ay United States Patent Garber 'US009988775B1 (10) Patent No. (45) Date of Patent: US 9,988,775 B1 Jun. 5, 2018 (54) CONCRETE I-BEAM FOR BRIDGE CONSTRUCTION (71) Applicant: David Garber, Miami, FL (US) (72) Inventor: David Garber, Miami FL (US) (3) Assignee: (£) Notice: Subject to any dselaimer, the term of this patent is extended or adjusted under 38, USC. 1540) by 0 days. days (21) Appl. Now 157830,656 (22) Filed: Dec. 4, 2017 6) mea, oan 506 (2006.01) EOD 202 (2006.01) OID 21/00 (2006.01) B04G 13/08 (2006.01) OID 10126 (2006.01) (2) EOID 292 (2013.01); EID 2100 (2013.01); Eo4B $706 2013.01), EosG 1304 (2013.01); BOLD 2101/26 (2013.01) (58) Field of Clasiication Search CPC. EOLD 2400; FOID 2102; FOLD 2/04; BOLD 2101/26; EOAD 5/04; EOsB 5/6; EOAC 320, FOG 13/04, spc 14/745, 77.1; 52/416, 419, 429, 431, 52/433, 437, 649.1, 650.1, 831, 837 ‘See application file for complete search history 37 66) References Cited USS, PATENT DOCUMENTS + 101868 Mongomery = "Sions Benner 1720603 4 © 74929 Saher 1887875 A © L982 Neleon 0433 . Beower nab St 73 . Kim ro1p 3100, 14745 S381485 82 Plat Bosh 7168 Mads sea9.383 82" Han EoID 192 9299.46 82 Han ob 202 300508 82" Sm orp 302 FOREIGN PATENT DOCUMENTS KR Isois4 BL + 22016 KR TorsoRS BL * cited by examiner Primary Examiner (14) cnorne Fisenschenke Gary {gent or Firm Hlaresann liwanebik, Lloyd & on ABSTRACT A beam used for construction, paticulatly of short= 19 mid-span bridges. A beam can include flanges extending froma web that are joined to flanges of another beam. When joined two beams form an open internal void. The beams ean tbe manufactored from conerste and include an embeded reinforcement cage, Manulactre of the beams ilies Formoork that ean be filled in single pou 9 Claims, 9 Drawing Sheets 10 2U.S. Patent Jun, 5, 2018 Sheet 1 of 9 US 9,988,775 BI Tv _ 75 60 37U.S. Patent Jun, 5, 2018 Sheet 2 of 9 US 9,988,775 BI 0 Cr : 6 a 6 Lo | FIG. 3A FIG. 3B (PRIOR ART} (PRIOR ART) 600, FIG. 3C ‘ata {PRIOR ART) FIG. 3E (PRIOR ART)U.S. Patent Jun, 5, 2018 Sheet 3 of 9 US 9,988,775 BI ~ Ca FIG, 4A (PRIOR ART) 5 CIE so FIG. 4B (PRIOR ART) FIG. 4D {PRIORART)U.S. Patent Jun, 5, 2018 Sheet 4 of 9 US 9,988,775 BI UA Gl oa ELIE EEL El a} 5 FIG. 5D 180U.S. Patent Jun, 5, 2018 Sheet 5 of 9 US 9,988,775 BI PRI # FIG. 6A 10 150- S i Bz FIG. 6B 175 a xy a LOE MaradhsU.S. Patent Jun, 5, 2018 Sheet 7 of 9 US 9,988,775 BI FIG. 9 FIG. 10U.S. Patent Jun, 5, 2018 Sheet 8 of 9 US 9,988,775 BI FIG. 11A et FIG. 1EU.S. Patent Jun, 5, 2018 Sheet 9 of 9 US 9,988,775 BI EZ a FIG. 128 Soa ome . Wd Anal SOT \ | 180 *s i! 7 FIG. 120.” 4 a 0 ri Ey Z BU 5 \ 5 | $ Sig @ FIG. 12DUS 9,988,775 BI CONSTRUCTION BACKGROUND OF INVENTION Pre-stresed concrete box-beams have been used since the 1950's to build short and medium span bridges, [ei est ‘mated that thete are approximately $8,000 box beam bridges in service in the United States. Box-beams are popular because they ean be used in multiple ways to quickly ad salely construct bridges. ox beams are typically manufactured by casting rein {forced concrete around a foam cone ina moor formwork. Rebar is used to build a reinforcing “cage” arund the foam core prior to pouring the concrete. The bottom part of the ‘age is placed first and then layer of concrete is poured. The foam core is place onthe layer oF canerete an the fof the cage is built up around the foam core. Concrete i poured to surround the foam core and the rest ofthe eae. ‘Because the foam core fils the cent space ofthe box beam and is surounded by concrete afer the pour, itis act possible to do a posteast inspection of the interior of the box-beam, Iris also posible forthe foam core to shift daring the pour causing inconsistencies in concrete thickness in the ‘webs and flanges, which change the strength of the beam. Further, the time involved ia constructing and pouring the concrete in to stages can result in formation of a “eold jin” berween the botiom and top parts of the Beam, which ‘re poured in to stags. cold joint can form when a hid fonerte is potred over soto séni-et concrete, The inte face where tw different phases of eoncrete meet can foam ‘cold joint, whieh can be weaker than other more consoi- ‘dated areas of the concrete mass During consirction, box Beams are placed adjscent 10 ‘one another with small ap between called a shear key. The shear key can be filled witha cementitious grout material Once the box-boams are set and grovted, a wansverss posttensioning (IPT) arrangement is used to apply force ‘cross the box-beas This is followed by laying 83°10 6" feinforcad deck slab over the box-beams of at asphalt overlay” for low-irallic bridges. When the box-beams, srouted-shear keys, TPT, and the deck slab are properly Integrate, «completed bridge can perform as a monolithic Tis nomnal for cracks to form in grout material beoween the boxcbeams. ‘The boxcbeams ean also develop smal Tractors or cracks. Water and other materials that step ino the cracks can be absorbed by the grout and the foam, This ereates an internal environment tht is moist and, overtime, promotes degradation of the grout material and the box intemal void eannot be inspected, the ate ff degmdation canaot be easly monitored, ‘Ura-high performance cooerote (UPC) has become an important stctural material. UPC beneis from being a “minimum defee™ material. Thats, UHPC isa