Patent Abstract:
A method of manufacturing an orthotropic deck panel includes securing a rib member in a first fixture, beveling an edge surface of the rib member while the rib member is secured in the first fixture, and releasing the rib member from the first fixture, attaching the rib member to a deck plate, and attaching a floor beam to the rib member and the deck plate.

Full Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims the benefit of U.S. Provisional Application No. 62/355,778, filed Jun. 28, 2016, which is incorporated by reference herein in its entirety. 
     
    
     FIELD 
       [0002]    The present disclosure is directed to orthotropic decks, as well as methods for their manufacture. 
       BACKGROUND 
       [0003]    Orthotropic decks are used in a variety of applications, including bridges. Improvements in the design and manufacture of orthotropic decks can improve the strength, durability, and quality of orthotropic decks and can improve the ease and efficiency of the manufacturing process. Such improvements are therefore always desirable. 
       SUMMARY 
       [0004]    Described herein are embodiments of orthotropic decks, as well as methods of manufacturing orthotropic decks. 
         [0005]    In one representative embodiment, a method of manufacturing an orthotropic deck panel comprises securing a rib member in a first fixture, beveling an edge surface of the rib member while the rib member is secured in the first fixture, and releasing the rib member from the first fixture, attaching the rib member to a deck plate, and attaching a floor beam to the rib member and the deck plate. 
         [0006]    In some embodiments, the method further comprises cambering the deck plate in a first direction and in a second direction using a second fixture prior to the act of attaching the rib member to the deck, wherein the second direction is transverse to the first direction. In some embodiments, the method further comprises securing the rib member against the deck plate with a plurality of third fixtures prior to the act of attaching the rib member to the deck, wherein the third fixtures are spaced relative to each other. 
         [0007]    In some embodiments, the method further comprises creating a profile of the rib member and deck plate at a location, and cutting the floor beam to match the profile at the location, wherein the acts of creating a profile and cutting the floor beam occur prior to the act of attaching the floor beam. In some embodiments, the profile of the rib member and the deck plate is created using laser tracking. 
         [0008]    In some embodiments, attaching the floor beam comprises tack welding the floor beam with the orthotropic deck panel in a first orientation, pivoting the orthotropic deck panel from the first orientation to a second orientation orthogonal to the first orientation, and welding the floor beam in continuous weld with the orthotropic deck panel in the second orientation. 
         [0009]    In another representative embodiment, a method of manufacturing an orthotropic deck panel comprises cambering a deck plate in a first direction and in a second direction using a first fixture, wherein the second direction is transverse to the first direction, positioning a plurality of rib members on the deck plate, securing the positioning of the rib members relative to the deck plate with a plurality second fixtures, wherein the second fixtures are spaced relative to each other and distributed along the rib members, and welding the rib members to the deck plate. 
         [0010]    In another representative embodiment, a method of manufacturing an orthotropic deck panel comprises attaching a plurality of rib members to a deck plate, creating a profile of the rib members and the deck plate at a plurality of locations spaced along the orthotropic deck panel, cutting a plurality of floor beams such that the floor beams include cut sections that correspond to the respective profiles of the rib members and the deck plate at the locations, and attaching the floor beams to the rib members and the deck plate. 
         [0011]    The foregoing and other objects, features, and advantages of the invention will become more apparent from the following detailed description, which proceeds with reference to the accompanying figures. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0012]      FIGS. 1-2  are perspective views of an exemplary embodiment of an orthotropic deck panel. 
           [0013]      FIG. 3  is a detail view of a rib of the orthotropic deck panel and an exemplary embodiment of a rib machining fixture. 
           [0014]      FIGS. 4-16  are various views the rib machining fixture and related components. 
           [0015]      FIGS. 17-18  are perspective views of a mill configured for milling ribs of the orthotropic deck panel. 
           [0016]      FIG. 19  is a detail view of the rib of the orthotropic deck panel and the rib machining fixture. 
           [0017]      FIGS. 20-29  are various views of an exemplary embodiment of a cambering fixture and related components. 
           [0018]      FIGS. 30-31  are various view of an exemplary embodiment of a rib fitting fixture. 
           [0019]      FIGS. 32-36  are various views of an exemplary embodiment of a grounding shoe assembly. 
           [0020]      FIG. 37  is a schematic of a laser tracking apparatus. 
           [0021]      FIGS. 38-39  are various perspective views of an exemplary embodiment of a vertical welding fixture. 
