Note : Les descriptions sont présentées dans la langue officielle dans laquelle elles ont été soumises.
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Method and Apparatus for Bridge Construction
FIELD OF THE INVENTION
[Para 1] The present invention is directed to an apparatus for use in
constructing a
bridge and a method for constructing a bridge.
BACKGROUND OF THE INVENTION
[Para 2] The main elements of the type of bridge to which the invention
is directed
are: (a) a substructure; and (b) a superstructure.
[Para 3] A substructure is comprised of (1) foundations and (2) piers.
The
foundations are the components of the substructure that engage or interact
with the earth to
support the bridge structure. A foundation can be constructed of one or more
piles, one or
more concrete drilled shafts, one or more concrete mats, and combinations
thereof
Presently, piles include precast concrete piles and steel piles. The piers are
the components
of the substructure that transfer the bridge structural loads to the
foundations. A pier can be
constructed of columns, struts, pile caps, pier caps, and combinations thereof
Presently,
columns include cast in place columns, precast concrete columns, and steel
columns.
[Para 4] A superstructure carries the traffic load (vehicular, rail,
and/or pedestrian)
on the bridge. A superstructure can be constructed using girders that each
typically span the
distance between two adjacent piers. Presently, girders include precast
concrete girders, cast
in place girders, precast concrete box girders, segmental box girders, steel
girders, and steel
box girders. Some superstructures use two or more different types of girders.
[Para 5] Presently, there are several methods of constructing a bridge
comprised of
a substructure and a superstructure (hereinafter referred to as a "bridge") in
situations in
which there is limited access from the ground. Characteristic of each method
is the use of
one or more conventional cranes that are each capable of rotating a boom about
horizontal
and vertical axes to either move an element of bridge into place or manipulate
a tool that is
used in constructing the bridge. One method employs a crane that is positioned
on top of and
near the end of the existing superstructure to position a pile driver and a
pile beyond the end
of the superstructure so that the pile can be driven into the earth to form
the next foundation.
Typically, a second crane is used to provide piles to the pile driver
associated with the first
crane, construct the pier that engages the pile or piles of the foundation
established by the
first crane, and construct the, either alone or in combination with the first
crane, the
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superstructure. A drawback associated with this method is that the piers must
be spaced
relatively close together due to the construction loads imposed upon the
bridge by the crane,
the pile driver, and the pile.
[Para 6] Another method for constructing a bridge when the bridge is
being built
over a watercourse or wetland involves using a temporary structure that
extends outside the
footprint of the resulting bridge to support cranes and the like that are used
in constructing the
bridge and, in particular, the substructure of the bridge. In many case, the
temporary support
structure adversely affects the portions of the watercourse or wetland that
are outside the
footprint of the bridge. Typically, the temporary support structure supports a
first crane to
which a pile driver has been attached, a second crane for loading a pile into
the pile driver
associated with the first crane, a third crane for constructing a pier on each
of the foundations
established by the first and second cranes, and a fourth crane for putting the
girders in place
between adjacent piers. In some cases, the third and/or fourth crane are
replaced with a
moveable gantry or truss that spans the distance between at least two adjacent
piers and is
located above and substantially parallel to the superstructure to construct
the piers and
establish girders between adjacent piers.
[Para 7] Also associated with the construction of bridges is the
attachment of L-
shaped form to the outer-most lateral girders and the subsequent pouring of
concrete into the
forms to establish an L-shaped concrete member along the lateral edges of the
superstructure.
These L-shaped members typically facilitate the establishment of barriers
along the lateral
edges of the superstructure and serve to contain the concrete or other fluid
material that is
used to establish the superstructure deck.
SUMMARY OF THE INVENTION
[Para 8] The present invention is directed to an apparatus and method
for use in
constructing a bridge that substantially avoids the need for a temporary
support structure for
cranes and other machinery and/or the need to use conventional cranes to
manipulate the
main elements of the substructure and superstructure that are used to form the
bridge.
[Para 9] In one embodiment, the apparatus is comprised of: (a) a truss
structure that
extends from a first end to a second end, (b) a support structure that, in
operation, supports
the truss structure such that a portion of the truss structure is above and
substantially parallel
to the superstructure or planned location of a portion of the superstructure,
(c) a trolley that,
in operation, is supported by the truss structure, capable of hoisting an
object associated with
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the building the bridge, and movable between the ends of the truss structure,
(d) a lead
assembly that, in operation, is operatively attached to the truss structure
and comprises a lead,
a pivot joint for pivotally connecting the lead to the truss structure, and an
actuating system
for causing the lead to pivot to a desired rotation position. When the lead is
in a predefined
position, the lead is capable of receiving an object from the trolley. For
example, the lead can
receive a pile from the trolley and rotate the pile to place the pile in the
desired rotational
orientation for establishing a pier.
[Para 101 Another embodiment of the apparatus comprises a lead assembly
that
comprises a lead, a pivot joint for pivotally connecting the lead to the truss
structure, an
actuator system for causing the lead to pivot to a desired rotational
position, and a tool that is
operatively attached to the lead. In one embodiment, the tool is a hammer that
is used to
drive a pile that is held by the lead into the ground. In another embodiment,
the tool is a drill
that is used in drilling a hole for accepting a portion of a pile or in
drilling a hole for a
concrete drilled shaft, i.e., a concrete pile that is formed by excavating a
hole within a casing
that has been hammered or otherwise driven into the ground, filling the hole
with concrete,
and subsequently removing the casing. Yet a further embodiment comprises a
conveyor
system that is used to remove the earth that the drill excavates from a hole
that is being
established in the ground.