material that is less susceptible to the Formation of defects such as ‘micro-cracks and interoonnected pores, and exhibits a maxi ‘mum packing density. Several types of UPC have been develope in diferent countries and hy diferent mamilac- turers. The four main types of UHPC are compact reinforced composites (CRC), muli-seale cement compete (MSC), and reactive powder cement (RPC). RPC is the most com ‘monly available UHPC and one such produet i enmeatly marketed under the name Ductusl by Lafimge, Bouygues and Rhoda, “There is nee fora reinforced concrete beam that can be cast na single eonerete pour that sill hasan intemal void 2 ‘o be wsed for inspecting the beam surfacesaer casting, The ability to use UHPC as a grout material between the Beams ‘would also beam advantage BRIEF SUMMARY ‘The subject invention provides devices and methods that tuldess the problems astocated with standard bos-beams and their construction, The subjeet invention provides pre-cast concrete beam with an imbedded reinforcement coge. The reinforcement cage can be entirely assembled in ‘8 Tomvork prior to aditon of concrete, which canbe done Jina single pour. The beams can be used in pairs to form stnictue similar to a box beam, Advantageously, « foam core isnot required, allowing for post-cast inspection of the interior void surface of the final beam structure Embodiments of a boam of the subject invention have an hape or similar shape, where there isa web cohumn with two top Ranges and two bottom flanges. An altemative cembodimeat lis a“ (or inverted-"T") shape, with web fad two botiom Hhanges. In use, nwo beams ean be placed side by side, with adjacent lages. The flanges can have Jeregular faces that allow a grout material tobe interme therebetween to feviltate holding the beams together and ing joint. When joined, two L-shaped beams can form a complete boe-beant type of structure, with an open interior void available for posteast inspection. Altematively, when 10 inverted T-shaped beams are joined, precast panels ean be placed on the webs between siko beams o fort a Box beam Type of sinctre, which also hes an open interior void available for posteast inspection. Grout material can be ‘sed t fil the space betwoen the web and pre-cast panels UUHPC has boon used in bridge constriction as & grout ‘material. UHPC can also be advantageonsly used fo connect beams ofthe subject invention, The use of UHPC as grout material o connect both the top and bottom Manges between ‘wo beams can minimize the risk of eracking in the desk where the Manges meet to form a joint A sectional formwork can be used to construct a beam without the need fora foam core. This ean provide improved fcctracy and precision of the beam dimensions, It aso allows the minforeement cage to be built entirely within the form before pouting the coneret into the Formwork BRIEF DESCRIPTION OF DRAWINGS In order that a more precise understanding ofthe above recited invention can be obtained, a more particular descrip. tion of the invention briefly described ahove will he re dered by reference to specific embodiments thereof that are ‘Mfustated in the appended drawings. The drawings pee- sented herein may not be dawn to seale and any relerence {0 dimensions inthe drawings or the following description is specific tothe embodiments disclosed, Any variations of these dimensions that will allow the subject invention to function fr its intended! purpose are considered tobe within the scope of the subject invention, FIG. I shows an embodiment ofa beam, according to the subject invention, having top flanges and bottom Banges. FIG, 2 shows two beams, according fo the subject inven- Aion, positioned sie-by-side with adjacent flanges, FIGS. 3A through 3E (prior an) illustrate casting smthod for forming a standard box beam. FIGS. 4 though 4D (prior aft) illustrate a method of joining of wo standard box beams.US 9,988,775 BI 3 FIGS, SA through SE illustrate an embodiment of the casting technique for forming a beam, according 10 the subject invention. FIGS. 6A theogh 6D illustrate # method foe joining two ‘beams, aecording tothe subject invention FIG. 7 demonstrates flanges of a beam, according to the subject invention, that have diferent maximum lengths. FIG, 8 demonstrates joints between beams that are offset tnd not vertically aligned IG. 9 shows an embodiment ofa beam, according to the subject invention, baving bottom flanges. FIG. 10 shows two beams, as scen in FIG. 9, positioned side-by-side with adjacent bottom fanges FIGS. ILA through TIE ilustate an embodiment of the casting technigue for casting an i-beam, according to the subject invention FIGS. 124 through 12D illustrate « method for joining ‘vo beams having only bottom flanges, according 10 the subject invention. DETAILED DISCLOSURE The subject invention provides methods and devices for casting and joining beams that can be used to build srvc- tures, particularly shor- and mid-span bridges. More spe: eifeally, the subject invention provides one or more beam ‘embodiments with flanges. The beams ean be placed adja- cent (© each other and joined at the anges to form a superstructure. Alematively, other sinietres oF compo: nents, soch as precast panels an be placed on, and joinod 3 to, the beams fo create a supersircture. “The structure of te joined! beams canbe use