           [0022]      FIG. 40  is a perspective view of an exemplary embodiment of a pre-heating apparatus. 
           [0023]      FIG. 41  is a schematic of a robotic welding apparatus. 
           [0024]      FIGS. 42-47  are various views of an exemplary embodiment of a deck support fixture and related components. 
           [0025]      FIG. 48  is an exploded perspective view of three orthotropic deck panels and a girder. 
           [0026]      FIG. 49  is a perspective view of the three orthotropic deck panels attached to the box girder. 
       
    
    
     DETAILED DESCRIPTION 
       [0027]    For purposes of this description, certain aspects, advantages, and novel features of the embodiments of this disclosure are described herein. The disclosed methods, apparatuses, and systems should not be construed as limiting in any way. Instead, the present disclosure is directed toward all novel and nonobvious features and aspects of the various disclosed embodiments, alone and in various combinations and sub-combinations with one another. The methods, apparatuses, and systems are not limited to any specific aspect or feature or combination thereof, nor do the disclosed embodiments require that any one or more specific advantages be present or problems be solved. 
         [0028]    Although the operations of some of the disclosed methods are described in a particular, sequential order for convenient presentation, it should be understood that this manner of description encompasses rearrangement, unless a particular ordering is required by specific language. For example, operations described sequentially may in some cases be rearranged or performed concurrently. Moreover, for the sake of simplicity, the attached figures may not show the various ways in which the disclosed methods can be used in conjunction with other methods. 
         [0029]    As used herein, the terms “a”, “an” and “at least one” encompass one or more of the specified element. That is, if two of a particular element are present, one of these elements is also present and thus “an” element is present. The terms “a plurality of” and “plural” mean two or more of the specified element. 
         [0030]    As used herein, the term “and/or” used between the last two of a list of elements means any one or more of the listed elements. For example, the phrase “A, B, and/or C” means “A,” “B,” “C,” “A and B,” “A and C,” “B and C” or “A, B and C.” 
         [0031]    As used herein, the term “coupled” generally means physically coupled or linked and does not exclude the presence of intermediate elements between the coupled items absent specific contrary language. 
         [0032]    Described herein are embodiments of orthotropic decks, as well as methods of manufacturing orthotropic decks. The orthotropic decks described herein can be used, for example, on bridges, ferryboats, offshore platforms (e.g., oil and drilling rigs), and various other applications. 
         [0033]    Orthotropic decks can comprise a plurality of deck panels that can be attached together and that can be further supported by additional structural members such as girders. For example,  FIG. 48  shows three exemplary orthotropic deck panels  100  and an exemplary box girder  1200 .  FIG. 49  shows the three orthotropic deck panels  100  coupled together via the box girder  1200 . It should be noted that in  FIGS. 48-49  the box girder  1200  is shown as partially transparent in order to show an internal support structure of the box girder  1200 . 
         [0034]    Referring to  FIG. 1 , the deck panel  100  comprises three main components: a plurality of ribs  102  (e.g., six in the illustrated embodiment), a deck plate  104 , and a plurality of floor beams  106  (e.g.,  11  in the illustrated embodiment). As best shown in  FIG. 2 , the ribs  102  can be spaced relative to each other and can extend in a longitudinal direction (i.e., the direction shown by arrow  108 ) relative to the deck plate  104 . The floor beams  106  can be spaced relative to each other and can extend in a transverse direction (i.e., the direction shown by arrow  110 ) relative to the deck plate  104  and the ribs  102 . The ribs  102 , the deck plate  104 , and the floor beams  106  can be fixedly secured together (e.g., welded), as further explained below. 
         [0035]    The ribs  102  can be formed by bending a relatively flat sheet or plate of material into a rib (e.g., with a press) having a desired cross-sectional shape (taken in a plane perpendicular to a longitudinal axis of the ribs  102 ), including U-shaped, V-shaped, and trapezoidal. For example, in the illustrated embodiment, the ribs  102  comprise a U-shaped cross-sectional shape. 
         [0036]    After the ribs  102  are formed in the desired shape, longitudinal edge portions  112  (i.e., the edges disposed against the deck plate  104  when the deck panel  100  is assembled) of the ribs  102  can be machined for fitting and attachment to the deck plate  104 . For example, the machined edge portions  112  can include a beveled portion  114 , as shown in  FIG. 3 . 
