building material is assumed to be 25 kN / m ³ . For a single-span bridge girder 1 with articulated mounting at the end points, a length of 40 m and the cross section according to FIG. 3, a bending moment of 1900 kNm results due to dead weight in the middle of the field. The tensions due to dead weight in the middle of the bridge girder 1 amount to -8.3 MPa at the Top and 8.3MPa at the bottom. A pretensioning force of 1310 kN applied with the two tendons 15 is required in order to ensure that the cross-section in the middle of the field of the bridge girder 1 has no tensile stresses due to its own weight.

Fig. 3 shows that the stress due to the effects of dead weight and bias at the bottom is zero and at the top of a compressive stress of -6.9 MPa is present.

A comparison of the cross section according to the invention produced in accordance with the invention with the trough-shaped cross section of FIG. 1 shows that both cross sections have the same area and thus for the selected example of the 40m long bridge girder the same bending moment due to dead weight in the middle of the field. For prestressing of the cross section produced by the method according to the invention, however, only a prestressing force of 1310 kN is required in order to ensure that in the middle of the field at the underside of the cross section no tensile stresses occur under load due to its own weight. When trough-shaped cross-section of FIG. 1, the required biasing force is 1750kN (+ 34%). The stresses on the tops of the cross sections due to the effects of dead weight and preload are only -6.9 MPa for the cross section produced by the method according to the invention and -15.8 MPa (+ 129%) for the trough-shaped cross section. The higher prestressing steel consumption and the higher compressive stresses are disadvantageous in the case of a trough-shaped cross section.

2 shows that the cross-section according to FIG. 2, because of the minimum thickness of 50 mm required for the production of wall panels 4, has a higher dead weight and thus a higher one Moment due to dead weight in the middle of the field. Therefore, a much higher biasing force of 2080kN (+ 59%) is required for biasing the bridge beam 1 with the cross section of FIG. The stresses at the top of the cross sections due to the effects of dead weight and biases are only -6.9 MPa for the cross section produced by the method according to the invention and 2 -7.4 MPa (+ 7%) for the cross section according to FIG. The higher prestressing steel consumption and the somewhat higher compressive stresses are disadvantageous in the cross section according to FIG. 2. However, a bridge support 1 with a cross section according to FIG. 2 is advantageous for the production of a layer 9 of reinforced concrete between the inner wall panels 53 and the outer wall panels 54th

In the following embodiments, the bottom plates 5, the cover plates 6 and the wall plates 4 are also referred to as plates 7 when common characteristics of these thin-walled concrete components are described. The plates 7 are connected to ribs 8, which are more accurately referred to in the embodiments in which it serves a clarification, for example as a rib 40 which is connected to a bottom plate, or as a rib 41 which is connected to a cover plate is, or as a rib 50 which is connected to a wall plate, or as a rib 52 in a double wall. In the following exemplary embodiments, the reinforcement arranged in the plates 7 and the layers 9 of reinforced concrete is not shown for the sake of clarity. Reinforcing steel, textile reinforcements and steel or stainless steel components can be used as the reinforcement. The reinforcement can be prestressed. Also fibers made of steel or plastic can be used as reinforcement.

In the following embodiments, the tendons 15 and the anchors and deflections of the tendons 15 are not shown in most cases for clarity. Tendons 15 with subsequent or immediate bond, tendons 15 without composite or external tendons 15 can be arranged.

Reference will first be made below to FIGS. 4 to 14, in which the production of an exemplary bridge girder 1 with a method according to the invention according to a first embodiment is described.

For the production of a first segment 3, two wall panels 4 are placed in a vertical position as shown in FIG. 4 on a mounting place 10. In each wall plate 4, a rib 50, which is non-positively connected to the wall plate 4, is arranged. The ribs 50 are made of T-shaped steel beams 18, the webs 24 are arranged normal to the center planes of the wall panels 4. In the next step, according to FIG. 5, two further wall panels 4, each with a rib 50, are set up on the assembly station 10 such that the median plane of these wall panels 4 is parallel to the median plane of the wall panels 4 erected in the first step and that the outsides of the wall panels 4 are at a distance have to each other, which corresponds to the width of the segment 3. The joints 17 between the wall panels 4 are then filled with a grout.

In the next step, as shown in FIG. 6, a bottom plate 5 is formed between the lower edges 13 of the wall panels 4. The surface of the assembly station 10 is equipped in this example with a formwork 21, so that the bottom plate 5 can be made in situ concrete on the assembly station 10. The wall panels 4 have at the lower edges 13 connection reinforcements, which are connected by in-situ concrete with the reinforcement of the bottom plate 5. The connection of the wall panels 4 with the bottom plate 5 is statically advantageous because it shear forces between the lower edges 13 of the wall panels 4 and the bottom plate 5 can be transmitted. Arranged in the bottom plate 5 ribs 40 are connected to the arranged in the wall panels 4 ribs 50 in frame corners 26 frictionally and rigidly.

In the next step, as shown in FIG. 7, two prefabricated cover plates 6 each having a rib 41 are mounted. The ribs 41 with the arranged at the ends frame corners 26 each have a length which is greater than the width of the cover plates 6. The ribs 41 of the cover plates 6 are placed in the assembly process on the arranged in the wall panels 4 ribs 50 and with these positively and rigidly connected. Due to the rigid connection of the arranged in the wall panels 4 ribs 50 with the arranged in the bottom plates 5 and in the cover plates 6 ribs 8 in the frame corners 26 in the segment 3 two transverse frames 20 are formed. These transverse frames 20 are so stiff that they give the segment 3 sufficient rigidity for later lifting, transporting and assembly operations. The transmission of shear forces between the cover plate 6 and the wall plates 4 takes place in this example on the transverse frame 20. The transverse frame 20 are in this example in planes that include an angle of 90 ° with the longitudinal axis of the segment 3.