silly to standard ox beams. Advantapeousl, the joined beams ean provide an interior void, ikea box hear, bit that not led ‘vith a foum core and allows for full pos-cast inspection, unlike standard box beams. Grout material such as, for example, ultra-high perfomance concrete (UHPC) can be ‘sed to join the beams to minimize cracking and separation The subject invention is particulary use inthe field of bridge construction, in particule short fo mid-span bridges While the subject application describes, and! many of the terms herein relate 10, a use for bridge constuction, other ties apparent to person with skill in the art and having benefit of the subject disclosure are contemplated to be within the scope of the presen invention. Reference is aso mace throughout the application the roxinaldiveton” ad “distal end” Or As used herein, the proximal ead oF proximal direction is that end tht is direted upwards in a Structure or that end against which force or weight is applied, particularly when used in bridge constuction. Con ‘versly, the distal end or distal diction ofthe device i that fend which is diacted downward o¢ forms the bottom side. For example, 2 modular reinforcement cage can be built fom the distal end. The present invention ismore particulary desribed in the following examples that are intended to be ilastativeoaly boensse mamerots modifications and variations thercin will be apparent to those skilled in the art. As used in the specification and inthe claims, the singular for “a” “an” and ihe” include plural referents unless the context clearly Aicates omherwise ‘Reference will be made to the atached Figures on whieh the same reference numerals ae used throughout wo indicate the same or similar components. With reference to the attached Figure, which show certain embodiments of the Subject invention, it can be soon thatthe subjet invention 4 pertains 1 @ beam 100 and methods for manufacturing a bam. One embodiment of a beam includes a web 150 with ‘opposing top anges 200 that protrude from the web and ‘opposing boom flanges 300 that protrude from the web. In fone embodiment, the top flange and bottom flanges are perpendicular tothe web. Other embodiments of & beam have web with ony bottom flanges. A reinforcement cage 500 and longitinal pre-sressing strands $75 canbe imbed- dd inthe beam to support the web and the bottom anges fndor top flanges and give the beum its required strength The method of esting a beam can utilize a formwork 600 that allows the entre reinforcement cage to be placed or built therein and secured, so that one coatinuous concrete pour can be made to fill dhe formwork and surround the reinforcement cage, Each of these general components al seps ean have one or more sub-components or sub-seps, ‘which will be discussed in detail below. Standard box beams placed side-by-side have a space between them called a “shear key” $8. The standard box ‘beam fommvork ean be designed to create a shear key when the box beam concrete is poured. FIGS. 34-3F illustrate a formwork having indentations 56 tht ean form a shea key ‘nthe sides ofa standard box beam. During the constuction of a structure, such as, by way of example, a shor or ‘id-span bridge, the shear key is led witha grout material 35, to transfer vertical shear and bending stresses between the box beams. For example, magnesium ammonium phos: phate grout mixed with pea gravel, polymer cements, fiber Feinforced cements, and epoxy-hasad grouts can he used ‘Conversely @ beam 100 of the subject invention can be ‘sed in pars to creat a alternative to a standard box beat. alike & typical box beam, a beam ofthe subject ivention ‘when joined in pars provides an open inter void 400. FIG. [illustrates one embodiment of a beam ofthe subjest ‘vention thot fs top Manges and bottom flanges. FIG. 2 ilstrates a par of beams prior to joining and demonstrates the openness ofthe intemal void, which allows inspection of the surface 480 inside the void. FIG. 9 ilastates an alter- native embadiment of beam that utilizes only bottom flanges. FIG. 10lustrates a pair of alternative embodiment beams that ae joined at the bottom flanges. The joined bottom flanges can form a joint 178 and the web has a support surface ISS on which t0 support a secondary structure 40, such as, for example, pre-cast slab papel, aan form the intemal void 400, One example of a eross- Sevctue supported on a support surface of web is shown jn FIGS. 12¢ and 120. The casting ofa standard box beam $0 utilizes a box-like Jaework 600, af shown, for example, in FIOS. 3A-3E. Part ofthe reinforcement cage s placed inthe bottom ofthe formwork and a layer of canerete or other materi is poured ‘ver that pat of the reinforcement cage, ss demonstrated in FIGS. 34 and 38. foam “blockout™ 30 is placed over the frst layer of eonerete and held in place with the remainder of the reinforcement cape, Brackets ae used to hold down the foam bloekout and inhibit it from outing as another layer of concrete is poured around the est of the reinforce- sent cage inthe framework. Examples ofthe foam blockout placement and the second pouring of eonerete are shown in FIGS. 3C and 3D. FIG. 38 shows the formwork removed fom around a final box beam with the foam bloskout therein, The foam blockout doesnot extend w the ends ofthe beam, i, there isan end block