Patent Publication Number: US-10329720-B2

Title: Pre-engineered flat-pack bridge

Description:
PCT/AU2016/000305, international application filing date 1 Sep. 2016, and Australian provisional patent application no. 2015903571 filed 1 Sep. 2015 are incorporated herein by reference hereto in their entireties. 
     FIELD OF THE INVENTION 
     The present invention relates to a pre-engineered flat-pack bridge. 
     BACKGROUND 
     On a world-wide scale there is increasing demand for small bridges, especially for pedestrian and bicycle use. The demand is from both developed, and undeveloped nations. Typically a unique solution is required for each location to address requirements including size, material and terrain at the bridge site, for example. 
     Currently, bridges are designed, engineered and constructed to meet site-specific demands including size, traffic characteristics, material and terrain, for example, at each location where a bridge is required. Using current approaches to design, engineering and construction, a bridge designed for one location tends to be unique and is rarely suited to another location. Consequently, the time and costs associated with design, engineering and construction of small bridge solutions are excessive. 
     The present invention attempts to overcome at least in part the aforementioned disadvantages of the current approach by providing a cost effective, pre-engineered holistic solution to the design, manufacture and construction of small bridges, in particular bridges for pedestrian and bicycle use. 
     SUMMARY OF THE INVENTION 
     In accordance with one aspect of the present invention there is provided a variably dimensionable bridge comprising pre-engineered components provided in a kit. 
     The kit may be provided as a flat-pack. 
     The pre-engineered components may be constructed of fibre reinforced polymer composite material. 
     The pre-engineered components may comprise: at least one floor module for providing a floor; at least two girders for providing opposing substantial vertical sides; and at least two cross beams to lend support to the girders. 
     The bridge according to claim  4 , wherein at least one cross beam is proximal to each end of the bridge. 
     The bridge may further comprise at least one reinforcement member receivable within channels within the girders. 
     The reinforcement member may be constructed of dowel materials. The reinforcement member may comprise continuous selected grout filling. 
     The bridge may be lengthened by providing a plurality of floor modules, pairs of girders, and cross beams, joined in sequence. The width of the bridge may be varied by providing alternative width floor modules and cross beams. 
     The girder may comprise a lengthened upright side portion for providing a balustrade to the bridge. The balustrade may be provided as a separate component to the girder. 
     The upright side portion may be filled for providing a solid balustrade. The upright side portion may be at least partially open for providing a balustrade containing spaces. 
     In accordance with a second aspect of the present invention there is provided a method for constructing a bridge of variable dimensions comprising the use of pre-engineered components provided in a kit. 
     The pre-engineered components of the method may comprise: at least one floor module for providing a floor; at least two girders for providing opposing substantial vertical sides; and at least two cross beams to lend support to the girders. 
    
    
     
       BRIEF DESCRIPTION OF DRAWINGS 
       The present invention will now be described, by way of example, with reference to the accompanying drawings, in which: 
         FIG. 1  is an upper perspective view of a flat-pack bridge  10  according to the present invention; 
         FIG. 2  is an upper perspective exploded view of components of the flat-pack bridge  10  of  FIG. 1 ; 
         FIG. 3  is an upper perspective exploded view of detail of the flat-pack bridge  10  of  FIG. 1 ; 
         FIG. 4  is a side plan view of a girder  12  with an open balustrade  24 ; 
         FIG. 5  is an upper perspective view of the flat-pack bridge  10  of  FIG. 1  in a disassembled arrangement; 
         FIG. 6  is an end plan view of a girder  12  of the flat-pack bridge  10  in accordance with a second embodiment of the present invention; and 
         FIG. 7  is an end plan view of the girder  12  of  FIG. 6  provided with a separate balustrade  24 . 
     
    
    