         [0037]    Machining the edge portions  112  after forming the ribs  102  can, for example, provide a tighter fit between the ribs  102  and the deck plate  104  than ribs having edge portions that are machined prior to forming the ribs and ribs having edge portions that are ground after forming the ribs. This tighter fit, in turn, can advantageously improve the quality of a weld between the ribs  102  and the deck plate  104 , resulting in a stronger and/or more durable deck panel  100 . For example, in one particular embodiment, the root gap between the ribs  102  and the deck plate can be about 0.010 inches (0.25 mm) or less; whereas, the root gap of typical ribs and deck plates can be about 0.020 inches (0.50 mm) or more. 
         [0038]    As best shown in  FIG. 4 , the edge portions  114  of the ribs  102  can be machined after the ribs  102  are formed by securing the ribs  102  in a rib machining fixture  200  and using a mill  300  to machine the edge portions  114  of the ribs  102 . Referring to  FIGS. 5-6 , the rib machining fixture  200  can comprise four main components: a rib receiving member  202 , a mandrel  204 , a wedge plate  206 , and compression assemblies  208  ( FIGS. 6A-6B ). The rib receiving member  202  can be adjustably coupled to the mandrel  204  by the compression assemblies  208 , and the wedge plate  206  can be adjustably coupled to the mandrel  204  by a plurality of fasteners (e.g., bolts)  210 . 
         [0039]    Referring to  FIGS. 7-8 , the rib receiving member  202  of the rib machining fixture  200  can comprise a base plate  212 , a plurality of cradle plates  214 , an interior plate  216 , side plates  218 , and top plates  220 . The cradle plates  214  can be spaced relative to each other and fixedly secured (e.g., welded) to the base plate  202 . The interior plate  216  can be fixedly secured to interior surfaces  222  of the cradle plates  214 . The side and top plates  218 ,  220  can be fixedly secured to respective side and top portions  224 ,  226  of the cradle plates  214 . The cradle plates  214  can comprise a plurality of projections  228  extending inwardly from the interior surfaces  222 . The interior plate  216  can comprise a plurality of angled surfaces  230  that extend from and longitudinally along the interior plate  216  and are spaced relative to each other. In this manner, the rib receiving member  202  can form a longitudinally extending opening  232  configured to receive a rib  102  of the deck panel  100 , as shown in  FIG. 8 . 
         [0040]    Referring to  FIGS. 9-13 , the mandrel  204  of the rib machining fixture  200  can comprise a main portion  234  and connection portions  236  disposed at ends of the main portion  234 . The main portion  234  can be an elongate beam-like member having angled side surfaces  238  that correspond to the interior surfaces  222  of the rib receiving member  202 , as best shown in  FIG. 12 . The main portion  234  can also have a plurality of openings  240  formed in a top surface  242 , as best shown in  FIG. 9 . The openings  240  can be configured to adjustably receive the fasteners  210  ( FIG. 6 ) that extend through the wedge plate  206  and into the main portion  234  of the mandrel  204 . In some embodiments, the openings  240  can comprise internal threads configured to engage corresponding external threads formed on the fasteners  210 . 
         [0041]    In some embodiments, the main portion  234  can also be cambered in the longitudinal direction, such that the main portion  234  initially contacts the rib  102  only in the center of the length of the main portion  234 . Accordingly, as the main portion  234  is forced downward at the connection portions  236  at each end of the main portion  234 , the pressure exerted by the mandrel  204  against the rib  102  is equalized along the length of the rib  102 . 
         [0042]    The connection portions  236  of the mandrel  204  can extend longitudinally away from end portions of the main portion  234  and can comprise openings (e.g., slots or holes)  244 . In some embodiments, the connection portions  236  and the main portion  234  can be integrally formed from a single, unitary piece of material. In other embodiments, the connection portion  236  and the main portion  234  can be formed from separate pieces of material that are coupled together such as by welding and/or fasteners. 
         [0043]    The slots  244  can be used to releasably connect the connection portions  236 , and thus the main portion  234 , of the mandrel  204  to one or more compression assemblies  208  (e.g., one compression assembly disposed adjacent each end of the mandrel  204  in the illustrated embodiment). Referring to  FIGS. 6A-6B , in certain embodiments the compression assemblies  208  can each comprise a hydraulic ram  245 , a connecting member  247 , and a base member  249 . 