[Para 111 Yet a further embodiment of the apparatus comprises a lead, a
two-axis
pivot joint for connect the lead to the truss structure and allowing the lead
to be rotated about
a first axis and a second axis, an actuator system for causing the lead to
rotate about the first
and second axes to desired rotational positions relative to the first and
second axes. The
ability to rotate the lead about two axes allows foundations that have
battered piles (i.e., piles
that are oriented other than plumb) to be constructed, as well as foundations
that have plumb
piles, and to compensate for various misalignments or variations in the
orientation of the truss
structure.
[Para 12] One embodiment of the method of constructing a bridge comprises
providing a bridge building apparatus that comprises (a) a truss structure
that extends from a
first end to a second end, (b) a trolley that is operatively attached to the
truss structure,
capable of hoisting an object, and movable between the first and second ends
of the truss
structure, (c) a lead that is operatively attached to the truss structure and
capable of being
rotated between a first position at which the lead is capable of receiving an
object from the
trolley and a second position. The method further comprises positioning the
bridge building
apparatus so that a portion of the truss structure is above and substantially
parallel to a
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portion of the superstructure or planned location of a portion of the
superstructure. The
method further comprises placing the lead in the first position, using the
trolley to move a
substructure related element so that the substructure related element is
received by the lead,
and rotating the lead so that lead and the substructure related element to an
orientation
suitable for positioning the substructure related element to aid in the
construction of the
bridge.
[Para 13] In an embodiment of the method in which the substructure
related element
is a pile, the method further comprises lowering the pile until the pile
engages the ground and
then hammering the pile into the ground. Similarly, in an embodiment in which
the
substructure related element is a casing for use in casting a concrete shaft,
the method further
comprises lowering the casing until the casing engages the ground and then
hammering the
casing into the ground.
[Para 14] An embodiment of the method in which the substructure related
element is
a pier column further comprises lowering the pier column until the pier column
engages a
pre-established foundation or pier structure. Similarly, an embodiment of the
method in
which the substructure related element is column form or casing for use in
casting a pier
column, the method further comprises lower the casing until the form or casing
engages a
pre-established foundation or pier structure.
[Para 15] Yet another embodiment of the method comprises using the
trolley to
position a girder between two adjacent piers.
[Para 161 A further embodiment of the method comprises: (a) providing a
bridge
building apparatus that include a truss structure, trolley, and lead that can
be rotated to a
position at which the lead can receive a substructure related element, (b)
positioning the truss
structure above and substantially parallel to a portion of the superstructure
or a planned
location for a portion of the superstructure, (c) positioning, if needed, the
truss structure so
that the lead can be used to put in place a substructure element, (d) using
the trolley and the
lead to position a substructure element, (e) positioning, if needed, the truss
structure so that
the trolley can be used without the lead to position a substructure element or
a superstructure
element, (f) using the trolley to position a substructure element or
superstructure element.
[Para 17] The present invention is also directed to a pre-cast edge
girder, i.e. a girder
that is used is the outer-most lateral girder in a bridge. The pre-cast edge
girder is comprised
of a laterally extending portion and an vertical extending portion that is
operatively connected
to the laterally extending portion thereby forming an L-shaped edge girder.
Since the L-
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shaped edge girder is pre-cast, the need to use forms to establish an L-shaped
concrete
member along the lateral edges of the superstructure is avoided.
BRIEF DESCRIPTION OF THE DRAWINGS
[Para 18] Fig. 1 illustrates the components of an embodiment of an
apparatus that is
useful in assembling a bridge;
[Para 19] Fig. 2 illustrates a first position of the apparatus shown in
Fig. 1 in which
the apparatus has been used to establish girders and deck between a first pair
of pier
structures and a lead pier structure;
[Para 20] Fig. 3 illustrates the repositioning of the supports of the
apparatus shown
in Fig. 1 so that the truss can be repositioned and then used to erect girders
between the lead
pier structure and the penultimate pier structure and to establish a new lead
pier structure;
[Para 211 Fig. 4 illustrates the repositioning of the truss of the
apparatus shown in
Fig. 1 so that girders can be erected between the lead pier structure and the
penultimate pier
structure and a new lead pier structure can be established;
[Para 22] Fig. 5 illustrates the delivery of a girder that is to be
placed between the
lead pier structure and the penultimate pier structure;
[Para 23] Fig. 6 illustrates the use of the trolley to erect the girder
shown in Fig. 5
between the lead pier structure and the penultimate pier structure;
[Para 24] Fig. 7 illustrates a complete set of girders extending between
the lead pier
structure and the penultimate pier structure;
[Para 25] Fig. 8 illustrates the delivery of a pile for the new lead pier
structure;
[Para 26] Fig. 9 illustrates the use of the trolley to lower the pile
shown in Fig. 8
onto the pile driver lead and hammer assembly;
[Para 27] Fig. 10 illustrates the rotation of the pile driver lead and
hammer assembly
and the pile held by the assembly;
[Para 28] Fig. 11 illustrates the use of the pile driver lead and hammer
assembly to
lower the pile so that the distal end of the pile engages the earth into which
the pile is to be
driven;
[Para 29] Fig. 12 illustrates the establishment of several piles in the
new lead pier
structure;
[Para 301 Fig. 13 illustrates the use of the trolley to establish a first
half of a pier cap
form or pre-cast shell on top of several of the piles of the new lead pier
structure;
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[Para 31] Fig. 14 illustrates the use of the trolley to establish a second
half of a pier cap
form or pre-cast shell on top of several of the piles of the new lead pier
structure;
1Para 32] Fig. 15 illustrates the use of the trolley to load rebar and
concrete into the pier
cap form or pre-cast shell established on top of the new lead pier structure;
[Para 331 Fig. 16A-C illustrates an embodiment of a lead assembly that
comprises a
lead, a hydraulic system that is used to rotate the lead, a hammer that is
attached to the lead,
and a winch for adjusting the position of the hammer on the lead;
[Para 341 Fig. 17 illustrates an embodiment of a pile collar clamp for holding
a pile in a
fixed position relative to the pile driver lead and hammer assembly during
rotation of the pile
driver lead and hammer assembly;
[Para 351 Figs. 18A and 18B illustrate alternative devices for holding a pile
or similar
structure in place on a lead;
[Para 361 Fig. 19 illustrates a portion of a lead assembly that includes a
drill for
excavating a hole for a pile, concrete drilled shaft, or similar structure;
[Para 371 Fig. 20 illustrates a system for the removal of drill tailings
produced by the
operation of the drill illustrated in Fig. 19;
[Para 38] Fig. 21 is a perspective view of the guide box of the system
illustrated in Fig.