of certain thickness formed of east concrete over the entire ends of the beam, thereby enclosing the foam blackout within the beam, Postinspes- tion ofthe surface isnot possible Becaise there fs no accessUS 9,988,775 BI 5 ‘0 the internal void 400 oF the sutface of the internal void 450 after the pour is complete. Certain embodiments of the subject invention provide a beam 100 that can be joined 10 a last one other beam, ‘hich together form, or can be used to form, a structure having an open inter! void 400, This provides the advan tage of allowing postinspection of the surface 480 of the {nernal void. Tn one embodiment, when to of more beams ate joined, the joins 175 formed between them result in'a Slab surfice 780 ad under-surfice 778. la certain eter ‘embodiments, when two or more beams are joined, the joint 178 formed between them provides an undersurface 78, The slab surface and undersurface can be smooth making the slab surface easier to cover over with concrete or asphalt andlor makes the undersurface more aesthetically pleasing. tcan be seen in FIGS. I and 9 that embodiments of a beam ofthe subject invention have a vertical web 150 and at least ewo bottom anges 300. In one embodiment, the bottom Manges extend perpendicularly from opposite sides of the bottom end 20 of the web, In another embodiment 2 there are additionally two top flanges 200. In ene embodi- ren, the top flanges extend perpendiculary from opposite sides ofthe lp end 10 of the Web. In a futhor embodiment, ‘one or both of the top Manges ae parallel fo one or both of the bortom Manges, sich as shows, for example ia FIG. 1. In one embodiment, the top flanges 200 and bottom ‘anges 300 of a beam 100 ean be joined tothe top anges 1nd bottom fangesof at least ene other beam to erate joints 178 betwoen the flanges, The joined beams can have slab surface 780, under-surlace 778, and an internal void 400. ‘The resulting anges can be joined together wilizing any of varity of materials, including, but not imited to, the same ‘rout mistrial 38 used to il the shear hey 3 between to Standard box beams 50, as diseussed above. In further embodiment, grout material can include Ultra-high perfor ‘mance concrete (UPC), In another embodiment, where a beam has only bottom flanges, the bottom flanges 300 ean be joined tothe boom Flanges of at least one other beam 10 crete a joint 178 berwoen them, The joined heams wil form an under-surice 78 and the top end 10 ofthe web can provide a support surface 185 Tiregulaities can provide areas or points where grout ‘material 38 can set or harden around of within the mega Tuvtes. This ean create resistance that inhibits the grout ‘material fom being Forced out ofthe space of are beeen the surfaces. BY Way of example, the shear key shown in FIG, 3E forms an indentation Within the box bears that it Wider atone point and rarrower above and below. When Silled witha grout material, the grout material will form pig that is wider than the top ofthe shear key, which ean Inhibit t fom working its way out ofthe shear key ‘To ficiltate joining of the flanges between two or more beams, one or more ofthe Manges can have a profile that is Jnreglar or that is otherwise beneficial for holding the erout ‘material 35 jn a joint 178, In one embodiment, top Mange 200 has a peolle 250 with one more indentations 287, in ‘which a grout material can foi a plug herween the profiles Df the top Banges. In snother emockiment, «bottom flange 4300 can have a profile 380 that forms a depression 359 ‘within the bottom end 20, such as shown, for example in FIGS. 1 and SE, The depression 389 in dhe bottom end ean be filed with a grout materi that ean also Form a plog, One ‘xaaiple of this ean be seen in FIGS, 6B through 6D. The surfaces of the profiles can also be soup, unfinished. or tuneven to further facilitate holding the grout material i place. For example, top Range profile 280, bottom flange 6 profile 360, and support surfaces 188 can be sandblasted 10 orm a roughened surface, which ean aid in adhering toa trout mitral. person with sil inthe aet can detelinine bother types of regularities tht can be used on the profiles of top flanges and bottom Manges that are beneficial in Securing a grout material in a joint, Such variations are ‘within the scope ofthis invention, ‘The length 28 ofthe top anges 200 andthe Tength of the bottom flanges 300 can vary, which ean change the location ofthe joints 178 between beams. maximnutn length 28 for f flange is the horizontal distance betwoen the vertical web 480 and the end of the profile 280 or 380 of the ange, as shown in FIGS. 12.7.8, and 9. Inone embodiment, the top flanges and botiom flanges have the same maximum length. In another embodiment, the top flanges have 2 maximum Jength thats shorter than the maximum length of the bottom anges, as shown, for example, in FIGS. 1 and SE. In yet nother embodiment, the top Manges exch have a diferent ‘maximum length, In tll another embodiment, the bottom flanges each havea different maximum length, FIGS. 7 and B illustrate non-limiting examples ofa beam having diferent Fength flanges, The lengths of the anges ean also determine the location ‘ofthe joints 178 berwoen the anges of 0 oF noee beams. Tnone embodiment, the maximum lengths ean be configured so that the joint between the top Thanges and