         [0044]    As best shown in  FIG. 6B , the hydraulic ram  245  of the compression assembly  208  can comprise a cylinder portion  246  and a piston rod  248 . The hydraulic ram  245  can also have a radially centrally disposed opening extending through the cylinder portion  246  and the piston rod  248 . 
         [0045]    Referring still to  FIG. 6B , the connecting member  247  of the compression assembly  208  can comprise a first end portion  251  and a second end portion  253 . The first end portion  251  of the connecting member  247  can be coupled to the cylinder portion  246  of the hydraulic ram  245 , the connecting member  247  can extend through the opening of the hydraulic ram  245  and the opening  244  ( FIG. 9 ) of the connection portion  236 , and the second end portion  253  of the connecting member  247  can be coupled to the base member  249 . In some embodiments, for example, the connecting member  247  can comprise a threaded shaft. In such embodiments, the first end portion  251  can be coupled to the cylinder portion  246  of the hydraulic ram  245  by a fastener (e.g., a nut)  255 , and the connecting member  247  can be threadably coupled to the base member  249 . As further explained below, the connecting member  247  can be configured such that the hydraulic ram  245  and the connection portion  236  are movable (e.g., in the direction shown by arrow  257  in  FIG. 6B ) relative to the connecting member  247 . 
         [0046]    The base member  249  of the compression assembly  208  can be fixed relative to the rib receiving member  202 , as shown in  FIG. 6A . As noted above, the base member  249  can also be fixedly coupled to the connecting member  247 . For example, in some embodiments, base member  249  can comprise an opening comprising internal threads configured to engage corresponding external threads of the connecting member  247 , as shown in  FIG. 6B . 
         [0047]    In this manner, when the hydraulic ram  245  is actuated such that the cylinder portion  246  and the piston rod portion move away from each other (e.g., in the direction shown by arrow  257 ), the cylinder portion  246  presses against the fastener  255 , and the piston rod  248  slides along the connecting member  247  and presses against the connection portion  236  of the mandrel  204 . This causes the connection portion  236  to slide along the connecting member  247  toward the base member  249 . When the hydraulic ram  245  is actuated such that the cylinder portion  246  and the piston rod portion move toward each other (e.g., opposite the direction shown by arrow  257 ), the connection portion  236  can slide along the connecting member  247  away from the base member  249 . As such, the compression assembly  208  can be used to secure a rib  102  relative to the rib machining fixture  200  as further describe below. 
         [0048]    In some embodiments, the compression assembly  208  can also comprise a locking mechanism  258 , as shown in  FIG. 6A . The locking mechanism  258  can comprise a shaft portion  260  and a fastener  262 . In some embodiments, the shaft portion  260  can be threaded and coupled to the base member  249  similar to the manner in which the connecting member  247  is connected to the base member  249 . The shaft portion  260  can extend from the base member  249  and through the connection portion  236  of the mandrel  204 . The shaft portion  260  can be movable relative to the connection portion  236  and can be adjustably coupled to the connection portion  236 , for example, by the fastener (e.g., a nut)  262 . In this manner, the connection portion  236  can slide along the shaft portion  260  when the mandrel  204  moves toward the base member  249 . Once the mandrel  204  is desirable positioned relative to the base member  249  and thus the rib receiving member  202 , the fastener  262  can be moved relative to the shaft portion  260  and the connection portion  236  such that the fastener  262  is secured tightly against the connection portion  236 . As a result, the fastener  262  prevents the connection portion  236  and thus the mandrel  204  from moving relative to the base member  249 , thereby locking the mandrel  204  in place relative to the rib receiving member  202 , if pressure from the hydraulic ram  245  against the connection portion  236  is reduced and/or removed (e.g., due to bleed and/or intentional release). 
         [0049]    Referring to  FIG. 14-16 , the wedge plate  206  can comprise first and second surfaces  250 ,  252 , and angled surfaces  254  configured in a trapezoid shape. The wedge plate  206  can also comprise a plurality of fastener apertures  256  extending through the wedge plate  206  from the first surface  250  to the second surface  252 . 