For reasons of clarity, the production of a segment 3 from four wall panels 4, one floor panel 5 and two cover panels 6 is shown in FIGS. 4 to 7. However, it would also be possible with the inventive method because of the use of prefabricated panels 7 to produce a much longer segment 3, for example, twenty wall panels 4, one floor panel 5 and ten cover panels 6 within a week. In compliance with the customary in the application of the clock shift method weekly clock construction time could be significantly shortened and the number of couplings for the tendons 15 can be reduced in this way.

Fig. 8 shows the preparation of a bridge girder 1 with segments 3 of thin-walled plates 7 and transverse frame 20 with the clock shift method. The sectioned segments 3 shown in FIGS. 4 to 7 are positioned at the right end of the bridge girder 1 and connected with tendons 15 to the already existing part of the bridge girder 1. Subsequently, the bridge girder 1 is shifted to the left by the length of the last mounted segment 3. The mounting of the segments 3 and displacement of the bridge girder 1 is repeated until the left end of the bridge girder 1 reaches the abutment 33 arranged in FIG. 8 and FIG. 9 on the left side.

Particularly advantageous in the application of the method according to the invention in this example is that the weight of the bridge girder 1 during construction, during the displacement of the bridge girder 1, is small, because the segments 3 consist of thin-walled plates 7, which are stiffened by transverse frame 20.

The cross-section shown in FIG. 10, despite its low weight, is sufficiently rigid to absorb the stresses occurring during the insertion of the bridge girder 1. Once the bridge girder 1 has reached its final position 12, it is possible to start applying layers 9 of reinforced concrete to the plates 7. According to FIG. 11, a layer 9 of reinforced concrete in the statically required thickness is first applied to the base plate 5. The weight of the layer 9 of reinforced concrete is removed from the bottom plate 5 of the segment 3 via bending in the longitudinal direction of the bridge girder 1 and introduced into the transverse frame 20. About the transverse frame 20, the weight of the layer 9 of reinforced concrete is introduced into the bridge girder 1 and removed via the arranged on the pillars 34 and abutments 33 warehouse. The thickness of the bottom plate 5 can be 80mm, for example are performed when the transverse frames 20 have a distance of 2m and the sum of the thicknesses of the bottom plate 5 and the layer 9 of reinforced concrete is 250mm.

In the next step, according to FIG. 12, a layer 9 of reinforced concrete is applied to the cover plate 6. The removal of the weight of the layer 9 of reinforced concrete is advantageously carried out over the cover plate 6 in the longitudinal direction of the bridge girder 1 and then on the transverse frame 20. After hardening of the layer 9 of reinforced concrete on the cover plate 6, the cover plate 6 and the layer 9 are made reinforced concrete monolithically connected to each other and form a piece of the deck slab 22nd

In the next step, as shown in FIG. 13, layers 9 of reinforced concrete are applied to the insides of the wall panels 4. The application of the concrete can be done for example with shotcrete. Alternatively, a formwork can be constructed in the interior of the bridge girder 1 and the concrete can be filled by means of a concrete pump from the top of the carriageway slab 22. The pressure of the fresh concrete must be absorbed by the formwork mounted inside the bridge girder 1 and by the wall plates 4. The wall panels 4 direct the concreting pressure over bending to the transverse frame 20.

In the next step, according to FIG. 14, the pressure struts 23 and the projecting parts of the roadway slab 22 are produced. Finally, a seal is applied to the top of the deck slab 22 and a pavement is produced.

The production of an exemplary bridge girder 1 with the method according to the invention in accordance with a second embodiment is shown in FIGS. 15 to 20.

FIG. 15 shows the vertical assembly of segments 3 for producing two sections 2 of a bridge girder 1 according to the method described in US Pat. No. 7,996,944 B2. In this method, it is of great importance that the weight of the sections 2 of the bridge girder 1 during the folding process is as small as possible in order to produce the joints and the lifting devices economically. Even during the lifting operations and vertical mounting of the segments 3, a lower weight of the segments 3 is advantageous. The joints 16 between the segments 3 can be formed as dry joints 16, when the end face of the segments 3 are machined by a milling process so that they have a precisely fitting surface.

FIG. 16 shows that the sections 2 of the bridge girder 1 consist of segments 3, which are formed from thin-walled plates 7. The bottom plate 5, the cover plate 6 and the two wall plates 4 are connected to ribs 8. Due to the rigid connection of the ribs 8 creates a transverse frame 20, which serves to stiffen a segment 3. The ribs 8 have recesses 19, which reduce the weight of the ribs 8 and are favorable for the laying of a longitudinally arranged in the segments 3 and laid on the plates 7 reinforcement. The connection of the rib 50 of the wall plate 4 with the rib 40 of the bottom plate 5 in the left lower frame corner 26 of Fig. 16 is shown in Fig. 17 in an enlarged scale. The ribs 8 consist of T-shaped steel beams 18 which have recesses 19 in the webs 24. FIG. 17 shows that the webs 24 of the T-shaped steel girders 18 are partially embedded in the concrete of the wall plate 4 and the bottom plate 5. As a result, the ribs 8 are connected to the wall plate 4 and the bottom plate 5 in a shear-resistant manner, which is favorable for absorbing bending moments in the transverse frame 20, because the ribs 8 and part of the plates 7 act as a common component. For better connection of the webs 24 of the T-shaped steel beams 18 with the plates 7 24 reinforcing rods can be welded to the embedded in the concrete part of the webs. In the frame corner 26 of the transverse frame 20, the ribs 8 are welded to additional steel plates 28. With screw 27 and embedded in the bottom plate 5 connection reinforcement of the wall plate 4, it is possible to produce a rigid frame corner 26, which can accommodate both positive and negative bending moments.