the joint between the bottom flanges is verically aligned, as shown, for example, in FIGS. 2 and 6D. Altematively, difering the ‘maximum lengths ofthe flanges can cause the joins to be offic, such that they are not vertically aligned, an example of which is shown in FIG. 8 Joining vo beams 100 to form a joint can require access to the botiom flanges through a channel 636 formed between the two top flanges. When beams 100 are adjacent, the profiles 380 of the bottom flanges ean abut to form a ‘depression 389, as desrihed below. se top flanges can be spaced apart to allow temporary access to the interior void 4400. In one embodiment, the length of the top anges provides a channel 636 that provides acces to the interior void when two beams are adjacent, In a more specific cembodiment, the combined maximum lengths of the top anges ae less than the combined mania lengths of the bottom Ranges. The embodiments ofthe subject invention ean also benefit from the use of reinforcement structures 50 and sresing strands $75. In one embodiment, a modular rein- Togcement cage 500 is used to reinforce the web and Manges of bean, A modular reinforcement eage ean comprise one for more reinforcement steuctures, such as, metal rods oF formed metal structures, such as shown ia FIG. A. The ‘modularity ofthe reinforcement cage allows the components of the cage to be placed individually in the assembled Jormvork, to reinforce the anges as well asthe web. The reinforcement structures ean be placed in formwork, which tan hold their position when the concrete is poured ia the Framework, Alternatively, one of more ofthe reinforcement snictures can he connected or tached fo each other fom f structure capable of maintaining form and position in the formwork when the conerete is poured in the formwork, A ‘modular reinforcement cage ean also comprise one ar more pre-stessing strands. Advantageously, al ofthe components ‘ofa modular reinforcement cage ean be positioned and if rocessary, connected within formork before the pouring of coneree. This allows ll section of the beam to be reinforced and the conerete to be applied in a single pour, ‘which promotes a more monolithic-fype structure ad inhib- its the formation of eokd joints. person of skill inthe artUS 9,988,775 BI 7 umber of configurations foe a aratons ao within the scope of can determine any of feinforcement cage. Soch this invention, In one embodiment, » modular reinforcement cage S00 bas a plurality of reinforcement structures S50, suc as, for ‘example, rebar, strategically placed within formwork 600 10 Support top flanges 200, bottom flanges 300, a the web 150, For example, rebar can be placed lengtwise, or per- pendicularto the direction of the maximum length 28, i the bottom end 20 of te fornork to reiaforve botiom Manges, se shown in FIGS. SA.and ITA. ln fare embodiment, a re-ensioning strand ean be position in the formwork, 10 be pled in the longitinal diction ofthe beam, perpen dicular to the maximum length 28, as show, for example, in FIGS. SB and 1B. In yet a further embodiment, com ponents of a reinforcement structure ean be. positioned ‘within the formssork to reinfore the web, as shown in FIGS, 51 and 118. AC least one reinforcing har can also be placed ‘cross the top flanges. In one embodiment, to reining bare are placed aeoss the top flanges. “The formvor in which a beam of the subject invention. js east can be constructed in sections that can be later ‘removed from around a east beam, This sectional formwork allows the bottom Manges and narrower web to be east simultaneously to avoid the issue of forming cold joins wherein softer concrete is poured on et or semiset con crete, This can also allow the reinforcement cage to be flly assembled in the formwerk prior to casting. which, again, can inhibit the formation ef cold joins. SelLeonsolidating fonerte( the entire formsork, particularly the bottom flanges area, are ctrly led FIGS. 8A though SE illustrate one embodiment of the ‘method for casting. a beam that will have both top anges 200 and bottom flanges 300, FIG. S4 shows a partially assembled reinforcement cage S00 positioned on fra ‘work base 610. In one embodiment, the formwork is "ssembled on the base and around the reinforeement cage so that a beam with both top fnges and bottom anges ean be east FIGS. IA through THE illustrate an alternative ‘embodiment of the method for casting a beam that will have ‘only bottom flanges, FIG, ILA shows a partially assembled reinforcement coge 500 positioned on a formwork base 610. In another embodiment, the formwork is assembled on the bse and around the reinforeement eae so that a beam with ‘only bottom Manges ean be east Th one embodiment, a pai of under-molds 620 is posi foned on ether side of the base. Each undersmold has a ‘mold face 625 that ean Torn a bottom Mange, bottom Mange profile, and part of the web, as shows in FIGS. SB, $C, and SD, ln one embodiment, the under-molds can encompass lower portion ofthe reinforcement cage S00 tht includes part ofthe reinforcement cage that willbe in the web 150. In an altemative embodiment, where the beam will pat include top flanges, the under-mold can form a bottom ange, bottom Range profile and the entire Web, such as shown for example in FIG. 11B. The under-mold ean also orm a formwork: por 638 through which