Innovative Prestressed Composite Underslung Technology
Steel requirement in the PCU bridge superstructure including the HTS cables is less than one third of the conventional open web steel girder bridge superstructure for long spans.
Deflection of the PCU bridge superstructure for the dead load and prestressed condition is hogging. For the live load condition the deflection is about two third of the Code requirement of span/800. Thus, total deflection for dead load with live load condition is less than one fourth of the required deflection of span/600. This makes long span PCU bridge superstructure ideally suitable for particularly high speed elevated rail tracks.
Due to one third overall weight of the PCU bridge superstructure, coupled with stage wise launching and concreting of the deck slab, erection of the bridge is highly facilitated.
Due to one third weight, in corrosive environment it is economically viable to use Chromium Alloy steel in the superstructure for its 100 years of life.
NCE Conference and Awards 2025, London
The invented PCU Bridge Design was awarded First Prize in the 'Best New Bridge Concept Design' category at the NCE Conference and Awards 2025, London.
The judges found the concept to be excellent, with a very thorough submission covering many areas including innovation, budget control, programming, and client satisfaction. Judges were especially impressed by PCU's holistic approach — the well-rounded submission which contained excellent evidence.
NCE Conference and Awards 2024, London
The invented bridge superstructure is selected in top 3 bridge designs by the NCE conference and awards-2024-London in the list of 'Best New Bridge Concept Design'.
Interesting proposal but difficult to see how scheme responds to moving loads and different users. Buildability is also not addressed in any depth.
In the invented bridge superstructure, under slung parabolic (polygon shape) tubular steel girder having composite RCC deck slab at the top and prestressing cables housed in the bottom chord are used. The superstructure uses age old tested truss technology, composite RCC deck, and prestress using HTS cables. At completion of the superstructure, full dead load plus half the live load are balanced by the prestressed cables, which are beneficially anchored into the composite RCC deck using shear stirrups, causing desirable pre-compression in it.
Under gradually increasing udl on the deck slab, the first mode of failure of the super structure is due to buckling of the top chord, which is easily prevented by making it composite with the RCC deck slab using shear stirrups, which also increases equivalent top chord area manifold, and doubles stiffness of the super structure. Under further increased load, rupture of the bottom chord takes place, which is prevented due to prestressed through the bottom chord.
Live load on the superstructure is taken by the composite steel girder and the anchored prestressing through the bottom chord, having double stiffness, and hence steel requirement reduces to one third. Total deflection for dead load with live load condition is less than one fourth of the required deflection of span/600. Due to hogging for half the live load, fatigue of the superstructure is also highly reduced.
Due to lighter girder and its erection in parts launching of the steel girders first, followed by cross girder connection, the total weight being handled at a time reduces to about 1/6th of the traditional truss weight. The deck slab may be cast in symmetrical spans using stage prestressing as per design.
Unit cost and weight of Fabricated Structural Steel (fy = 250 N/mm2) and High Tensile Cables (fp = 2000 N/mm2), are nearly equal, where as cables are about 8-times stronger in tension.
In the invented superstructure, at the bridge completion stage, full permanent load and half the transient load are balanced by the prestressed and anchored cables.
Under the live load condition, the composite RCC deck, steel girder and the anchored HTS cables, having double stiffness due to the composite action, steel requirement in the girder reduces to less than one third of the conventional steel truss superstructure.
Thus, considering both the permanent load and the transient load conditions, overall cost of the superstructure remains less than one third of the conventional steel truss superstructure.
Exceptional Benefits of the Invented Bridge Superstructure
Apart from the main advantage in the invented bridge superstructure cost, which reduces to less than one third of the conventional steel truss bridge superstructure in medium and long spans, the following other advantages in the invented bridge superstructure are there.
The invented bridge superstructure is very suitable for specially long spans due to its light weight as all the death load and half the live load are balanced by the cables having about eight times higher strength than the structural steel.
The conventional segmental PSC box girder is susceptible to shrinkage and creep deformations in long run making it unsuitable for high speed trains. The invented long span, light and robust steel girder has practically no time dependent deflections, and hence it may be very suitable for high speed elevated train tracks.
As steel consumption in the invented bridge girder is less than one third, in highly corrosive environment chromium alloyed steel can be afforded for the construction, making it corrosion resistance for 100 years.
Anchorage of the cables at the ends induces desirable precompression in the RCC deck through shear stirrups, rendering its design possible longitudinally on no crack basis.
It is very light weight due to maximum load supported by the cables, making it suitable for high seismicity areas.
Due to the light weight superstructure, cost of the substructure is also low, making the overall cost of bridge competitive.
Due to the composite deck, stiffness of the superstructure doubles and hence depth of the girder can be reduced to say 8m in 100m span that is span/12.5.
Due to long span and light weight superstructure and substructure, the bridge has sleek and elegant look.
Individual long span girders are launched first, followed by cross members connections, and deck casting in parts with stage wise designed prestress, rendering its erection easy.
Structural steel requirement in the girder reduces due to the composite deck, and stagewise girder launching, deck casting and prestressing as per design.
Reserve strength of the girder in ULS condition is more than 3-times its strength in SLS condition making it robust.
Due to hogging deck for half the live load, girder deflection from the mean is reduced to half, and consequently the girder fatigue is highly reduced.
Due to hogging, pre-stressed shear force under dead load plus live load is reduced, which is highly desirable in design of the shear stirrups.