         [0050]    The rib machining fixture  200  can be used to releasably secure the ribs  102  of the deck panel  100  such that the ribs  102  are securely held in place and the edge portions  112  of the ribs  102  are exposed so that the edge portions  112  can be machined with precision. This can be accomplished, for example, by placing a rib  102  in the rib receiving member  202 , as shown in  FIG. 8 . The rib  102  can be secured against the rib receiving member  202  by placing the mandrel  204  within the opening  232  ( FIG. 8 ) of the rib receiving member  202 , as best shown in  FIG. 5 . The connection portions  236  of the mandrel  204  can then be coupled to the compression assemblies  208 , as shown in  FIGS. 6A-6B . The hydraulic rams  245  of the compression assemblies  208  can be actuated such that the mandrel  204  moves toward the rib  102  and the rib receiving member  202  and presses the rib  102  against the rib receiving member  202 , thereby clamping the rib  102  between the rib receiving member  202  and the mandrel  204 . In embodiments with the locking mechanism  258 , the locking mechanism  258  can be secured such that the mandrel  204  and thus the rib  102  cannot move relative to the rib receiving member  202 . 
         [0051]    The wedge plate  206  can then be attached and/or tightened against the rib  102  and/or the mandrel  102  by adjusting the fasteners  210 . This clamps the rib  102  between the top plates  220  of the rib receiving member and the angled surfaces  254  ( FIG. 16 ) of the wedge plate  206 . As a result, the rib  102  is secured relative to the rib machining fixture  200 , and the edge portions  112  of the ribs  102  are exposed. As shown in  FIG. 5 , in some embodiments, there can be a gap  264  between the wedge plate  206  and the mandrel  204 . In such embodiments, the fasteners  210  can be adjusted such that the fasteners  210  draw the wedge plate  206  toward the mandrel  204  (e.g., by rotating the fasteners  210  in a first direction relative to the wedge plate  206  and the mandrel  204 ). This causes the angled surfaces  254  ( FIG. 16 ) of the wedge plate  206  to apply pressure to the rib  102  and urges the edge portions  112  of the ribs  102  against the top plate  220  of the rib receiving member  202  in preparation for machining. 
         [0052]    The edge portions  112  of the rib  102  can then be machined using the mill  300 . As shown in  FIGS. 17 and 18 , multiple cutters  302  can be attached to an arbor  304  of the mill (sometimes referred to as “gang milling”). This configuration allows both of the edge portions  112  of the rib  102  to be milled with each pass of the mill. In this manner, the edge portions can be machined to desired specifications. For example,  FIG. 19  shows the edge portions  112  after an initial pass of the mill  300 , and  FIG. 3  shows the edge portions  112  after a successive pass of the mill  300  after which both the beveled portion  114  and the flat portion  115  have been machined. The ribs  102  can then be attached (e.g., welded) to the deck plate  104 , as further explained below. 
         [0053]    Prior to attaching the ribs  102  to the deck plate  104 , the deck plate  104  can be cambered in the longitudinal and/or transverse (also referred to as “cross-slope”) directions. Cambering the deck plate  104  prior to attaching the ribs  102  to the deck plate can advantageously reduce and/or eliminate residual stress in tack welds that are used to initially attach the ribs  102  to the deck plate  104 . As a result, the tack welds are much more likely to securely hold the ribs  102  to the deck plate rather than break just ahead of the robotic welder than tack welds that were formed prior to cambering the deck plate. This in turn improves the weld quality between the ribs  102  and the deck plate  104 , and thus improves the strength and/or durability of the deck panel  100 . 
         [0054]    The deck plate  104  can be cambered with a cambering fixture  400 , as shown in  FIGS. 20-24 . The cambering fixture  400  can comprise two main components: a support frame  402  ( FIG. 23 ) and a deck plate support structure  404  ( FIG. 26 ) disposed on the support frame  402 . As best shown in  FIG. 20 , the support frame  402  can comprise a plurality of first beams  406  (e.g., nine in the illustrated embodiment, i.e., three rows each having three first beams  406 ) and a plurality of second beams  408  (e.g.,  11  in the illustrated embodiment) disposed on and transverse relative to the first beams  406 . The first beams  406  can be coupled together, for example, with a plurality of fasteners  410  and plates  412 , as shown in  FIG. 24 . The second beams  408  can be coupled to the first beams  406 , for example with a plurality of fasteners  414 , as shown in  FIG. 25 . 
         [0055]    As best shown in  FIG. 26 , the deck plate support structure  404  can comprise a plurality of connecting members  416  (e.g. 20 in the illustrated embodiment, 10 on each side) extending longitudinally, and a plurality of cambering members  418  (e.g., 11 in the illustrated embodiment) spaced apart relative to each other and transverse relative to the connecting members  416 . As shown in  FIG. 20 , the connecting members  416  can extend parallel to the first beams  406 , and the cambering members  418  can extend parallel to the second beams  408 . The connecting members  416  can be coupled together and to the cambering members  418 , for example, with fasteners  420 , as shown in  FIG. 27 . 