The connection of the rib 50 of the wall plate 4 with the rib 41 of the cover plate 6 in the left upper frame corner 26 of Fig. 16 is shown in Fig. 18 in an enlarged scale. The ribs 8 are provided to form the frame corner 26 with additional steel plates 28 which are welded to the ribs 8. With screw 27, a rigid connection of the arranged in the wall plate 4 rib 50 can be made with the arranged in the cover plate 6 rib 41. To form a rigid frame corner 26, which is suitable for the transmission of positive and negative moments, it will be necessary to weld part of the reinforcing steel reinforcement arranged in the wall plate 4 and in the cover plate 6 to the steel plate 28.

FIG. 19 shows a detail corresponding to FIG. 17 in a later construction state after unfolding the sections 2 of the bridge girder 1 and applying a layer 9 of reinforced concrete to the floor slab 5. For producing the layer 9 of reinforced concrete on the wall slabs In this example, thin-walled prefabricated panels 30 made of ultra high-strength concrete with a textile reinforcement are inserted from the upper side of the bridge girder 1 in such a way that each precast slab 30 rests on the flanges 25 of two T-shaped steel girders 18.

A section through two prefabricated panels 30 and a wall panel 4 is shown in FIG. It may be advantageous to place sealing strips 29 between the prefabricated panels 30 and the flanges 25 of the T-shaped steel girders 18 to ensure that no concrete can escape into the interior of the bridge girder 1 when the layer 9 of reinforced concrete is formed on the wall panels 4. The introduction of the concrete into the cavity 31 formed by the wall panels 4 and the prefabricated panels 30 can take place by means of a concrete pump from the top of the carriageway panel 22. The pressure of the fresh concrete can be absorbed by the wall panels 4 and the precast panels 30 and directed to the transverse frames 20. The webs 24 of the T-shaped steel beams 18 have anchoring elements 32 in order to safely accommodate the concreting pressure in the To allow transverse frame 20. As anchoring elements 32 reinforcing bars can be used, which are welded to the web 24 of a T-shaped steel beam 18 and embedded in the wall plate 4

The production of an exemplary bridge girder 1 with the method according to the invention according to a third embodiment is described in FIGS. 21 to 25.

The wall panels 4 are made in this example in a match-cast process. In this method, the end face of the last produced component serves as a part of the formwork 21 for the next component. By this manufacturing method, it is possible to prefabricate the segments 3 and add to the installation site 11 with a dry joint 16 or a joint 16 with a thin Epoxidharzschicht together.

FIG. 21 shows a construction state in which two wall panels 4 produced by the match casting method are set up and connected with a dry joint 16 to an already finished segment 3. The bottom plate 5 of a segment 3 to be produced was concreted against the bottom plate 5 of the already completed segment 3 in a match-casting process. The ribs 8 are made of reinforced concrete in this example. After the base plate 5 has been produced, the rib 40 connected to the base plate 5 via a connecting reinforcement is concreted and joined to the ribs 50, which are connected to the wall plates 4, in a force-fitting and rigid manner.

In the next step, the cover plate 6 is produced in a match-cast process. At the same time connected to the cover plate 6 rib 41 is produced. The rib 41 connected to the cover plate 6 is arranged below the cover plate 6 in this example. About a arranged in the ribs 50 of the wall plate 4 connection reinforcement the rib 41 of the cover plate 6 is non-positively and rigidly connected to the ribs 50 of the wall plate 4.

At the assembly location 10, six segments 3 are joined together to form a section 2 of a bridge girder 1 with tendons 15 arranged in the longitudinal direction of the bridge girder 1. Fig. 22 shows a construction state in which a portion 2 of the bridge girder 1 is superimposed on an abutment 33 and the pillar 34 and the second portion 2 of the bridge girder 1 with two cranes, which are not shown in FIG. 22 for clarity, lifted becomes.

The transverse frames 20 formed by the ribs 8 are in this example arranged in planes which enclose an angle α of 90 ° with the longitudinal axes 36 of the segments 3.

Fig. 23 shows a construction state after applying layers 9 of reinforced concrete on the floor panels 5 and the cover plates 6. On the wall panels 4 of the segments 3, no layer 9 of reinforced concrete is applied in this example. To produce a roadway slab 22, a layer 9 of reinforced concrete is applied to the cover plates 6 of all segments 3. On the bottom plate 5 is in this example only in the area of the centered pillar 34 applied a layer 9 of reinforced concrete to increase the height of the pressure zone in the range of negative moments.

Fig. 24 shows a cross section through a portion 2 of the bridge girder 1, during the lifting. The segments 3 of the section 2 consist of wall panels 4, bottom plates 5 and cover plates 6 and are stiffened by transverse frame 20.

FIG. 25 shows a cross section through the bridge girder 1 in the final layer 12 after the application of layers 9 of reinforced concrete on the cover plates 6 in all segments 3 and the bottom plates 5 of two segments 3.

The production of an exemplary bridge girder 1 with the method according to the invention according to a fourth embodiment is shown in FIG. 26 and FIG. 27.

FIG. 26 shows the production of a segment 3. The wall panels 4 have a trapezoidal shape in the view. The height of the wall panels 4 changes in the longitudinal direction of the segment 3. The ribs 50 of the wall panels 4 are connected to the ribs 40 of the bottom panel 5. The ribs 8 lie in a plane which is not normal to the longitudinal axis of the segment 3.

