PCU Bridge Design

PCU Bridge Design

Innovative Prestressed Composite Underslung Technology

Highlights

Highlights of Prestressed Composite Underslung (PCU) Bridge Superstructure

1

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.

2

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.

3

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.

4

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.

The Award

NCE Award 2025
2025

First Prize Winner

Best New Bridge Concept Design

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.

Judges' Comments

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 Award 2024
2024

Top 3 Finalist

Best New Bridge Concept Design

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'.

Judges' Comments

Interesting proposal but difficult to see how scheme responds to moving loads and different users. Buildability is also not addressed in any depth.

Downloads

Download award-winning documents and papers

Technology

Elevation of the open web steel girder is shown in Fig. 1.

Figure 1 - Open Web Steel Girder Elevation

Anchorage details of the cables at the ends are shown in Fig. 2

Figure 2 - Cable Anchorage Details

3-D view of the FEM model used in analysis of the prestressed composite under slung open web steel girder superstructure is shown in Fig. 3

Figure 3 - 3D FEM Model

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.

Cost Advantage

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.

Economic Excellence

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.

Other Advantages

Exceptional Benefits of the Invented Bridge Superstructure

Main Advantage

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.

1
Light Weight & Long Span

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.

2
High Speed Train Suitable

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.

3
Corrosion Resistant - 100 Years

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.

4
No Crack Design

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.

5
Seismic Resistant

It is very light weight due to maximum load supported by the cables, making it suitable for high seismicity areas.

6
Lower Substructure Cost

Due to the light weight superstructure, cost of the substructure is also low, making the overall cost of bridge competitive.

7
Reduced Girder Depth

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.

8
Sleek & Elegant Look

Due to long span and light weight superstructure and substructure, the bridge has sleek and elegant look.

9
Easy Erection

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.

10
Reduced Steel Requirement

Structural steel requirement in the girder reduces due to the composite deck, and stagewise girder launching, deck casting and prestressing as per design.

11
Robust Reserve Strength

Reserve strength of the girder in ULS condition is more than 3-times its strength in SLS condition making it robust.

12
Reduced Fatigue

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.

13
Reduced Shear Force

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.

14
Cable Protection

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.

15
Aggressive Environment Protection

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.

Infrastructure Applications

The invented unique superstructure is applicable to infrastructure projects related to transportation systems like:

Highways Railways Metro Rail Flyovers Bullet Trains Coastal Road Sea Links

PCT Publication

PCT Patent Application

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 WIPO
PCT Approval Information

As 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.

157
Countries
1
Patents Granted

Already approved in several countries

2
Patents In Progress

Applications under review

3
Countries List

Complete list of applications

PCT Documents Download

Download official PCT publication documents

Patents

A. Patents Granted

1India Patent

Invented bridge superstructure is granted by India Patent

Check Status: Application No. 202111043274

2African Intellectual Property Organization (OAPI) Patent

Countries: 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


3Republic of South Africa Patent

Invented bridge superstructure is granted by Republic of South Africa

Download

B. Patents in Progress

1
USA Patent

Invented Bridge Superstructure is published by USA Patent office

Search: 20240060253
2
Hong Kong Patent
Hong Kong Patent Detail
3
4
5
6

C. List of Countries Where Patent is Applied as per PCT

OUR REF. NO.COUNTRYPCT NO.APPLICATION NO.FILING DATE
ABH:AKS:FOR-1158 USAPCT/IN2022/05020018/271,41044463
ABH:AKS:FOR-1159 JapanPCT/IN2022/0502002023-54153344463
ABH:AKS:FOR-1160 ChinaPCT/IN2022/050200202280009434.044463
ABH:AKS:FOR-1168 CanadaPCT/IN2022/050200320590944463
ABH:AKS:FOR-1169 AustraliaPCT/IN2022/050200202235193244463
ABH:AKS:FOR-1196 Hong KongPCT/IN2022/0502006202408893445370
ABH:AKS:FOR-1209 ARIPOPCT/IN2022/050200AP/P/2024/01559645372
ABH:AKS:FOR-1210 OAPIPCT/IN2022/050200Will provide once available45373
ABH:AKS:FOR-1211 EuropePCT/IN2022/050200EP22872352.445368
ABH:AKS:FOR-1212 EurasiaPCT/IN2022/05020020249052745370
ABH:AKS:FOR-1213 Saudi ArabiaPCT/IN2022/050200SA 11202415245375
ABH:AKS:FOR-1214 UAEPCT/IN2022/050200P2024-0071545375
ABH:AKS:FOR-1215 QatarPCT/IN2022/050200Will be allotted shortly45375
ABH:AKS:FOR-1216 OmanPCT/IN2022/050200OM/P/2024/00016745373
ABH:AKS:FOR-1217 BahrainPCT/IN2022/05020020240007945373
ABH:AKS:FOR-1218 EgyptPCT/IN2022/050200EG/P/2024/40945373
ABH:AKS:FOR-1220 KoreaPCT/IN2022/050200Application Filing Pending-
ABH:AKS:FOR-1222 MalaysiaPCT/IN2022/050200PI202400175745373
ABH:AKS:FOR-1225 New ZealandPCT/IN2022/05020080945145374
ABH:AKS:FOR-1226 South AfricaPCT/IN2022/0502002024/0234745373
ABH:AKS:FOR-1229 MexicoPCT/IN2022/050200MX/a/2024/00354345373
ABH:AKS:FOR-1230 IsraelPCT/IN2022/050200Will provide once available45371

Typical Bridge Designs

Composite RCC Deck and Prestressed Parabolic Bottom Chord Underslung Open Web Steel Girder Bridge Superstructure

1
100M

100M Span Bridge Design

Composite RCC Deck and Prestressed Parabolic Bottom Chord Underslung Open Web Steel Girder Bridge Superstructure
Technical Specifications
Span: 100 Meters
Type: Composite Structure
Design: Prestressed Parabolic
2
60M

60M Span Bridge Design

Composite RCC Deck and Prestressed Parabolic Bottom Chord Underslung Open Web Steel Girder Bridge Superstructure
Technical Specifications
Span: 60 Meters
Type: Composite Structure
Design: Prestressed Parabolic
Bridge Design Information

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.

Royalty & Licensing

Innovative Bridge Technology with Exceptional Cost Benefits

Revolutionary Cost Savings

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.

1

Royalty Fee

5.0%

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.

2

Design & Supervision

Design and supervision charges, if any, for the awarded patent license shall be charged in addition to the licensing fees as above.

3

Patent Sale

The country wise patent can be negotiated for sale in part or full as decided by the patent holder.

Patent Information & Licensing

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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