         [0056]    Referring to  FIG. 21 , the cambering fixture  400  can be cambered in a first direction (e.g., the longitudinal direction shown by arrow  422 ) such that a first height  424  at end portions  426  of the cambering fixture  400  is greater than a second height  428  at an intermediate portion  430  (e.g., a center portion) of the cambering fixture  400 . In other words, the cambering members  418  at end portions  426  of the cambering fixture  400  are the tallest cambering members  418 , and the cambering members  418  get progressively shorter toward moving inwardly from the end portions  426 . In this manner, the connecting members  416  form a slight U-shaped curve when viewed from a side of the cambering fixture  400 , as illustrated in  FIG. 21 . 
         [0057]    Referring to  FIG. 22 , the cambering fixture  400  can be cambered in a second direction (e.g., the transverse direction shown by arrow  432  such that a third height  434  at side portions  436  of the cambering fixture  400  are less than a fourth height  438  at an intermediate portions  440  (e.g., a center portion) of the cambering members  418 . In this manner, the cambering members  418  form a slight upside-down U-shaped curve when viewed from an end portion of the cambering fixture  400 , as illustrated in  FIG. 22 . 
         [0058]    The deck plate  104  of the deck panel  100  can be disposed on the connecting members  416  and/or the cambering members  418  of the cambering fixture. The deck plate  104  can be releasably secured to the cambering fixture  400  such that the deck plate  104  assumes the cambered configuration of the cambering fixture  400 . In some embodiments, the deck plate  104  can be releasably secured to the cambering fixture with a plurality of hold-down clips  442 , as shown in  FIGS. 28-29 . The clips  442  can be configured to engage a perimeter of the deck plate  104  and the connecting members  416  and can be releasably secured to the connecting members  416 , for example, by a plurality of fasteners. In other embodiments, the deck plate  104  can be releasably secured to the cambering fixture, for example, with a plurality of clamps (e.g., C-clamps) and/or other fasteners. 
         [0059]    Cambering the cambering fixture  400  in the second direction can counteract the deck plate&#39;s tendency to curl around the ribs when the ribs  102  are welded to the deck plate  104 . As a result, this produces a deck plate  104  that is flat in the second direction  432 , thus reducing and/or eliminating the need to heat straighten the deck plate  104  after the ribs  102  are welded to the deck plate  104 . 
         [0060]    The ribs  102  can be attached to the cambered deck plate  104  using rib fitting fixtures  500  (only one shown for purposes of illustration) to hold the ribs  102  in the desired positions. As shown in  FIGS. 30-31 , the rib fitting fixtures  500  can each comprise web portions  502  (e.g., two in the illustrated embodiment), stiffening members  504 , and a picking element  506 . The web portions  502  can be spaced relative to each other, and the stiffening members  504  can be disposed between the web portions  502 . The picking element  506  can be dispose on and coupled (e.g., welded and/or bolted) to a stiffening member  504 . 
         [0061]    The web portions  502  can comprise a plurality of rib openings  508  spaced relative to each other. The rib openings  508  can comprise a plurality of ridges  510  configured to engage the ribs  102  of the deck panel  100 . In some embodiments, the web portions  502  can comprise a plurality of secondary openings  512  spaced relative to each other and disposed between the rib openings  508 . 
         [0062]    When attaching the ribs  102  to the deck plate  104 , the rib fitting fixtures  500  can be disposed on and span across the ribs  102  to securely hold the ribs  102  to the deck plate  104 . The rib fitting fixtures  500  can be spaced relative to each other and disposed on the ribs  102  at the locations that the floor beams  106  will be attached. In this manner, the rib fitting fixtures  500  can simulate the floor beams  106  the deck panel  100 . Once the rib fitting fixtures  500  are desirable positioned, the ribs  102  can be attached (e.g., tack welded) to the deck plate  104 . The rib fitting fixture  500  can then be removed, and the ribs  102  can be attached (e.g., robotically welded with a robotic welding apparatus) to the deck plate  104 . 