The section in FIG. 27 shows that the ribs 8 are inclined at an angle α to the longitudinal axis 36 of the segments 3. The angle α in FIG. 27 is approximately 120 °. FIG. 27 shows the production of a prestressed concrete bridge 35 according to the cantilever method. Four segments 3 are already mounted and form part of the bridge girder 1. In this example, the operation in which the girder 1 is brought into the final layer 12 is eliminated because the segments 3 are mounted in the final layer 12. The segments 3 could be raised, for example, with cranes positioned on the ground, positioned at the end of the cantilevers and connected with tendons 15 to the already manufactured part of the bridge girder 1. The low weight of the segments 3 produced by the method according to the invention is particularly favorable for the rapid implementation of the lifting operations and for a reduction in the number of required tendons 15 for fixing the segments 3 in comparison to the conventional segment construction method.

A possible manufacturing variant would be the joining of several segments 3 to a section 2 of a bridge girder 1 and the lifting and mounting of this section 2. As a result, the number of lifting and clamping operations could be reduced and the construction process can be accelerated.

The production of an exemplary bridge girder 1 with a method according to the invention in accordance with a fifth embodiment is shown in FIGS. 28 to 38.

For the production of a first segment 3 according to FIG. 31, two double walls 51 are set up in a vertical position according to FIG. 28 on an assembly site 10. In every double wall 51 is a rib 52 which is frictionally connected to the inner wall plate 53 and the outer wall plate 54, respectively. The ribs 52 are made of T-shaped steel beams 18, the webs 24 are arranged normal to the center planes of the double walls 51.

In the production of a double wall 51, the flange 25 of the T-shaped steel beam 18 can be welded to the reinforcement of the first prepared wall plate 4. After filling and hardening of the concrete for producing the first wall plate 4 of a double wall 51, in a horizontal position, the double wall is turned and the web 24 of the T-shaped steel beam 18 is pressed into the fresh concrete of the second wall plate 4. After hardening of the concrete of the second wall plate 4, the two wall panels 4 are connected to each other by the T-shaped steel beam 18. The flange 25 of the T-shaped steel beam 18 opposite side of the web 24 may be formed as a dowel strip with a profiling to improve the thrust connection between the T-shaped steel beam 18 and the second wall plate 4. If it is required to accommodate the concreting pressure that results when filling the concrete in the cavity 31 between the inner wall plate 53 and the outer wall plate 54, additional connecting elements can be installed in the production of the double wall 51.

In the next step, according to FIG. 29, two further double walls 51, each with a rib 52, are set up on the assembly station 10 such that the center planes of these double walls 51 are parallel to the center planes of the double walls 51 erected in the first step and that the outer sides of the outer wall plates 54 have a distance from one another which corresponds to the width of the segment 3. The joints 17 between the wall panels 4 of the double walls 51 are then filled with a grout.

In the next step, as shown in FIG. 30, a bottom plate 5 is formed between the lower edges 13 of the double walls 51. The surface of the assembly station 10 is equipped in this example with a formwork 21, so that the bottom plate 5 can be made in situ concrete on the assembly station 10. The outer wall panels 54 of the double walls 51 have at the lower edges 13 connection reinforcements, which are connected by in-situ concrete with the reinforcement of the bottom plate 5. The connection of the double walls 51 with the bottom plate 5 is statically advantageous because it shear forces between the lower edges 13 of the double walls 51 and the bottom plate 5 can be transmitted. Arranged in the bottom plate 5 ribs 40 are connected to the arranged in the double walls 51 ribs 52 in frame corners 26 frictionally and rigidly.

In the next step, according to FIG. 31, two prefabricated cover plates 6, each with a rib 41, are placed on the inner wall plates 53 and mounted. The ribs 41 with the arranged at the ends frame corners 26 each have a length which is greater than the width of the cover plates 6. The ribs 41 of the cover plates 6 are placed in the assembly process on the arranged in the double walls 51 ribs 52 and with these in the frame corners 26 positively and rigidly connected. By the rigid connection of the ribs 52 arranged in the double walls 51 with the ribs 40 arranged in the bottom plates 5 and the ribs 41 arranged in the cover plates 6 in the frame corners 26, two transverse frames 20 are formed in the segment 3. These transverse frames 20 are so stiff that they give the segment 3 sufficient rigidity for later lifting, transporting and assembly operations. The transmission of shear forces between the cover plate 6 and the double walls 51 takes place in this example on the transverse frame 20. Alternatively, a connection between the cover plates 6 and the inner wall panels 53 of the double walls 51 could be made to shear forces between the cover plates 6 and the double walls 51 to transfer. This connection could be done, for example, by welding in the cover plates 6 and in the inner wall panels 53 of the double walls 51 inserted fixtures. The transverse frames 20 lie in this example in planes which form an angle of 90 ° with the longitudinal axis 36 of the segment 3. On the upper frame corners 26, which are made of steel in this embodiment, support structures 37 are attached. The support structures 37 may be made of steel tubes and welded to the top of the upper frame corners 26. On the support structures 37 Verschublager 38 are attached, which allow the movement of a carriage 39 used in subsequent steps in the longitudinal direction of the bridge girder 1.

For the sake of clarity, the production of a segment 3 from four double walls 51, a bottom plate 5 and two cover plates 6 is shown in FIGS. 28 to 31. However, it would also be possible with the method according to the invention to produce a much longer segment 3, for example, of twenty double walls 51, one base plate 5 and ten cover plates 6 within one week. In compliance with the usual in the application of the clock shift method weekly clock construction time could be significantly shortened and the number of couplings for the tendons can be reduced in this way.