The cables are fully protected in the tubular bottom chord, epoxy grouted at the end anchorages, and cement concrete grouted in the remaining cable length, making it most suitable for highly corrosive environment.
Tubular steel may be produced using alloying, and/or hot dipped Galvanizing for aggressive environment. About 11.5 percent chromium alloying of steel makes it fully corrosion resistant in sea environment for more than 100 years.
The invented unique superstructure is applicable to infrastructure projects related to transportation systems like:
The PCT application for award of the patents in different countries, and approval for the same is given in the link below.
View PCT Publication on WIPOAs per the PCT approval given in the above link, the applicant was advised to obtain patents in the 157 countries before 24 April 2024, accordingly application for the patents within the prescribed time have been made in most of the PCT approved countries, for which the patents are in process.
Already approved in several countries
Applications under review
Complete list of applications
Download official PCT publication documents
Invented bridge superstructure is granted by India Patent
Check Status: Application No. 202111043274Countries: Benin, Burkina Faso, Cameroon, Central African Republic, Chad, Comoros, Congo, Côte d'Ivoire, Equatorial Guinea, Gabon, Guinea, Guinea-Bissau, Mali, Mauritania, Niger, Senegal, and Togo
Invented bridge superstructure is granted by Republic of South Africa
Download| OUR REF. NO. | COUNTRY | PCT NO. | APPLICATION NO. | FILING DATE |
|---|---|---|---|---|
| ABH:AKS:FOR-1158 | USA | PCT/IN2022/050200 | 18/271,410 | 44463 |
| ABH:AKS:FOR-1159 | Japan | PCT/IN2022/050200 | 2023-541533 | 44463 |
| ABH:AKS:FOR-1160 | China | PCT/IN2022/050200 | 202280009434.0 | 44463 |
| ABH:AKS:FOR-1168 | Canada | PCT/IN2022/050200 | 3205909 | 44463 |
| ABH:AKS:FOR-1169 | Australia | PCT/IN2022/050200 | 2022351932 | 44463 |
| ABH:AKS:FOR-1196 | Hong Kong | PCT/IN2022/050200 | 62024088934 | 45370 |
| ABH:AKS:FOR-1209 | ARIPO | PCT/IN2022/050200 | AP/P/2024/015596 | 45372 |
| ABH:AKS:FOR-1210 | OAPI | PCT/IN2022/050200 | Will provide once available | 45373 |
| ABH:AKS:FOR-1211 | Europe | PCT/IN2022/050200 | EP22872352.4 | 45368 |
| ABH:AKS:FOR-1212 | Eurasia | PCT/IN2022/050200 | 202490527 | 45370 |
| ABH:AKS:FOR-1213 | Saudi Arabia | PCT/IN2022/050200 | SA 112024152 | 45375 |
| ABH:AKS:FOR-1214 | UAE | PCT/IN2022/050200 | P2024-00715 | 45375 |
| ABH:AKS:FOR-1215 | Qatar | PCT/IN2022/050200 | Will be allotted shortly | 45375 |
| ABH:AKS:FOR-1216 | Oman | PCT/IN2022/050200 | OM/P/2024/000167 | 45373 |
| ABH:AKS:FOR-1217 | Bahrain | PCT/IN2022/050200 | 202400079 | 45373 |
| ABH:AKS:FOR-1218 | Egypt | PCT/IN2022/050200 | EG/P/2024/409 | 45373 |
| ABH:AKS:FOR-1220 | Korea | PCT/IN2022/050200 | Application Filing Pending | - |
| ABH:AKS:FOR-1222 | Malaysia | PCT/IN2022/050200 | PI2024001757 | 45373 |
| ABH:AKS:FOR-1225 | New Zealand | PCT/IN2022/050200 | 809451 | 45374 |
| ABH:AKS:FOR-1226 | South Africa | PCT/IN2022/050200 | 2024/02347 | 45373 |
| ABH:AKS:FOR-1229 | Mexico | PCT/IN2022/050200 | MX/a/2024/003543 | 45373 |
| ABH:AKS:FOR-1230 | Israel | PCT/IN2022/050200 | Will provide once available | 45371 |
Composite RCC Deck and Prestressed Parabolic Bottom Chord Underslung Open Web Steel Girder Bridge Superstructure
These typical bridge designs showcase the innovative Composite RCC Deck and Prestressed Parabolic Bottom Chord Underslung Open Web Steel Girder Bridge Superstructure technology. Available in 100M and 60M span configurations, these designs represent cutting-edge engineering solutions for modern infrastructure projects.
Innovative Bridge Technology with Exceptional Cost Benefits
The invented bridge superstructure cost is about half of the conventional truss bridge cost for medium and long spans, further resulting in saving of the substructure and foundation cost. Parallel foundation and substructure construction with superstructure construction saves time and cost. Also, girder wise launching followed by cross member connections, and insitu deck casting in symmetrical parts starting from both ends, further reduces the construction time and cost.
In view of the multifarious advantages, a royalty of 5.0% of the estimated cost of the bridge superstructure only with taxes like GST is chargeable.
Design and supervision charges, if any, for the awarded patent license shall be charged in addition to the licensing fees as above.
The country wise patent can be negotiated for sale in part or full as decided by the patent holder.
This revolutionary bridge technology is protected by patent rights. All licensing terms are subject to negotiation and agreement with the patent holder.
Note: All fees mentioned are exclusive of applicable taxes unless otherwise specified. Terms and conditions apply.
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