20;
[Para 39] Fig. 22 illustrates a lead with a ground engaging structure that can
be extended
to contact the ground so as to reduce the force being applied to the end of
the truss structure
when a heavy object, such as a pile, is being positioned to be driven into the
ground;
[Para 401 Fig. 23 illustrates an alternative embodiment lead assembly that
utilizes a
cable, pulley, and winch system to rotate a lead;
[Para 41] Fig. 24 illustrates an alternative embodiment of a device that is
suitable for
rotating a lead in a plane that is transverse to the longitudinal axis of the
truss structure;
[Para 421 Fig. 25 illustrates a prior-art edge form that is used to establish
an L-shaped
concrete member along the lateral edge of a bridge superstructure; and
[Para 43] Fig. 26 illustrate a pre-cast edge girder that avoids the need to
use the prior art
edge form shown in Fig. 25.
DETAILED DESCRIPTION
[Para 44] The present invention is directed to an apparatus for use in bridge
construction
that is comprised of: (a) a truss structure, (b) a support structure for
supporting
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the truss structure such that a portion of the truss structure is above and
substantially parallel
to a portion or planned portion of a superstructure of a bridge, (c) a trolley
structure that is
supported by the truss structure and used to move materials used to build the
bridge, and (d) a
lead assembly that is operatively attached to the truss structure and
comprised of a rotatable
lead that is capable of receiving a object from the trolley that is useful in
constructing the
bridge.
[Para 45] Figure 1 illustrates an embodiment of the bridge construction
apparatus,
hereinafter referred to as apparatus 50. The apparatus 50 is comprised of: (a)
a truss structure
52; (b) trolley structure 54; (c) a support structure 56; and (d) a lead
assembly 58.
[Para 46] The truss structure 52 is comprised of a first truss 60A and a
second truss
60B that is situated substantially parallel to the first truss 60A. The truss
structure 52 extends
from a first terminal end 61A to a second terminal end 61B. It should be
appreciated that
other truss structures are feasible. For example, a truss structure that is
comprised of a single
truss or a truss structure that is comprised of more than two trusses is
feasible and may be
desirable in certain situations. Further, in contrast to straight character of
the truss structure
52, a truss structure that is curved is feasible and may be desirable if a
bridge design follows
a curve rather than a straight line. Additionally, a truss structure that is
capable of being
modified or articulated so that the truss follows a path that comprised of
combinations of
straight segments, combinations of curved segments, and combinations of
straight and curved
segments is also feasible.
[Para 47] The trolley structure 54 is comprised of four elements: a first
main trolley
62A, a second main trolley 62B, a first auxiliary winch 64A, and a second
auxiliary winch
64B. As illustrated, the first and second main trolleys 62A, 62B, and first
and second
auxiliary winches 64A, 64B, are capable of operating as a single unit, as
separate units, and
as intermediate combinations. The ability to operate the elements of the
trolley system 64A
as separate elements or as one or more combinations of two or more elements
facilitates
many of the bridge building operations of the apparatus 50. Nonetheless, it
should be
appreciated that a trolley system with a different number of elements is
feasible. For
instance, a trolley system comprised of a single trolley is feasible.
[Para 48] The support structure 56 is comprised of a center support 66A,
rear
support 66B, center auxiliary support 68A, and rear auxiliary support 68B.
After the initial
positioning of the supports at the commencement of the bridge construction,
the center and
rear supports 66A, 66B, and the center and rear auxiliary supports 68A, 68B,
must be moved
from one location to another location to facilitate the forward movement of
the truss structure
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52 to a new location. At least the center support 66A and rear support 66B are
moved from
one location to another using the trolley system 54. Typically, the center and
rear auxiliary
supports 68A, 6B are also moved using the trolley system 54. The center
support 66A and/or
the rear support 66B incorporate motors and related structures that engage the
truss structure
52 to move the truss structure 52 relative to the center support 66A and rear
support structure
66B as is known to those in the art that have employed such trusses to
position girders. It
should be appreciated, however, that the incorporation of motors into the
center and rear
supports 66A, 66B is not necessary and that movement of the truss structure
can be
accomplished by other devices, including winches. It should be appreciated
that other
support systems that are capable of supporting the truss structure such that a
portion of the
truss structure 52 is above and substantially parallel to a portion or planned
portion of the
superstructure are feasible. For example, a support system that comprises a
motorized,
tracked or wheeled, rear support can be fixedly attached to the rear of the
truss structure and
thereby eliminate the need for the rear auxiliary support. Other support
structures could
incorporate more supports than the four elements of the support structure 56.