Fig. 32 shows the preparation of a bridge girder 1 with segments 3 of double walls 51, thin-walled plates 7 and transverse frame 20 with the clock shift method. The sectioned segments 3 shown in FIGS. 28 to 31 are positioned at the right end of the bridge girder 1 and connected with tendons 15 to the already existing part of the bridge girder 1. Subsequently, the bridge girder 1 is shifted to the left by the length of the last mounted segment 3. The mounting of the segments 3 and displacement of the bridge girder 1 is repeated until the left end of the bridge girder 1 reaches the abutment 33 arranged in FIG. 32 and FIG. 33 on the left side.

FIGS. 32 and 33 show that support structures 37 and Verschublager 38 are mounted on the bridge girder 1. On the Verschublagern 38, as shown in FIG. 33, a carriage 39 are moved in the longitudinal direction of the bridge girder 1.

Particularly advantageous in the application of the method according to the invention in this example is that the weight of the bridge girder 1 in the construction state, during the displacement of the bridge girder 1, is small, because the segments 3 consist of thin-walled plates 7, which are stiffened by transverse frame 20.

The cross section illustrated in FIG. 34, despite its low weight, is sufficiently rigid to absorb the stresses occurring during the insertion of the bridge girder 1. Once the bridge girder 1 has reached its final position 12, it is possible to start applying layers 9 of reinforced concrete to the plates 7. According to FIG. 35, a layer 9 of reinforced concrete in the statically required thickness is first applied to the base plate 5. For introducing the layer 9, a carriage 39 can be used for the transport of the concrete and the workers. The carriage 39 is thereby moved on the Verschublagern 38 in the longitudinal direction of the bridge girder 1 and positioned at the installation site 11 for carrying out the concreting work. The weight of the layer 9 of reinforced concrete is removed from the bottom plate 5 of the segment 3 via bending in the longitudinal direction of the bridge girder 1 and introduced into the transverse frame 20. About the transverse frame 20, the weight of the layer 9 of reinforced concrete is introduced into the bridge girder 1 and removed via the arranged on the pillars 34 and abutments 33 bearing 44. The thickness of the bottom plate 5 may be made 80mm, for example, when the transverse frames 20 are spaced 2m apart and the sum of the thicknesses of the bottom plate 5 and the reinforced concrete layer 9 is 250mm.

In the next step, according to FIG. 36, a layer 9 of reinforced concrete is applied to the cover plate 6. The removal of the weight of the layer 9 of reinforced concrete is advantageously carried out over the cover plate 6 in the longitudinal direction of the bridge girder 1 and then on the transverse frame 20. After hardening of the layer 9 of reinforced concrete on the cover plate 6, the cover plate 6 and the layer 9 are made reinforced concrete monolithically connected to each other and form a piece of the deck slab 22nd

In the next step, as shown in FIG. 37, concrete is filled into the cavities 31 of the double walls 51. The concreting pressure is absorbed by the inner wall panels 53 and the outer wall panels 54 and forwarded to the ribs 52. In addition, if it is required statically, connecting members may be provided between the inner wall panels 53 and the outer wall panels 54 for receiving the concreting pressure.

In the next step, according to FIG. 38, the pressure struts 23 and the projecting parts of the roadway slab 22 are produced. Also, for the mounting of the struts 23 and the production of the projecting parts of the deck plate 22, the use of the carriage 39 may be advantageous. Finally, a seal is applied to the top of the deck slab 22 and a pavement is produced.

The production of an exemplary bridge girder 1 with the method according to the invention in accordance with a sixth embodiment is shown in FIGS. 39 to 45. FIG. 39 shows the vertical assembly of segments 3 for producing two sections 2 of a bridge girder 1 according to the method described in US Pat. No. 7,996,944 B2. In this method, it is of great importance that the weight of the sections 2 of the bridge girder 1 during the folding process is as small as possible in order to produce the joints and the lifting devices economically. Even during the lifting operations and vertical assembly of the segments 3, a low weight of the segments 3 is advantageous. The joints 16 between the segments 3 can be formed as dry joints 16, when the end face of the segments 3 are machined by a milling process so that they have a precisely fitting surface.

FIG. 40 shows that the sections 2 of the bridge girder 1 consist of segments 3 which are formed from thin-walled plates 7 and double walls 51. In this embodiment, the double walls 51 and the thin-walled plates 7 are prefabricated to increase the mounting speed. FIG. 40 shows that the rib 40 connected to the bottom plate 5 and the rib 41 connected to the top plate 6 are connected to the ribs 52 of the double walls 51 in the frame corners 26. Due to the rigid connection of the rib 40, the rib 41 and the ribs 52 in the frame corners 26 creates a transverse frame 20, which serves to stiffen a segment 3. The ribs 40, which are connected to the bottom plates 5, and the ribs 41, which are connected to the cover plates 6, have recesses 19 which reduce the weight of the ribs 40 and the ribs 41 and favorable for laying a longitudinal direction Segments 3 are arranged and laid on the bottom plates 5 and the cover plates 6 reinforcement. The ribs 52 in the double walls 51 are formed by lattice girders 56. The diameter of the lattice girder 56 must be chosen so large that no buckling can occur under pressure stresses in the diagonal bars. In this embodiment, the inner wall plate 53, which has lower demands on the concrete cover due to the more favorable Eurocode exposure class, is made smaller in thickness than the outer wall plate 54 to reduce the weight of the segment 3.