concrete can be poured into the mold, as illustrated, by way of example in FIG. MIB In a farther embodiment, «pair of upper-molds 630 can be positioned above and adjacent to each of the Undersmolds Each upper-mold bas a meld Fae 638 that can orm atop flange, atop flange profile, andthe remaining top part of the web tht is not formed by the underamold. The lppsrmold face can aso provide a formwork port 638 on the top end 10 through whic conerste can be poired into the mold. FIGS. 5B, SC and SD illustrate an example of an °C) can ala be vse forthe pour fo ensure that 8 Uuppersmold As seen in these Figure, the uppers ean cencompass an upper portion ofthe reinforcement cage. The remaining portion of the reinforcement cage can be pt in place after the upper-mold is positioned. In one embod fen, the uppersmold can inclide one or more ducts 637 through which pre-tensioning strands $75 ean be pullein yeta funer embodiment, an under mold 620 and an upper- ‘mold 630 can be configured so that when they ate positioned ajacentlyon the hase hore isa space oe wedge-shaped gap 629 betwcen them, in which a spacer 680 can be inserted. The spacer can hold the upper-old and undee-mold in the proper position of alignment and hold open the gap. After the concrete is east in the mold and sets, the space can be removed. The gap ean thea close and provide the necessary space to “break” or separate the under-mold and upper-mole fom seound the beam, as demonstrated, for example, in FIGS, SD and SE, In an altemative embodiment, the under mold 620 aad uppersmold ean be replaced with a unitary ‘old piece 670. unitary mold piece ean have a profile 671 that forms Manges, such as bottom flanges, and the web, 28 shovon in FIGS. 118 through ID. ARer casting, the unitary an be separated by moving or pulling in a 1 divection aay from the beam, as shawn, for example, in FIG. 11D. A person of skill in the art can ‘determine say of a numberof configurations for formwork for these beams, Such variations in formwork design are Within the scope ofthis invention. When placed side-by side, box beams have a space berwoon thom called “shear key" $8, Theshear key is illed with grout material, for example, magnesium ammonium phosphate grout mixed with pea gravel, polymer cements, ‘bersinforced cements, and epoxy-based grouts, Ula high performance eoncreie (UHPC) can also be an advan tageots grout material a iis less susceptible to enicking and more elicient 10 use, usually hardening ina few days. Regardless of the grout material used, the shear key between box beans is a recognized weak point in box beam smvetures, Many grout materials are susceptible to Tongity- ‘inal eracks that allow ingress of Watee ant other chemicals between the box beams and into the eoneree, This eam create ‘8 moist environment besween the box beams thit cin commode the reinforcement cage, spall the concrete, and generally limit the lifespan of the structure. Many studies have been done in an effort to understand and find ways 10 prevent cracks in the grout material andor inhibit the damage done by water and other chemicals The embodiments of the subject invention are advanta neous because they can provide an alternative othe stan- dard shear Key configuration and provide a method for joining beams that can minimize the damage caused by ‘Water or chemicals that may seep past the grout material. Ax described above, tho top flanges 200 and the bottom flanges 4300 can have profiles, 250 and 380, respectively, that are ‘shaped to hold grout material in place between the Manges The subject invention also provides unique methods for filing the space hetween the Manges. Furthermore, the location of the joints 17S alles water an other materials 19 flow into the intemal voids 400 alling ito drain out of the ‘open ends 9 in the beam. The joint between the bottom anges can be formed before she joint between the top flanges. This is fovilitated by a channe 636 that i formed berwoon the top flanges when the beams are adacent, While the botiom Manges can abut, as deseribed above, the top flanges can be spaced apart, forming a channel that provides sccess to the interior void 400 and the depression 389 in the bottom endUS 9,988,775 BI 9 none embodiment, the bottom Mange 300 of beam 100 i molded witha ridge 387 that extends out fom the profile 380, When two beams are placed adjacent, with their profiles lacing cach other, the ridges can form a depression 389 within the bottom end of the interior void 400, such as shown, for example, in FIGS, 2 and 12A. In one embod ‘ment the depression can be filed with grout material or UHPC 35 to join the bottom flanges and form a joint 175 ‘Ina further embodiment, the ridge can be Formed so that the bottom end 20 of the depression is lower than the sides of the depression. FIGS. 6A and 124 illustrate a non limiting example of a depression with a bottom end lower than the sides. In a more specific embodiment, the depres som fons an apex 388 where the Nanges mest giving the depression @ V'shape, as shove, for example, in FIG. 124. ‘When filled, there will be more grout material, such as, for ‘example, UHPC, over the apex pushing down to form a seal between the Manges. In a yet furher embodiment a backing 360 can be disposed inthe depression to cover af least part ofthe depression where the ridges