[Para 49] Figure 2 illustrates the apparatus 50 in a first position with
respect to a
bridge 80 that is under construction. The bridge 80 is comprised of a
superstructure 82 and a
substructure 84 that supports the superstructure 82. The substructure 84 is
comprised of
foundations that are each comprised of a series of piles and piers that are
each comprised of a
pier cap that engages the piles of a foundation. The superstructure is
comprised of steel
girders that are of sufficient length to extend between and engage adjacent
pier caps. It
should be appreciated that the bridge 80 is exemplary of the type of bridge
that the apparatus
50 is capable of being used to construct and that the apparatus is capable of
being used to
construct bridges with: (a) foundations that are each comprised of a concrete
precast pile(s), a
concrete drilled shaft(s), a steel structural member(s) or pile(s), a concrete
mat(s), any other
main foundation element known in the art, and combinations thereof, (b) piers
that are each
comprised of cast in place column(s), a precast concrete column(s), a steel
column(s), a
strut(s), a pile cap(s) (precast or cast in place), a pier cap(s) (precast or
cast in place), a bent
cap(s), any other main pier element known in the art, and combinations
thereof, and (c)
superstructures comprised of precast girders, cast in place box girders,
precast box girders,
segmental box girders, hollow slabs, steel girders, steel box girder, any
other main
superstructure elements known in the art, and combinations thereof.
[Para 50] With continuing reference to Fig. 2, for the purpose of
describing the
method in which the apparatus is used to construct a bridge, the substructure
84 is comprised
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of a last or latest pier structure 86 and a first pair of pier structures 88.
The first pair of pier
structures 88 is comprised of a penultimate pier structure 90, i.e., the pier
structure that is
next to the last pier structure 86. Each of the pier structures is comprised
of a plurality of
piles 92 and a pier or pile cap 94.
[Para 51] Figure 3 illustrates the positions to which the center support
66A, rear
support 66B, and the center auxiliary support 68A are moved with the trolley
structure 54 to
enable the truss structure to be repositioned 52 so that girders can be
erected between the lead
pier structure 86 and the penultimate pier structure 90 and a new lead pier
can be established.
Specifically, the center auxiliary supports 68A have been moved forward to a
location just
behind the penultimate pier structure 90. Subsequently, the center support 66A
has been
moved from the penultimate pier structure 90 to the lead pier structure 86.
Subsequently, the
rear support 66B has been moved forward to a location substantially adjacent
to the pier that
precedes the penultimate pier structure 90.
[Para 52] Figure 4 illustrates the repositioning of the truss structure 52
so that girders
can be established between the lead pier structure 86 and the penultimate pier
structure 90
and a new lead pier can be established. The truss structure 52 is moved using
motor
assemblies (not shown) that are associated with the center support 66A, rear
support 66B,
trolley structure 54, and/or an external force applying structure. Movement of
the truss
structure 52 also repositions the center auxiliary supports 68A immediately
behind the center
support 66A and the rear auxiliary supports 68B immediately behind the rear
support 66B.
[Para 53] Figure 5 illustrates the delivery of a girder 100 that is to be
erected
between lead pier structure 86 and the penultimate pier structure 90.
[Para 54] Figure 6 illustrates the use of the first and second main
trolleys 62A, 62B
in lowering the girder 100 into place between the lead pier structure 86 and
the penultimate
pier structure 90. As should be appreciated, the apparatus 50 is used to
position the girder
100 but the establishment of a welded, bolted, or other suitable connection
between the girder
100 is not done by the apparatus 50 but by other means. This is also the case
with other
elements of the bridge.
[Para 55] Figure 7 illustrates the use of the first and second main
trolleys 62A, 62B
in lowering a final girder of a plurality of girders that extend between the
lead pier structure
86 and the penultimate pier structure 90 into place. It should be appreciated
that in
establishing the plurality of girders between the lead pier structure 86 and
the penultimate
pier structure 90, the truss structure 52 moves laterally. The lateral
movement is
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accomplished by motor assemblies associated with the center support 66A and
the rear
support 66B as is known in the art.
[Para 561 Figure 8 illustrates the delivery of a pile 110 that will be
part of a new lead
pier structure that the apparatus 50 will be used to establish at a location
beyond the current
lead pier structure 86.
[Para 57] Figure 9 illustrates the use of the trolley structure 54 to
lower the pile 110
onto the lead assembly 58, which in the illustrated embodiment comprises a
hammer for use
in driving the pile into the ground, a guide system for holding the pile in
the lead and guiding
the pile during the hammering of the pile into the ground, and a winch for
lowering the
hammer and the pile 110 until the pile engages the ground and thereafter
lowering the
hammer as the pile is driven into the ground. The pile 110 is received by a
guide and
engaged by a collar clamp that prevents the pile 110 from slipping during
rotation of the pile
into position for driving into the earth. Further, the pile 110 is positioned
so that an end of
the pile is located adjacent to the hammer that is used to drive the pile into
the earth.