The connection of the rib 52 of the double wall 51 with the rib 40 of the bottom plate 5 in the left lower frame corner 26 of Fig. 40 is shown in Fig. 41 in an enlarged scale. The rib 40, which is connected to the bottom plate 5, consists of a T-shaped steel beam 18, which has recesses 19 in the webs 24. Fig. 41 shows that the web 24 of the T-shaped steel beam 18 is partially embedded in the concrete of the bottom plate 5. As a result, the rib 40 is connected to the bottom plate 5 in a shear-resistant manner, which is favorable for absorbing bending moments in the lower part of the transverse frame 20, because the rib 40 and part of the bottom plate 5 act as a common component. For better connection of the web 24 of the T-shaped steel beam 18 with the bottom plate 5 24 reinforcing rods can be welded to the embedded part of the web in the concrete. In the frame corner 26 of the transverse frame 20, the rib 40 of the bottom plate 5 is welded to an additional steel plate 28. At the end of the arranged in the double wall 51 rib 52 is a steel plate 28 in the concrete of the inner wall plate 53 and the outer Wall plate 54 embedded and anchored. When connecting the bottom plate 5 to the outer wall plate 54 of the double wall 51, a longitudinal joint 55 is formed because the two thin-walled plates 7 are prefabricated. After joining the bottom plate 5 and the outer wall plate 54, the longitudinal joint 55 is filled with a grout. With screw 27, it is possible to produce a rigid framework corner 26, which can accommodate both positive and negative bending moments.

The connection of the rib 52 of the double wall 51 with the rib 41 of the cover plate 6 in the left upper frame corner 26 of Fig. 40 is shown in Fig. 42 in an enlarged scale. The ribs 41 are equipped to form the frame corner 26 with additional steel plates 28. With screw 27, a rigid connection of the arranged in the double wall 51 rib 52 can be made with the arranged in the cover plate 6 rib 41. To form a rigid frame corner 26, which is suitable for the transmission of positive and negative moments, it will be necessary to weld part of the reinforcing steel reinforcing steel arranged in the double wall 51 and in the cover plate 6 to the steel plates 28.

FIG. 43 shows a detail corresponding to FIG. 41 in a later construction state after unfolding of the sections 2 of the bridge girder 1 and the application of a layer 9 of reinforced concrete on the floor slab 5. The application of the layer 9 of reinforced concrete becomes Base plate 5 rigidly connected to the double wall 51. In this embodiment, the distance from the bottom of the inner wall plate 53 to the top of the bottom plate 5 is smaller by 20 mm than the thickness of the layer 9 of reinforced concrete applied to the bottom plate 5. The inner wall plate 53 is therefore embedded on its underside in the layer 9 of reinforced concrete.

A section through the double wall 51 is shown in FIG. 44. The introduction of the concrete into the cavity 31 formed by the inner wall plate 53 and the outer wall plate 54 can take place by means of a concrete pump from the upper side of the roadway plate 22. The pressure of the fresh concrete is absorbed by the inner wall plate 53 and the outer wall plate 54 and introduced into the lattice girder 56, which forms part of the transverse frame 20.

The production of an exemplary bridge girder 1 with the method according to the invention according to a seventh embodiment is described in FIGS. 45 to 49.

In this example, the manufacture of a bridge girder 1 with a displacement machine 42 will be explained. In the English language, such a translation engine 42 is referred to as a launching gantry or erection gantry. Fig. 45 shows how a portion 2 of the bridge girder 1, which is fastened with tension members 43 on the displacement machine 42, is lowered. For the sake of clarity, the segments 3 and the joints 16 between the segments 3 in FIGS. 45 to 47 are not shown. The section 2 is lowered so that a horizontal distance a remains between the suspended on the transfer unit 42 section 2 and the last mounted section 2. By this horizontal distance a between the end faces of the sections 2, a working space is created, which allows coupling of the tendons 15. The tendons 15, which consist of tension wire strands 46, transition pieces 48, sheaths and anchors are already installed in the suspended on the Versetzmaschine 42 section 2. The tension wire strands 46 protrude from the right end of the section 2. After coupling the tendons 15, the attached to the Versetzmaschine 42 segment 3 is moved to the right and the joint 16 between the sections 2 closed.

According to FIG. 46, additional tension members 43 are mounted in the next work step. The tension members 43 may be attached to the support structures 37. In the next step, layers 9 of concrete are applied to the bottom plate 5 and the cover plate 6 and concrete is introduced into the cavities 31 in the double walls 51. The additional tension members 43 serve to support the section 2 during the concreting process. After the partial hardening of the introduced at the installation site concrete, after a period of, for example, 6 to 48 hours, the tension members 43 are removed and the weight is absorbed by the bridge girder 1.

In the next step, the displacement machine 42 is moved to the left as shown in FIG. 47 by one field. The weight of the displacement machine 42 is introduced into the pillars 34 via brackets 45, which are mounted laterally on the pillars 34. FIG. 47 shows that a further section 2 is delivered. The section 2 is mounted during the horizontal displacement along the bridge girder 1 on the Verschublagern 38 mounted on the upper side of the Auflagerkonstruktionen 37. Fig. 47 shows a state in which tension members 43 are mounted on the left end of the section 2 just supplied. The tension members 43 are tensioned after assembly to a predetermined force in order to minimize the load on the last filled with concrete section 2 of the bridge carrier during the following feed. Subsequently, the section 2 is moved so far to the left until the tension members 43 can be mounted at the right end of the section 2. After assembly of the tension members 43 at the right end of the section 2, the section 2 is raised and transported to the left until one of Fig. 45 corresponding position is reached.

FIG. 48 shows a section through a section 2 which is fastened with tension members 43 to the displacement machine 42. The cross section through the section 2 shows a transverse frame 20 through which the double walls 51 are connected to the bottom plate 5 and the cover plate 6. On the upper frame corner 26 Auflagerkonstruktionen 37 are secured with Verschublagern 38. The support structures 37 may be used to secure the tension members 43. It can also be seen in FIG. 48 that the supports of the displacement machine 42 are arranged on brackets 45. The brackets 45 may consist of steel profiles which are fastened laterally to the pillar 34 with tension rods. The brackets 45 and the tie rods are reusable elements that can be disassembled after passing over the Versetzwagen 39. FIG. 49 shows a section through two sections 2 of the bridge girder. Between the wall panels 4 of the double walls 51 of the right section 2 concrete was introduced. The right section 2 is almost completely provided with layers 9 of reinforced concrete on the bottom plate 5 and the cover plate 6. Only in a region with the length b at the left end of the already concreted section 2 has no concrete been applied to the bottom plate 5 and the cover plate 6, because in this area the connection reinforcement between the two sections 2 is housed.