meet, prior to being filled ‘with grout material ike UPC. A backing can be any Structure or material placed over of in the depression, particularly where the'langes mit, prior to filing with trout like UHPC. By way of example, backing can be ‘hoet material or qbular material that sits in and lines the 2 depression. Altematively, the backing ean be @ material that is applied to the bottom end ofthe depression, for example pte, pastes, adhesives, o other types of materials can be Spplied fo the depression prior to filling with grout material ike UHPC. FIGS. 2,64, 10, and 12A lustate examples of| backing 360 na depression 389. Ina specific embodiment, the backing material isa backer rod disposed within the apex 858, The depression can be filled with grout material ike UHC over the backer fod Aer the joint between the bottom flanges i formed, the space or channel 636 between the top flanges 200 can be closed or filed. The method for closing the channel depends ‘apon whether the beam has top flanges 20 or if the beam supports secondary-structures 40, such as slab panels for example, on the web 180. Both methods will result in closure ofthe channel an formation of an open interior Void ‘sccessble om either open ead 110, FIGS. 6A through 6D illustrate an embodiment of a ‘method for closing the channel 636 and forming a joint 175 between the top flanges 200 of two of more Beams 100. ‘one embodiment, a joint formwork 680 is used to enclose frout_materia like UHPC in the channel 636. A joint Tormvork can have an inside mold 6§8 and an outside mold (687. The inside mold can press against the top end 10 ofthe internal void 400 to forma type of shear pocket 160 between the inside mold and the profiles 280 of the adjacent top ‘Manges. A connector 659 can he attached to the inside mold and extend out ofthe top end 10 of the shear pocket 160. The ‘Shear pocket canbe filled with gront material ike UHPC 38 ‘round the connector. Aa outside mold can be operably ftached to the connector so that the outside mold pushes ‘uninst the slab surface 780. When the inside mold and outside mold are secured with the connector, grout material fr UNC is enclosed between the profiles 250 and can harden or sot in place. The outside mold 687 can then be removed and asphalt or other cover material ean then be ‘applied over the joint, FIGS. 12A through 12D illustrate non-limiting example ‘ofa method for closing the channel 636 and forming a joint 175 with beams that support socondary-strictres 40 the web 150, In one embodiment, scoondary-stmictres are Positioned on the top end 10 of the web, foming an 10 iterative typeof shear pocket 160 between the op end oF the web and the socondary-srctures. I fuer embodi- ‘meat, the shear pocket is filed with row lke UHC. FIG. 12D iilustrates an example ofa filled shear pocket In a farther embodiment, when the reinforcement Cage is com sinicted in the formwork, a portion thereof can be raised hove the level of the suppomt surface, This mised portion fan reinforce the grout material ike UHPC when the shear key is filed, whichis shown, by way of example, in FIG. ABD. This raised portion of reinforcement also creates composite connection between the beam and the precest sab 40, Asphalt or olher cover material ean then he appli over the growed in shear keys and the ssoondary-stntctre re-stressd concrete box beams have been ted to con- struct shor to mid-span bridges for decades. They provide ‘fast, economical way to construct bridges, The structure of box beam asthe disadvantage of having closed intel ‘oid that inhibits fll post-castinspaction of the box beam snd complete inspection of any structures built therewith Box beams ae installed adjacently with shear key between them that is filed with grout material to inubit water seepage between the box beams. This presents a further disadvantage because the grout material is susceptible 10 Jongituinal cracking, which allows ingress of Water and other materials between the box beams, This promotes deterioration of the box beams and shortens the Hifespaa of the overall structure. The subject inveation provides a viable allerative to the use of standard box beans, The beam embodiments ofthe subject invention, when installed, pro Vide a structure similar 19 a box boam, bot without a closed Jemma void. Embodiments of the subject invention also inhibit moisture from being retained between the beams, by having joints that open into the internal void, whieh allows water to be more emily dissipated Any reference in this specification o “one embodiment,” an embodiment.” “example embodiment,” “fuer embodiment,” “alternative embodiment,” ete. s fo literary convenience. The implication is that any paricolae feature, ‘nictre, or eharacteristie describe in connection with sich ‘an embodiment sineludd in at least one embodinent of the vention. The appearance of such phrases in various places inthe specifleation does not necessarily refer o the same embodiment. In addition, any elements or limitations of any invention or embodiment thereof disclosed herein can be combined with any andor all other elements or limitations {individually o in any combination) or any’ othe iavention fr embodinent thereof dislosed herein, and all soch con- binations are contemplated with the scope ofthe invention without Finittion thereto, ‘What