         [0063]      FIGS. 32-36  show an exemplary embodiment of a movable grounding shoe assembly  600 . As best shown in  FIG. 34 , the grounding shoe assembly  600  can comprise a main body  602 , a plurality of contacts  604 , and a mounting bracket  606 . The contacts  606  can extend from the main body  602  and can comprise a bristles formed from a conductive material such as copper. The mounting bracket  606  can be coupled to a robotic welder, and the contacts  604  can be movably coupled to the deck panel  100  (e.g., to the deck plate  104 ). The grounding shoe assembly  600  can be configured to move relative to and in contact with the deck panel  100  as the robotic welder moves along the rib  102  and the deck plate  104 . This allows the distance and/or the positioning of the grounding shoe relative to the robotic welder to remain constant, or at least substantially constant, as the robotic welder moves along the rib  102  and the deck plate  104 . As a result, the flow path of the electrical current flowing from the robotic welder, through the deck panel  100 , and to the grounding shoe assembly  600  is relatively consistent and predictable. This advantageously produces more consistent and/or predictable welds than stationary grounding clamps or shoes where the relative distance and/or positioning between the grounding shoe and the robotic welder changes as the welder move along the deck panel. 
         [0064]    A laser tracking apparatus  700  can then be used to measure and record profiles of the ribs  102  and the deck plate  104  at locations at which the floor beams  106  will be attached to the ribs  102  and the deck plate  104 , as shown schematically in  FIG. 37 . For example, in some embodiments, the laser tracking apparatus  700  can be a FARO Vantage™ laser tracker manufactured by Faro Technologies, Inc. Corporation. Using this profile and a CNC machine, the floor beams  106  can be custom machined for their respective locations relative to the ribs  102  and the deck plate  104 . For example, referring to  FIG. 1 , each of the  11  floor beams  106  can have a unique cut-out portion configured for the exact location to which the floor beam  106  will be attached relative to the ribs  102  and the deck plate  104 . This can reduce tolerances between the floor beams  106 , the ribs  102 , and the deck plate  104  compared to decks in which the floor beams are cut from to a single, generic profile. As a result, the weld quality between the components is improved, thus improving the strength and/or durability of the deck panel  100 . 
         [0065]    The floor beams  106  can then be positioned at their respective locations relative to the ribs  102  and the deck plate  104  and attached to the ribs  102  and the deck plate  102 . This can be accomplished by tack welding the floor beams  106  to the ribs  102  and the deck plate  104  with the deck panel  100  in a horizontal orientation, as shown in  FIG. 2 . The deck panel  100  can then be pivoted from the horizontal orientation to a vertical orientation, or in other words rotated 90 degrees about the longitudinal axis of the deck panel  100 , as shown in  FIG. 38   
         [0066]    The deck panel  100  can then be attached to a vertical welding fixture  800 , as shown in  FIG. 38 . The vertical welding fixture  800  can comprise a plurality of support stands  802 , first attachment members  804 , and second attachment members  806 . The stands  802  can be spaced relative to each other. The first attachment members  804  can be lower attachment members disposed adjacent a first location  116  of the deck panel  100  and can be configured to releasably secure the deck panel  100  to the vertical welding fixture  800 . The second attachment members  806  can be upper attachment members disposed adjacent a second location  118  of the deck panel  100  and can be configured to releasably secure the deck panel  100  to the vertical welding fixture  800 . 
         [0067]    In some embodiments, the ribs  102 , the deck plate  104 , and the floor beams  106  can be pre-heated (e.g., by induction heaters) prior to welding the floor beams  106  to the ribs  102  and the deck plate  104 . For example,  FIGS. 39-40  show pre-heating apparatus  900  which can be used to pre-heat the ribs  102 , the deck plate  104 , and the floor beam  106 . As best shown in  FIG. 40 , the pre-heating apparatus  900  can comprise a support plate  902 , a plurality of heating cables  904 , and a mounting bracket  906 . The support plate  902  can be formed from a non-ferrous (e.g., non-magnetic) material and can have a plurality of undulating openings  908  configured to fit over the ribs  102  of the deck panel  100 , as shown in  FIG. 39 . The heating cables  904  can be coupled to the support plate  902  adjacent the opening  908 . As such, the pre-heating apparatus  900  can be disposed on the deck panel  100  as shown in  FIG. 39  and can be used to pre-heat the rib member  102 , the deck plate  104 , and the floor beam  106  prior to welding the floor beam  106  to the rib member  102  and the deck plate  104 . 