     DESCRIPTION OF PREFERRED EMBODIMENTS 
     Referring to  FIG. 1 , there is shown a flat-pack bridge  10 , in its assembled arrangement, for providing a span of a distance. The bridge  10  comprises: at least one floor module  14  for providing a floor; at least two girders  12  for providing opposing substantially vertical sides; and at least two cross beams  16  to lend support to the girders  12 . It is preferred that these primary components of the bridge  10  are constructed of fibre reinforced polymer (FRP) composite incorporating carbon and glass fibre. This allows the bridge  10  to be very lightweight while still possessing structural compliance with international design standards. 
     With reference to  FIG. 2 , each girder  12  is elongated in shape, having at least one upper and one lower chord  28 . The chords  28  preferably comprise a wider profile than that of the remaining girder  12 . In accordance with a first embodiment of the present invention, the girder  12  may comprise a lengthened upright side portion  24  providing a balustrade to the bridge  10 . 
     Alternatively, in accordance with a second embodiment, the girder  12  may be provided without lengthened upright side portions  24 , as shown in  FIG. 6 . Further still, the bridge  10  may be provided with balustrade  24 , but as a separate component, rather than integrally formed with the girder  12 , as shown in  FIG. 7 . With reference to  FIG. 4 , any embodiment of the bridge  10  may be optionally provided with a railed or otherwise open balustrade  24 , or with the solid or filled balustrade  24  as shown in  FIG. 2 . 
     Each girder  12  further comprises at least one channel  18  arranged so that a reinforcement member  20  is receivable within its length. The reinforcement members  20  may be constructed of dowel materials. The channel  18  may be disposed in the upper and/or lower chords  28  of the girder  12 , or through a central chord  28 , and run the entire length of the girder  12 . It is preferred that each girder  12  comprises at least two channels  18 . Accordingly a pair of reinforcement members  20  are disposed within the chords  28  of the girder  12 . 
     It is preferred that the lower or central chord  28  of the girder  12  is shaped such that a substantially square edge  30  is provided on the inner side of the girder  12 . The edge  30  provides a suitable point of attachment for a floor module  14 . 
     According to a first embodiment of the present invention, the cross beam  16  is a somewhat square U-shaped frame component with opposed uprights  32  joined to a horizontal span  34 . The uprights  32  comprise at least one aperture  22  disposed so that when the cross beam  16  is aligned with the girders  12 , the channels  18  in the girders  12  are aligned with the apertures  22  in the cross beam  16 . Accordingly, a reinforcement member  20  may pass into and/or through an aligned aperture  22 . The horizontal span  34  is of complementary length to the width of the floor module  14  and hence the bridge  10 . In accordance with a second embodiment, the cross beam  16  is merely the horizontal span  34  of the frame component, with no opposed uprights. 
     Both the girder  12  and cross beam  16  are each preferably manufactured as a single moulded piece. Accordingly, high quality finishes not generally available to bridge structures can be achieved with this invention. 
     It is preferred that the floor module  14  is substantially flat and quadrilateral in shape. As above, the width of the floor module  14  defines the width of the bridge  10 . It is preferred that the length of the floor module  14  is a fraction of the length of the girders  12  such that numerous aligned floor modules  14  form the floor of the bridge  10 . The floor module  14  optionally comprises end rails  36  disposed at opposite ends of the floor module  14 . The end rails  36 , if present, are shaped and arranged such that they complement the square edge  30  of the girders  12 . Accordingly, the end rails  36  of the floor module  14 , or merely each side of the floor module  14 , fit with the square edge  30  of the girder  12  for secure connection thereto, as best seen in  FIG. 3 . It has been advantageously found that connection of the floor module  14  in this manner provides lateral stability to the bridge  10 , and the need for secondary bracing is eliminated. 
     With further reference to  FIG. 3 , the length of the bridge  10  may be varied by increasing the number of each of the components of the bridge  10  and interconnecting them longitudinally as represented by the broken lines in  FIGS. 1 and 4 . Hence, another pair of girders  12  with one or more floor modules  14  disposed between them may be aligned with an end of the bridge  10 . In this case, the pair of reinforcement members  20  span the join between multiple girders  12 , passing through the apertures  22  provided within the cross beam  16  connecting the two pairs of girders  12 . 
     In the case of this lengthened bridge  10  comprising at least two pairs of girders  12 , it is preferred that longer reinforcement members  20  are provided within the length of the channels  18  of the bridge  10 . Accordingly, continuous reinforcement members  20  lend increased strength to the lengthened bridge  10 . 
     With reference to  FIG. 5 , the bridge  10  is shown in its disassembled arrangement. Accordingly, the pairs of girders  12 , floor modules  14 , cross beams  16  and reinforcement members  20  may be stored, transported and delivered to site as a flat-pack, thereby resulting in a saving of space, time and costs. Additionally, the components are factory finished, including colour-infused, according to the preference of the bridge  10  customer, prior to packing. 
     As described above, variable length bridges  10  may be provided in accordance with the present invention. Similarly, variable width bridges  10  may also be provided, to meet the needs of users, or the span across which the bridge  10  is to be constructed, for example. As such, the width of each floor module  14  may be provided to correspond with the desired width of the bridge  10 . As would be understood, the horizontal span  34  of the cross beam  16  would be adjusted accordingly. 
     In use, the bridge  10  components are provided in a flat-pack arrangement for storage and transportation, for example, in preparation for construction of the bridge  10 . The number and size of packed bridge  10  components varies according to the desired length and width of the bridge  10 . At an appropriate time, usually once the flat-pack bridge  10  components have been transported to a suitable location for assembly, the components are unpacked and assembled to form the bridge  10 . 
     The primary elements of the bridge  10  are assembled as would be understood by a person skilled in the art. During assembly, at least one reinforcement member  20  is inserted into the channel  18  within a single girder  12  or multiple girders  12  in longitudinal alignment. Optionally, resin is injected into the one or more channels  18 , after insertion of its respective reinforcement member  20 , and allowed to cure, to further reinforce the bridge  10 . 
     Once fully assembled and cured, the bridge  10  is lifted to its preferred location to enable spanning of a distance therewith. Preferably, the bridge  10 , once in its final location, is securely attached to previously provided foundations. 
     The conveniently provided components of the bridge  10  within a kit, which are lightweight and manageable, make the invention suitable for rapid assembly. In addition, only a small crane, if any, is required to complete installation of the bridge  10 . This results in not only a cost saving, but the environmental impact during construction is low. 
     Other embodiment flat-pack bridges  10  are also contemplated in accordance with the present invention. For instance, the aforementioned floor module  14  may, instead of being provided as substantially flat and quadrilateral in shape, be any shape and profile suited to the relevant function of providing a bridge floor. Likewise, the square edge  30  of the girder  12  and end rails  36  of floor modules  14  may be provided as any suitable means for complementarily securing a floor module  14  to a girder  12 . 
     Further, a reinforcement member  20  may be provided as continuous selected grout filling to a channel  18  within a girder  12 , rather than comprising dowel materials. In such a case, when constructing the bridge  10 , the reinforcement member is provided by filling the channel  18  with the grout filling. The cross beams  16  may also be reinforced with continuous selected grout filling optionally in combination with rods. 
     Modifications and variations as would be apparent to a skilled addressee are deemed to be within the scope of the present invention.