is claimed is 1. A conerete beam comprising: 1 wb having a top end and a bottom end; 8 support surface at the top end of the web having a engi ‘one of more bottom flanges, each having a a ridge, that the bottom end ofthe wed, each ofthe one wn flanges having @ maximum length that is preter than the length of the support surface, 1 modular reinforcement cage comprising connectable ‘components embedded in the web and the one oF more bottom flanges wherein fist concrete beam with the ridge abutting the Fidge ofa second conerete beam forms a depeesson, apie ‘o gontain grout material, for joining the bottom Manges 2. A beam, according to claim 1, further comprising one cor iors top flanges that extend from the top end of the web land are parallel to the one or more bottom Ranges, the oneUS 9,988,775 BI " ‘or more top flanges having a maximum Tength that is less than the maximum length of said: one or more bottom ‘anges, such tht when the ridge ofthe frst concrete beam is abutig wo the ridge ofthe second concrete beam there is 4 eu between the top flanges 3A beam, according 1 claim 2 further comprising a joint oemwork operably connectable between one of said one or sore top flanges ofthe firt concrete beam and one of sid ‘one or more top Mange ofthe second eonerete beam, the joint ormwork being adapted to enclose grout material in the channel to jin the top anges, thereby forming an internal ‘oid between the eonerets hea 4. beam, aecording to claim 1, wherein the support suc i adapted to suppor secondary stractire between the first beam and the recond beam, sch that an enclosed Jineral void is formed between the beans and the second ary structure 5. A method for constructing superstnctre tiling two for more beams, wherein each beam comprises: 1 web having a top end and a bottom end: 8 support surface at the top end of the web having a Fengt; ‘wo oF more Manges, esch having a ridge, extending from ‘opposite sides of the hotom en of the wed and ving ‘maximum length that is greater than the length of the support surface ‘wherein the method comprises: positioning the two or more beams with the ridges ofthe Flanges abuting one another to Form a depression, and utilizing the depression, adspte to receive & grout mat rial to forma joint that connects the adjacent anges the beam further comprising one or more top Manges that extend from the top end of the web, ane of said one or tore top flanges being parallel to one of said one or ‘ore bottom flanges and having # maximum length that js les than the maximum length of the one oF more bottom flanges, wherein the method futher compels uilizing a joi formwork wo connect the top Maages ofthe two or more side-by-side beams, whieh comprises, positioning an inside mold between and against two connected top flanges to form a shear key adapted 10 ‘ceive the grout material: 12 attching a connector to the inside mold that extends throug the shear key: filling the shear key with the grout materia: ‘connecting an outside mold tothe connector so thatthe ‘ulside mold is aginst the connected top flanges and ‘over the shoar key thereby containing the grout mate al within the shear key such that an internal void is formed between the 0 beams 6. The method, accoring to claim 5, wherein the depres sow is further adapted to oceive a backing material the method further comprising placing the backing material in the depression between or against the ridges 7. A concrete beam, adapted for use in superstructure, comprising: ‘2 Web having atop end and a bottom ends ‘one or more botiom anges, each having a ridge, extend ing from opposite sides ofthe bottom end of the web and each having a maximum Feng, ‘one or more top flanges that extend fom opposite sides of the top end of the web, parallel to the one or more bottom flanges, each top dange having a maximum length that sles than the maximum length one of sid ‘one of more bottom flanges: 1 reinforcement cage embedded within the beam: such thatthe one or more bottom flanges and the one oF more top flanges of a fist beam are joined fo the one or more bottom flanges and the one or more top Manges of second beam, to provide an open intemal void between the joined anges and the webs. 8. The concrete beam, according 10 claim 7, wherein joining the bottom Hanges insides positioning the ridge of 8 bottom flange ofthe first beam abutting the ridge of the bottom flange ofthe second beam, thereby forming a depres son between the bottom flanges and a channel between the ‘op Manges othe frst beam and the top ange of the second bean, 9. The concrete beam, according to elim 8, wherein the depression and the chanael are adopted to receive & grout ‘material to join the eonerte beams,UNITED STATES PATENT AND TRADEMARK OFFICE CERTIFICATE OF CORRECTION PATENT NO, 9,988,775 BI Page | of | APPLICATION NO, : 15/830656 DATED June 5, 2018 INVENTOR(S) Garber et a. tis cert that error appears in the above-‘dentiied patent and that said Letters Patent is hereby corrected as shown below: On the Title Page tem 12 “Garber” should read ~Garber et al Item (75; “Inventor: David Garber, Miami, FL (US)” should read ~Inventors: David Garber, Miami, FL (US) and Francisco Chitty Gozalo, Miami, FL (US)- Signed and Sealed this Fourth Day of June, 2019 prrbec bro Andrei anew Director ofthe Unite Ses Patent and Trademark Ofce