[Para 581 Figure 10 illustrates the use of the lead assembly 58 to rotate
the pile 110
into a position that is suitable for driving the pile 110 into the earth.
[Para 591 Figure 11 illustrates the use of the lead assembly 58 to lower
the pile 110
to the point at which the distal end of the pile 110 engages the earth and can
be driven into
the earth using the hammer associated with the lead assembly 58.
[Para 601 Figure 12 illustrates the apparatus 50 after the lead assembly
58 has been
used to drive several piles that are associated with a yet to be completed,
new lead pier 120
into the earth and the delivery of a first pier cap form or pre-cast shell
122A that will be
placed on top of a number of the piles of the new lead pier 120.
[Para 61] Figure 13 illustrates the use of the first main trolley 62A to
lower the first
pier cap form or pre-cast shell 122A onto several of the piles of the new lead
pier structure
120. Prior to the lowering of the first pier cap form or pre-cast shell 122A
onto the piles, the
hammer associated with the lead assembly 58 was removed from the lead assembly
58. The
removal of the hammer reduces the force that is applied to the truss structure
54 during the
establishment of the pier cap of the new lead pier structure 120. In
appropriate
circumstances, removal of the hammer may not be necessary. In addition, prior
to the
lowering of the first pier cap form or pre-cast shell 122A onto the piles, the
lead portion of
the lead assembly 58 was rotated into the illustrated upright position so as
not to interfere
with the lowering of the first pier cap form or pre-cast shell 122A onto the
piles.
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[Para 62] Figure 14 illustrates the use of the first main trolley 62A to
lower the
second pier cap form or pre-cast shell 122B onto a number of the piles
associated with the
new lead pier structure 120.
[Para 63] Figure 15 illustrates the use of the first main trolley 62A to
lower rebar
and/or cement into the cap form or pre-cast shell created by the first and
second pier cap
forms or pre-cast shells 122A, 122B, thereby establishing the cap 94 of the
now completed,
new lead pier structure 120. At this point, the lead portion of the lead
assembly 58 can be
rotated to a substantially horizontal position so that the hammer can be
reattached to the
assembly 58. Further, upon repositioning the first main trolley 62A and the
first auxiliary
trolley 64A, the apparatus 50 is in substantially the same orientation as
shown in Fig. 2.
Consequently, the process can be repeated to establish girders between the new
lead pier
structure 120 and the now old, lead pier structure 82 and to establish a newer
lead pier
structure beyond the new lead pier structure 120. It should be appreciated
that the sequence
of steps followed in constructing the bridge can be varied. For example, after
the truss
structure 52 is positioned as shown in Fig. 4, the piles could be driven for
the new lead pier
structure 120 before the girders are erected between the lead pier structure
86 and the
penultimate pier structure 90. As another example of a variation in the
sequence of steps
followed in constructing the bridge, the operations of driving a pile for the
new lead pier
structure 120 and the erection of a girder between the lead pier structure 86
and the
penultimate pier structure 90 can be alternated with one another. Typically,
there are several
different operations that can be performed at any given point in time using
the apparatus 50
with the timing of the delivery of elements needed to construct the bridge
typically being
determinative of the operation that the apparatus is used to perform at any
particular point in
time.
[Para 64] With reference to Figs. 16A-C, the lead assembly 58 is
described in greater
detail. The assembly 58 is comprised of a truss or lead 70, a guide 72 for
receiving a pile, a
collar clamp 74 for guiding and gripping a pile, a hammer 76 for repeated
striking of one end
of a pile to drive the pile into the earth, a cord 78 for connecting the
collar 74 to the hammer
76, a cable/pulley/winch system 80 for controlling the position of the hammer
76 relative to
the lead 70, a two-axis pivot joint 82 that connects the lead 70 to the truss
52, and a hydraulic
system 84 for rotating the lead 70 about the pivot joint 82. The two axes of
the pivot joint 82
are typically perpendicular to one another. The guide 72 and the collar clamp
74 preferably
are each of a clam-shell type of design that allows two halves to be separated
so as to receive
a pile from the trolley structure 54.
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[Para 65] In operation, the assembly 58 is initially in a substantially
horizontal
position, as shown in Fig. 16A. To receive a pile, the guide 72 and the collar
74 are placed in
an open position. After a pile has been received, the guide 72 and collar 74
are placed in a
closed position. When the guide 72 and the collar 74 are in the closed
position, the pile is
substantially fixed in a position relative to the lead 70. In this regard, the
collar 74 holds the
pile, and the cord 78 that is connected to the hammer 76 prevents the pile
from moving
longitudinally, i.e. in the direction of the longitudinal axis of the lead 70,
absent movement
allowed by the cable/pulley/winch system 80. The guide 72 and the collar 74
also prevent the
pile from rolling off of the lead 70.
[Para 66] After the pile has been fixed in position relative to the lead
70, the
hydraulic system 84 is used to rotate the pile about the two-axis pivot joint
82 to a desired
orientation. In this regard, the hydraulic system 84 is comprised of a first
and second
hydraulic actuators 86A, 86B and a third hydraulic actuator 88 that both
engage a shuttle 90
that is engaged to the lead 70 and whose position along the lead depends on
length of the first
and second hydraulic actuators 86A, 86B and the third hydraulic actuator 88.