In the right-hand portion 2 of FIG. 49, an anchoring block 49 made of concrete with a steel plate 28 and a transition piece 48 is arranged between the wall plates 4 of the double walls 51. In the tensioning of the arranged in the right portion 2 clamping member 15, the biasing force of the clamping member 15 is transferred to the steel plate 28 and from there to the anchoring block 49. The coupling of the tendons 15 is carried out by the usual method in the working space, which is formed by the distance a shown in Fig. 45. After coupling the tension wire strands 46, as already described in the explanation of Fig. 45, the left portion 2 is moved to the right. In this movement, a relative displacement between the tension wire strands 46 and the cladding tube in the left part 2 takes place. The tight connection of the transition piece 48 to the prestressed in the right portion 2 clamping member 15 is achieved in that a steel ring 47 which is fixed in the left portion 2, to the steel plate 28 which is fixed in the right part 2, is pressed. It would also be possible to insert an annular seal of sponge rubber between the steel ring 47 and the steel plate 28 to assure a tight connection between the tendons 15. Establishing a tight connection between the tendons 15, which are arranged in the left and right section 2, is important because when introducing the concrete into the cavity 31 between the wall panels 4 no concrete must penetrate into the tendon 15.

In the examples, the production of prestressed bridge girders 1 having a box-shaped cross-section has been described with the tact shift method, the bridge folding method, the cantilever method, with a crane mounting and with a displacement machine 42. Analogously, the inventive method can also be used for the production of bridge girders with other construction methods.

In the examples, the preparation of the bottom plate 5 has been described before the manufacture of the cover plate 6. It is also possible with the method according to the invention to produce the cover plate 6 in front of the base plate 5 or the base plate 5 and the cover plate 6 at the same time.

In the examples, the production of plates 7 with attached ribs 8 has been described. It is also possible with the method according to the invention to form the ribs 8 within the thickness of the plates 7. In the examples, the production of the layers 9 of reinforced concrete was described in one operation. However, it is also possible with the method according to the invention to produce a layer 9 by the staggered production of several thin concrete layers.

In the examples, the preparation of bridge girders 1 has been described, which correspond in their static behavior to a continuous carrier. However, it is also possible with the method according to the invention to build bridge girders 1, which correspond in their static load behavior to a single-span girder or a frame structure.

In the examples, the production of segments 3 of constant width and variable height has been described, which have a rectangular shape in a section normal to the longitudinal axis 36 of the segment 3. However, it is also possible with the method according to the invention to build segments 3 which, in a section normal to the longitudinal axis 36 of the segment 3, have a trapezoidal shape. Such a trapezoidal cross-section need not be symmetrical.

List of reference numbers:

1 bridge girder

2 section of a bridge girder

3 segment

4 wall plate

5 base plate

6 cover plate

7 plate

8 rib

9 layer of reinforced concrete

10 mounting place

11 installation location

12 Final location

13 Lower edge of a wall plate

14 Upper edge of a wall plate

15 tendon

16 joint between two segments or between two segments

17 Fugue between two plates within a segment

18 T-shaped steel girder

19 recess in a rib

20 transverse frames formwork

carriageway

strut

Bridge of a T-shaped steel girder

Flange of a T-shaped steel girder

frame corner

screw

steel plate

sealing tape

Precast concrete slab

cavity

anchoring element

abutment

pier

prestressed concrete bridge

longitudinal axis

support construction

Verschublager

dare

Rib connected to a bottom plate Rib connected to a top plate Offset machine

tension member

warehouse

console

Spanndrahtlitze

steel ring

Transition piece

anchoring block

Rib connected to a wall plate. Double wall

Rib in a double wall

Inner wall plate

Outer wall plate

longitudinal joint

girder

Claims

claims

1. A method for producing a prestressed bridge girder with hollow box-shaped cross-section of prefabricated segments, characterized in that

- For the production of a first segment (3) at least two wall plates (4), which in a section through the median plane preferably have a rectangular shape, are made of reinforced concrete;

- each wall plate (4) having at least one rib (50) which is formed substantially normal to the median plane of the wall plate (4), is positively connected;

- The at least two wall panels (4) are placed on a mounting station (10) so that they are in a sectional plane normal to the longitudinal axis of the segment (3) spaced from each other and that the ribs (50) are arranged in sectional planes, with the longitudinal axis of the segment (3) enclose an angle α between 45 ° and 135 °, preferably 90 °;

a bottom plate (5) made of reinforced concrete having at least one rib (40) which is frictionally connected to the bottom plate (5) is formed between the lower edges (13) of the wall plates (4), the at least one rib (40 ) is arranged in the bottom plate (5) so that the at least one rib (40) of the bottom plate (5) and the ribs (8) of the wall plates (4) lie in one plane;

- The wall panels (4) with the bottom plate (5) by connecting the in the wall plates (4) arranged ribs (50) with the at least one in the bottom plate (5) arranged rib (40) in frame corners (26) non-positively and rigidly get connected;

- A cover plate (6) made of reinforced concrete with at least one rib (41) which is frictionally connected to the cover plate (6), between the upper edges (14) of the wall plates (4) is formed, wherein the at least one rib (41 ) the cover plate (6) is arranged so that the at least one rib (41) of the cover plate (6) and the ribs (50) of the wall plates (4) lie in a plane;

- The wall panels (4) with the cover plate (6) by connecting the in the wall plates (4) arranged ribs (50) with the at least one in the cover plate (6) arranged rib (41) in frame corners (26) non-positively and rigid be connected and at least one transverse frame (20) is formed by these compounds;

- at least one further segment (3) is produced in the same way; - The at least two segments (3) are moved to a mounting location (11);

- The at least two segments (3) are joined together at the installation site (11) to form a bridge girder (1);

- The bridge girder (1) is brought into the final position (12) and

- In the final position (12) of the bridge girder (1) in at least one segment (3), preferably in all segments (3), on at least two plates (7) preferably on all plates (7), a layer (9) reinforced concrete is applied.