         [0068]    It should be noted that pre-heating can be used for the various other welds that are described herein. For example, the ribs  102  and the deck plate  104  can be pre-heated prior to welding the ribs  102  to the deck plate  104 , as described above. 
         [0069]    With the deck panel  100  in the vertical orientation (e.g.,  FIGS. 39-40 ), a robotic welding apparatus can be used to weld the floor beams  106  to the ribs  102  and the deck plate  104 . The vertical orientation of the deck panel  100  advantageously allows the weld direction to be vertically upward, and the robotic welding apparatus allows the weld to be continuous. For example, the robotic welding apparatus can begin at the first location  116  of the deck panel  100  (e.g., a bottom end as illustrated in  FIG. 38 ) and move upwardly toward the second location  118  of the deck panel  100  (e.g., a top end as illustrated in  FIG. 38 ), following the junction of the floor beams  106  and the ribs  102  and/or the deck plate  104 , in a continuous weld. Welding the floor beams  106  to the ribs  102  and the deck plate  104  in this manner can improve the weld quality between the components compared to non-continuous and/or non-vertically upward welding. As a result, the strength and/or durability of the deck panel  100  can be improved. 
         [0070]    As noted above, the ribs  102  and/or the floor beams  106  can be attached to the deck plate  104  and/or to each other by robotically welding the components together. This can be accomplished, for example, by welding the components with one or more robotic welding apparatus  1000 , as shown schematically in  FIG. 41 . 
         [0071]    The deck panel  100  can be attached to a girder (e.g., the girder  1200 , as shown in  FIGS. 48-49 ) using a deck support fixture  1100 , as shown in  FIG. 42 . The deck support fixture  1100  can comprise first and second support structures  1102   a ,  1102   b  (referred to collectively as “the support structures  1102 ”) that can be spaced relative to each other. The support structures  1102  can comprise a plurality of main frames  1104 , a plurality of secondary supports  1106 , a plurality of lateral supports  1108 , and a plurality of adjustment members  1110 , as best shown in  FIGS. 43-47 . Referring again to  FIG. 42 , the secondary supports  1106  can be pivotably coupled to the main frames  1104 , and the lateral supports  1108  can be fixedly secured to the main frames  1104 . The adjustment mechanisms  1110  can be disposed on and removably coupled to first surfaces  1112  of the support structures  1102 . 
         [0072]    The deck support fixture  1100  can be configured such that the main frames  1104  and the secondary supports  1106  align with respective floor beams  106  of the deck panel  106 . The support structures  1102  can be spaced relative to each other such that a girder can be position between the support structures  1102 . 
         [0073]    The adjustment mechanisms  1110  can be individually adjusted to accommodate camber relative to the box girder and/or tapered floor beams. Referring to  FIG. 46 , the adjustment mechanisms  1110  can each comprise a base portion  1114 , a threaded portion  1116 , a stopper member  1118 , and a pad portion  1118 , configured similar to a jack stand. As noted above, the base portions  1114  can be removably coupled to the first surfaces  1112  of the support structures  1102 . The base portions  1114  can comprise various heights. The threaded portions  1116  can comprise external threads configured to engage corresponding internal threads of respective base portions  1114 . The pad portion  1120  can be coupled to the threaded portion  1116 . As such, the height of the pad portion  1120  relative to the base portion  1114  can be adjusted by rotating the threaded portions  1116  in a first direction (e.g., counterclockwise) relative to the base portion  1114  to raise the pad portion  1120  relative to the base portion  1114  and by rotating the threaded portions  1116  in a second direction (e.g., clockwise) to lower the pad portion  1120  relative to the base portion  1114 . 
         [0074]    In some embodiments, the adjustment mechanisms  1110  can include pedestals  1122  which can be disposed between the first surface  1112  of the support structure  1102  and the base portion  1114  of the adjustment mechanisms  1110 . The pedestal  1122  can comprise various heights. 
         [0075]    In some embodiments, the deck support fixture  1110  can also comprise one or more lifting mechanisms (e.g., a hydraulic ram) configured to lift a deck panel relative to the deck support fixture  1110 . This can make adjusting the adjustment members  1110  relatively easier. 
         [0076]    In view of the many possible embodiments to which the principles of the disclosure may be applied, it should be recognized that the illustrated embodiments are only examples and should not be taken as limiting the scope of the invention. Rather, the scope of the invention is defined by the following claims. We therefore claim as our invention all that comes within the scope and spirit of these claims.

Technology Classification (CPC): 1