By appropriate
manipulation of the first and second hydraulic actuators 86A, 86B and the
third hydraulic
actuator 88, the lead 70 and any associated pile can be positioned at a
desired angle within a
vertical plane that is substantially parallel to the longitudinal axis of the
truss structure 52 or,
stated differently, at a desired rotational position relative to the first
axis of rotation provided
by the two-axis pivot joint 82. The first and second hydraulic actuators 86A,
86B also allow
the rotational position of the lead 70 and any associated pile within a plane
that is transverse
to the longitudinal axis of the truss structure 52 (or, stated differently,
within a plane that is
substantially parallel to or passes through the first axis of rotation
provided by the two-axis
pivot joint 82) to be adjusted. This is accomplished by adjusting the lengths
of the first and
second hydraulic actuators. To elaborate, when the lengths are equal, the lead
70 is
positioned as shown in Fig. 16C. However, when the lengths are unequal, the
lead 70 is
rotated clockwise or counter-clockwise relative to the position of the lead 70
in Fig. 16C.
During rotation of the pile, the cable/pulley/winch system 80 prevents
movement of the
hammer 76; the cable 78 that is attached to the hammer 76, in turn, prevents
movement of the
collar 74; and the collar 74, in turn, prevents, movement of the pile relative
to the collar.
Consequently, the position of the pile is maintained during rotation of the
pile by the
assembly 58. It should be appreciated that rotation of the lead 70 can be
accomplished using
any number of other mechanical devices and combinations of mechanical devices
known in
the art or readily conceived by those skilled in the art. For example, a
winch, cable, and
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pulley system or a system that includes one or more motorized screws could be
used to adjust
the rotational position of the lead.
[Para 67] After the desired rotational position of pile has been
achieved, the
cable/pulley/winch system 80 is used to lower the hammer 76 and the pile until
the distal end
of the pile engages the earth into which the pile is to be driven. At this
point, the cable 78
becomes slack and the hammer 76 is used to drive the pile into the earth.
[Para 68] Figure 17 illustrates an embodiment of the collar 74,
hereinafter referred to
as clamp pile collar clamp 130, that is suitable for engaging a pile with a
square cross-
section. It should be appreciated that clamps are feasible for piles with
different cross-
sections, such as a circular cross-section. The clamp 130 is comprised of a
first and second
C-shaped members 132A, 132B, which are pivotably connected to one another by a
hinge pin
134. Respectively located on the interior surfaces of the first and second
members 132A,
132B are first and second friction surfaces 136A, 136B that, in operation,
engage a pile to
prevent the pile from slipping relative to the clamp 130. A tensioner/lock
assembly 138
allows the clamp 130 to be placed in an open condition in which at least one
of the members
132A, 132B rotates about the axis defined by the hinge pin 134 so that a pile
can be placed
within the clamp 130. After a pile has been placed in the clamp 130, at least
one of the
members 132A, 132B is rotated about the axis defined by the hinge pin 134 so
as to place the
clamp in a closed position, substantially as shown in Fig. 17. The
tensioner/lock 138 is then
used to fix the position of the first and second members 132A, 132B to one
another and pull
the first and second members 132A, 132B towards one another to apply a
sufficient gripping
force to the pile.
[Para 69] In many situations, a pile can be guided using only the guide
72.
Consequently, the collar 74 is not mounted to the lead 70. If, however, it is
desirable that the
collar 74 also assist in guiding a pile, the collar 74 can be slidably mounted
to the lead 70. In
the illustrated embodiment, the clamp 74 can be slidably mounted to in a
number of ways
known or conceivable to those skilled in the art. For example, the clamp 74
can incorporate
C-shaped brackets that engage the two rails that define the open side of the
lead 74 that
receives a pile or other object. In the case of the clamp 130, two such C-
shaped brackets can
be mounted to the appropriate one of members 132A, 132B to achieve a slidable
mount.
[Para 70] Other clamps or devices for holding a pile or similar structure
are feasible.
For example, Fig. 18A illustrates a holder 200 that is suitable for receiving
a pile or similar
structure with a circular cross-section and through which a transverse hole
has been
established. The holder 200 comprises first and second members 202A, 202B that
are
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connected to one another by a hinge joint 204. A connector 206 is used to fix
the first and
second members 202A, 202B to one another after a pile has been received. The
first and
second members 202A, 202B respectively have pin holes 208A, 208B for receiving
a pin 210
that also passes through the hole in the pile, column, or other bridge
element. The pin 210
has first and second cotter pin holes 212A, 212B that respectively receive
cotter pins 214A,
214B, to fix the pin 210 in place relative to the first and second members
202A, 202B.
[Para 711 Figure 18B illustrates another clamp that can hold a pile or
similar object.
In this case, clamp 220 has first and second members 220A, 220B that are
connected to one
another by a hinge joint and fixed together by a connector, just as with the
clamp 130 and
holder 200. The first and second members 220A, 220B respectively have male
members
224A, 224B that engage a groove 226 in a pile 228 or similar structure.
[Para 72] The lead assembly 58 can be used to receive columns and other
similar
structures that do not require the use of a hammer to be put in place, rotate
the column or
similar structure, and lower the column or similar structure into place. With
respect to the
placement of such structures, the lead assembly 58 does not need to
incorporate a hammer.
[Para 731 The lead assembly 58 can also incorporate tools other than a
hammer.