2. The method according to claim 1, characterized in that in each case at least two segments (3) at the installation site to pieces (2) of a bridge girder (1) are joined together, the sections (2) of the bridge girder (1) in the final position (12 ) and connected with each other.

3. The method according to any one of claims 1 or 2, characterized in that the wall plates (4) at the lower edges (13) with the bottom plate (5) and / or at the upper edges (14) with the cover plate (6) non-positively get connected.

4. The method according to any one of claims 1 to 3, characterized in that the joining of the at least two segments (3) to a bridge girder (1) or a portion (2) of a bridge girder (1) by the clamping of preferably in the longitudinal direction of the segments (3) arranged tendons (15).

5. The method according to any one of claims 1 to 4, characterized in that a layer (9) made of reinforced concrete on the cover plate (6) and / or on the bottom plate (5) and / or on the inner sides of the wall plates (4) and / or on the outer sides of the wall panels (4) is applied.

6. The method according to any one of claims 1 to 5, characterized in that the wall panels (4) are prefabricated in a match-cast process and / or the bottom plate (5) and / or the cover plate (6) in the manufacture of a segment ( 3) in the match-casting process.

7. The method according to any one of claims 1 to 5, characterized in that the joints (16) between the segments (3) in the assembly of the segments (3) as Vergussfugen with a width of 1 mm to 100 mm, preferably 10 to 30 mm, are produced.

8. The method according to any one of claims 1 to 5, characterized in that the end faces of the segments (3) are milled and the joints (16) between the Segments (3) are produced in the joining of the segments (3) as dry joints.

9. The method according to any one of claims 1 to 8, characterized in that at least two plates (7) of a segment (3), preferably all plates (7) of a segment (3), with a thickness between 25 mm and 250 mm, preferably 50 mm to 150 mm.

10. The method according to any one of claims 1 to 9, characterized in that a segment (3) with wall plates (4) having a non-uniform height and / or bottom plates (5) and / or cover plates (6) with a non-uniform width will be produced.

11. The method according to any one of claims 1 to 10, characterized in that the ribs (8) are made of T-shaped steel beams (18) and the webs (24) of the T-shaped steel beams (18) during concreting of the plates (7 ) are partially embedded in the concrete, wherein the webs (24) are made of trapezoidal sheet or corrugated metal.

12. The method according to claim 11, characterized in that in the webs (24) of the T-shaped steel beam (18) recesses (19) which extend up to the web edges, which are not connected to the flange (25) extend, to be ordered.

13. The method according to any one of claims 1 to 10, characterized in that the ribs (8) of truss girders or lattice girders (56) are made of steel and the lower chords of the truss girder or the girder (56) when concreting the plates (7). be embedded in the concrete.

14. The method according to any one of claims 1 to 10, characterized in that the ribs (8) are made of reinforced concrete.

15. The method according to any one of claims 1 to 14, characterized in that in the layers (9) of reinforced concrete arranged reinforcement on the mounting station (10) at least partially, preferably completely laid.

16. The method according to any one of claims 1 to 15, characterized in that the transverse frame (20) have a distance from each other which is at least 0.5 m and at most 10 m and preferably between 1.0 m and 3.0 m.

17. The method according to any one of claims 1 to 16, characterized in that at least one wall plate (4) as a double wall (51) with at least one rib (52), which is arranged substantially normal to the median plane of the double wall (51) and both with the inner wall plate (53) of the double wall (51) and with the outer wall plate (54) of the double wall (51) is non-positively connected, and that the lower edge (13) of the inner wall plate (53) has a distance between Omm and 50mm smaller than the thickness of a layer (9) of reinforced concrete applied to the bottom plate (5) to the upper side the bottom plate (5).

18. The method according to claim 17, characterized in that in at least one double wall (51), the inner wall plate (53) is made with a smaller thickness than the outer wall plate (54).

19. The method according to any one of claims 17 or 18, characterized in that a rib (52) in a double wall (51) as a steel sheet, trapezoidal sheet, corrugated iron, steel profile, T-shaped steel beams (18), truss structure, lattice girder (56) or made of concrete.

20. The method according to any one of claims 17 to 19, characterized in that an outer wall plate (54) of a double wall (51) at the lower edge (13) with the bottom plate (5) and / or that an inner wall plate (53) of a double wall (51) at the upper edge (14) with the cover plate (6) is non-positively connected.

21. The method according to any one of claims 1 to 20, characterized in that on frame corners (26) support structures (37) are arranged with arranged on the top Verschublagern (38) and on the Verschublagern (38) a carriage (39) and / or Pieces (2) of the bridge girder (1) are moved in the longitudinal direction of the prestressed concrete bridge (35).

22. prestressed bridge girder (1) with a hollow box-shaped cross-section of prefabricated segments (3), wherein the bridge girder (1) was produced by a method according to one of claims 1 to 21, characterized in that the bridge girder (1) transverse frame (20) , wherein the transverse frames (20) have a distance from each other which is at least 0.5m and at most 10m, and preferably between 1.0m and 3.0m.