System and method for slip forming monolithic reinforced composite concrete structures having multiple functionally discrete components

A process for sequentially forming composite concrete structural components for road and bridge construction, wherein one or more component parts of the resultant concrete structural components have exposed rebars for the later integration with additional concrete and/or mechanical structural elements, said additional concrete and/or mechanical structural elements selected from the group consisting essentially of barrier walls, barricades, guard rails and any combination thereof, wherein the process comprises:

• A. Providing an iron work array wherein said iron work array comprises both (1) rebars for embedding within, and reinforcing, a first concrete highway structure and (2) rebars for extending from within said first concrete highway structure, for integration within and reinforcing a second concrete highway structure, to be formed at a later time;
• B. Providing a machine assembly having a tunnel mold comprising a mold cavity defined by a plurality of molding surfaces for forming said first concrete structure having both embedded and exposed rebars, wherein said tunnel mold has a leading or forward molding surface, a trailing or rear molding surface, and at least one tunnel, through said mold cavity, extending from said leading or forward molding surface to said trailing or rear molding surface of said tunnel mold, said tunnel being of a sufficient height to accommodate passage of said extending rebars, through said mold cavity, from said leading or forward molding surface to said trailing or rear molding surface of said tunnel mold;
• C. Slip forming said first component of said composite concrete structure by
• a. Placing said machine assembly, equipped with said tunnel mold, in slip forming relation to said iron work array;
• and
• b. Introducing concrete into said machine assembly for transfer into said mold cavity of said tunnel mold assembly, while continuously moving said machine assembly, equipped with said tunnel mold, over said iron work array, to slip form a first component of said concrete composite structure having both rebars embedded in first concrete structure, and concrete free rebars, which extend from said iron work array embedded in said slip formed concrete structure,
• D. Slip forming a contiguous component onto said first component of said concrete composite structure, by incorporating therein, said concrete free rebars from said first component of said composite concrete structure, as reinforcement of said contiguous component.