With reference to Fig. 19, the lead assembly 58 comprises a drill 300. The
drill 300 is
comprised of a bit 302, a motor 304, a kelly bar 306 for connecting the motor
304 to the bit
302, and mounts 308A, 308B for slidably mounting the motor 304 to the two
rails 310A,
310B that define the open side of the lead 70. The cable, pulley, and winch
system 80 is used
to control the position of the drill 300 relative to the lead during the
drilling operation. In this
regard, the cable 312 is attached to the motor 304. In an alternative
embodiment, a pass-
through motor is mounted to the lead 70 with a fixed or semi-fixed bracket
that allows the
motor to move up and down the lead for a limited distance. The Kelly bar and
drill bit are
suspended using the winch and cable. The motor is designed to allow the kelly
bar to pass
through an opening that is designed to transfer torque from the motor to the
Kelly bar and the
drill bit.
[Para 74] Figure 20 illustrates a tailings removal system 400 for
removing the drill
tailing produced during operation of the drill 300 or other excavation tool
that might be
associated with the lead assembly 58. The tailings removal system 400 is
attached to the
underside of the truss structure 52 and positioned so as to receive the drill
bit 302 of the drill
300 that is attached to the lead 70. The system 400 comprises an upper casing
402 that has a
lower opening 404 and through which the drill bit 302 passes, a guide box 406
with a hole
408 (Fig. 21) through which the drill bit 302 can pass, a cover plate 410, a
hydraulic actuator
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412 for moving the cover plate 410 so as to cover and uncover the hole 408, a
rake 414 for
use in pushing drill tailings off of the cover plate 410 when the cover plate
410 is covering
the hole 408, a hydraulic actuator 416 for moving the rake 412, a hopper 418
for receiving
tailings that either slide of the cover plate 410 when the cover plate 410 is
covering the hole
408 or are pushed off of the cover plate 410 by the operation of the rake 414
and hydraulic
actuator 416 when the cover plate 410 is covering the hole 408, a conveyor 420
for receiving
tailings from the 418 and conveying the tailings to a desired location.
Associated with the
upper casing 402 is a vibrator 422 that, if needed, can be used to shake
tailings free from the
drill bit 302 when the drill bit 302 has been retracted into the upper casing
402. Similarly,
associated with the hopper 418 is a vibrator 424 that, if needed, can be used
to shake tailings
free from the hopper 424. The vibrators 422, 424, are typically needed when
the tailings are
comprised of material that has a high clay content or is very viscous.
Depending on the
material being excavated, the vibrators 422, 424 may or may not be needed. It
should also be
appreciate that the cover plate 410 and rake 414 can each be actuated by other
types of
actuators. For example, a motorized screw or rack-and-pinion type of actuator
can be used,
as well as other types of actuators known in the art.
[Para 75] Prior to the use of the drill 300 to excavate a hole and the
use of the system
400 is remove the tailings produced by the excavation, a lower casing 428 is
driven into the
ground. Typically, the lower casing 428 is driven into the ground using the
lead assembly 58
with an associated hammer. The lower casing 428 serves both to guide the drill
bit 302 and,
once a sufficient amount of material has been excavated by the drill bit 302,
contain the
tailings as the drill bit 302 is retracted.
[Para 76] After the lower casing 426 is in place, excavation of a hole
with the drill
300 and removal of the tailings with the system 400 commences with, if
necessary, putting
the drill 300 into place on the lead 70 and putting the system 400 in place on
the truss
structure 52. Typically, the trolley structure 54 is used to put the drill 300
into place on the
lead 70. Putting the drill 300 into place on the lead 70 may involve using the
trolley structure
54 to remove a tool that is already attached to the lead 70, such as a hammer,
and then use the
trolley structure 54 to place the drill 300 in place. The trolley structure 54
is also used to
position the elements of the system 400 for attachment to the truss structure
52.
[Para 77] With the drill 300 in place on the lead 70 and the system 400
operatively
attached to the truss structure 52 with the cover plate 410 and the rake 412
each retracted as
shown in Fig. 20, the excavation of a hole using the drill 300 and the
excavation of the
tailings therefrom commences with the rotation of the lead 70 so that the
drill bit 302 is
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aligned from insertion through the upper casing 402 and the lower casing 426.
Once aligned,
the cable, pulley, winch system 80 is used to lower the drill until the drill
bit 302 engages the
ground. Typically, the drill 300 is activated to begin rotating the drill bit
302 before the bit
engages the ground. Excavation commences when the drill bit 302 has engaged
the ground
and the drill 300 has been activated. The weight of the motor 304 and other
elements of the
drill 300 that are located above the drill bit 302 is used to force the bit
into the ground. In
many case, this weight is too great for the type of drill bit being used
and/or for the earth that
is being excavated. In such cases, the cable, pulley, winch system 80 is used
to moderate the
force being applied to the drive the drill bit 302 into the ground.
[Para 781 Once the drill bit 302 has progressed a certain distance into
the ground, the
cable, pulley, winch system 80 is used to retract the drill bit 302 into the
upper casing 402.
After the tip of the drill bit 302 moves past the top of the lower casing 426,
the hydraulic
actuator 412 is used to position the cover plate 410 over the hole 408 of the
guide box 406.
At this point, excavated material may fall of the drill bit 302 and onto the
cover plate 410 and
guide box 406. After the tip of the drill bit 302 moves past the lower opening
404 of the
upper casing 402, the hydraulic actuator 416 can be used, if needed, to push
any excavated
material that has fallen off of the drill bit 302 into the hopper 418.
[Para 79] Excavated material may naturally fall off of the drill bit 302
and onto the
cover plate 410 and guide box 406. Further, this material may slide down the
cover plate 410
and the guide box 406 and into the hopper 418 without any assistance. If,
however, the
material either does not slide down the cover plate 410 and the guide box 406
or does so too
slowly, the rake 414 and hydraulic actuator 416 can be employed to force the
material into
the hopper 418. In many cases, the excavated material does not naturally fall
off the drill bit
302. In such cases, the vibrator 422 is used to shake the material off of the
drill bit so that the
material falls onto the cover plate 410 and the guide box 406. The material
can then, if
needed, be pushed into the hopper 418 using the rake 414 and hydraulic
actuator 416. It
should be appreciated that regardless of the consistency of the excavated
material, the rake
414 may be actuated at a desired frequency. Moreover, the actuation of the
rake 414 may be
coordinated with the operation of the vibrator 422. For example, the vibrator
422 could
activated to cause material to fall onto the cover plate 410 and guide box 406
while the rake
414 is retracted, and then the vibrator 422 can be deactivated and the rake
414 actuated to
push the material that previously fell onto the cover plate 410 and guide box
406 into the
hopper 418. This cycle can be repeated as needed.
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[Para 801 Excavated material that is in the hopper 418 is dispensed onto
the
conveyor 420, which transports the material to a desired location for
disposal. The material
may naturally flow out of the hopper 418 and onto the conveyor 420. If,
however, the
material is of a consistency that such a natural flow does not occur, the
vibrator 424 can be
utilized to force the material out of the hopper 418 and onto the conveyor
420.
[Para 81] Figure 22 illustrates a ground engagement structure 600 that is
attached to
the lead 70 and can be extended from the bottom of the lead 70 to engage the
ground. The
ground engagement structure 600 engages the lead 70 in a manner comparable to
an
extension ladder. When engaging the ground, the structure 600 and the lead 70
operate to
apply a force to the truss structure 52 that counteracts the force that is
applied to the truss
structure when the lead assembly is being used to drive a pile or other
significant force is
being applied adjacent to the terminal end 61B of the truss structure. The
ground engagement
structure 600 is extended and retracted using a hydraulic actuator 602.
However, it should be
appreciated that other types of actuators can be employed.
[Para 82] Figure 23 schematically illustrates a second embodiment of a
lead
assembly 700 that comprises a lead 702, a two-axis pivot joint 704 for
connecting the lead
702 to the truss structure 52, a winch 406, a cable 408 that extends from the
winch 406 to the
lead 702, and a pair of pulleys 410A, 410B that guide the cable 408, a hinged
resistive
element 412 that moderates the rotation of the lead 702 caused by the winch
406. The hinged
resistive element 412 provides resistance by utilizing a hydraulic element. It
should be
appreciated that the other resistive elements are feasible, including elements
that are not
hinged. In operation, the winch 406 and cable 408 are used to move the lead
702 to a desired
rotational position about an axis that is transverse to the longitudinal axis
of the truss
structure. The hinged resistive element 412 moderates the rotational
operation.
[Para 83] Figure 24 illustrates a second embodiment of a device 800 for
use in
causing the lead to rotate in a plane that is transverse to the longitudinal
axis of the truss
structure 52. The device 800 comprises a curved plate 802 that is fixed to a
lead 804, a
slotted box 806 that receives the plate 802, a hydraulic actuator 808 with a
cylinder that is
pivotally attached to the slotted box 806 and a rod that is pivotally and
operatively attached to
the lead 804, and a pivot attachment 810 for a support 812 that is attached to
the truss
structure 52 and not readily susceptible to rotation about the longitudinal
axis of the truss
structure 52. In operation, the hydraulic actuator 808 is used to apply a
force to the lead 804
that causes the lead to move relative to the slotted box 810 and, more
specifically, to rotate in
a plane that is transverse to the longitudinal axis of the truss structure 52.
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CA 02813772 2013-12-06
=
[Para 841 Figure 25 illustrates a girder 140 that is the outer-most lateral
girder of a
bridge superstructure and the form 142 that must be attached to the girder 140
to create an L-
shaped edge that is attached to the girder 140. The L-shaped edge serves to
contain concrete
or other fluid material that is poured on top of the girder to establish the
superstructure deck.
In addition, the L-shaped edge provides a surface for attaching a lateral
barrier, such as a
fence.
[Para 85] Figure 26 illustrates a girder 150 that is used in a bridge
superstructure as the
outer-most girder. The girder 150 is pre-cast so as to have a laterally
extending portion 152
and a vertically extending portion 154 that is operatively connected to the
laterally extending
portion so as to form an L-shaped edge that is useful for containing concrete
or other fluid
material that is poured on top of the girder to establish the superstructure
deck. If desired
rebar 156 can be incorporated into the vertically extending portion 154 of the
girder. The
rebar 156 extends between first and second terminal ends. A portion of the
rebar 156 is
located within the vertically extending portion 154 of the girder 150. Another
portion of the
rebar 156 is located within the horizontally extending portion 152 of the
girder 150. A least
one of the first and second terminal ends of the rebar 156 is exposed. In the
illustrated
embodiment, both of the first and second terminal ends of the rebar 156 are
exposed. It
should be appreciated that the edge can be other shapes that serve the various
purposes for
which an edge is used on a bridge superstructure.
[Para 86] The embodiments of the invention described above are intended to
describe
the best mode known of practicing the invention and to enable others skilled
in the art to
utilize the invention.
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