Trapezoidal sleeper bottom-to-top grouting bag construction method and trapezoidal sleeper system

Abstract

The invention discloses a construction method for grouting bags from bottom to top for a trapezoidal sleeper and a trapezoidal sleeper system.The construction process of the method includes the steps that a base is poured firstly, then the trapezoidal sleeper is laid, then the grouting bags are pasted and poured, grouting materials in the grouting bags are condensed and hardened, supporting is provided for the trapezoidal sleeper, and then side blocking tables are poured; the bottom of the longitudinal beam of the trapezoidal sleeper is prevented from being adhered to the concrete of the base, so that a wrapping sleeve is not required to be sleeved, the problems of voids, pitted surfaces and empty hoisting are avoided, and the phenomenon of'collision between hardness' of the sleeper bottom is more difficult to occur and the observation and maintenance of the sleeper bottom are easier due to the fact that the grouting bag adopts point-type support and the distance between the sleeper bottom and the base is farther.

Description

Technical Field

[0001] The invention belongs to the technical field of rail transit pouring construction, and specifically relates to a bottom-up grouting bag construction method for a trapezoidal sleeper and a trapezoidal sleeper system. Background Art

[0002] Polypropylene wrapping is often used as a temporary isolation material in the construction of ladder sleeper tracks. The construction process has become mature, but it is found that polypropylene wrapping still has shortcomings during its application. Due to its poor air permeability, polypropylene wrapping requires high wrapping technology from the construction team and takes a long time. If it is not operated properly, the wrapping at the bottom of the ladder sleeper will be wrinkled, causing bubbles to form at the contact point between the ladder sleeper vibration damping pad and the base concrete, leading to honeycomb surface problems; at the same time, problems such as empty hanging and hard wall collision need to be considered during the construction process.

[0003] Empty suspension refers to the fact that the vibration-damping pad of the trapezoidal sleeper cannot fully contact with the concrete ballast bed, which affects the transmission of the load on the upper part of the trapezoidal sleeper track; hard collision refers to the direct contact between the trapezoidal sleeper and the exposed concrete on the ballast bed, and the vibration-damping pad and the buffer pad cannot fully contact to reduce vibration, which affects the overall vibration reduction effect of the trapezoidal sleeper.

[0004] Based on this, the inventors have conducted in-depth research on the track bed construction work, considered eliminating the influence of isolation materials, and fundamentally solved the problems of honeycombed surface and empty hanging by connecting the trapezoidal sleeper vibration damping pad directly to the rigid base, and then designed a bottom-up grouting bag construction method for trapezoidal sleepers and a trapezoidal sleeper system that can solve the above problems. Summary of the invention

[0005] In order to overcome the above-mentioned problems, the inventors have conducted intensive research and designed a bottom-up grouting bag construction method for trapezoidal sleepers and a trapezoidal sleeper system. In the construction process of this method, the base is first poured and then the trapezoidal sleepers are laid, followed by pasting and pouring the grouting bags. The grouting material in the grouting bags solidifies and hardens to provide support for the trapezoidal sleepers, and then the side guards are poured. This construction method avoids the adhesion between the bottom of the trapezoidal sleeper longitudinal beam and the concrete of the base, so there is no need to put on a wrapping sleeve, and the problems of honeycombed surface and empty hanging are eliminated. In addition, because the grouting bag is a point support, the bottom of the pillow is farther away from the base, so it is less likely to cause the pillow bottom to "hit hard" phenomenon, and it is easier to observe and repair the pillow bottom, thereby completing the present invention.

[0006] Specifically, the purpose of the present invention is to provide a bottom-up grouting bag construction method for a trapezoidal sleeper, the method comprising the following steps:

[0007] Step 1, tying the track bed reinforcement cage;

[0008] Step 2, erecting formwork on both sides of the ballast steel cage to cast the ballast once, i.e., casting the concrete base 1;

[0009] Step 3, sticking the vibration damping pad 3, the buffer pad and the pearl cotton on the trapezoidal sleeper 2, assembling the rail row and installing it to the predetermined position through the support frame 4;

[0010] Step 4, grouting the grouting bag 5 at the bottom of the vibration damping pad 3;

[0011] Step 5: Set up a retaining wall on the outside of the track and cast the ballast bed for the second time, that is, cast the side retaining platform.

[0012] Among them, the steps 4 and 5 can be performed in any order, that is, step 5 can be performed first and then step 4; step 4 can be performed first and then step 5; or step 4 and step 5 can be performed simultaneously.

[0013] Among them, in step 2, after the concrete is poured, a groove 11 is pressed on the surface of the concrete base 1.

[0014] After the trapezoidal sleeper 2 is installed in place, the groove 11 is located directly below the vibration damping pad 3 of the trapezoidal sleeper 2;

[0015] Preferably, the groove 11 has a depth of 1 cm, and its length and width are consistent with those of the grouting bag.

[0016] Wherein, the step 3 includes the following sub-steps:

[0017] Sub-step 3-1, laying the vibration-damping pad 1 point on the bottom of the trapezoidal sleeper longitudinal beam, and laying the buffer pad point on the side of the trapezoidal sleeper longitudinal beam;

[0018] Sub-step 3-2, sticking the pearl cotton at the bottom of the trapezoidal sleeper longitudinal beam between multiple vibration damping pads; sticking the pearl cotton at the side of the trapezoidal sleeper longitudinal beam between multiple buffer pads;

[0019] Sub-step 3-3, assembling a plurality of trapezoidal sleepers 2 into a rail row;

[0020] Sub-step 3-4, hoisting the rail row above the concrete base 1, arranging a pair of support frames 4 every 1.5 to 3 meters, and supporting the rail row through the support frames;

[0021] Sub-step 3-5, adjusting the height position of the rail row by the support frame 4 so that the rail row is just in the pre-installation position;

[0022] Sub-step 3-6, through the fine-tuning trolley, the geometric state of the track on the track arrangement is fine-tuned as a whole based on the pile control network.

[0023] The support frame 4 includes a vertically arranged upright pole 41 and a horizontally arranged supporting plate 42;

[0024] An external thread 411 is provided in the middle of the vertical rod 41;

[0025] A sleeve 421 fixed as an integral body is provided at one end of the support plate 42 , an internal thread is provided in the sleeve 421 , and the external thread 411 is screwed together with the internal thread, and the support plate 42 can be controlled to reciprocate along the axis direction of the vertical pole 41 by rotating the vertical pole 41 .

[0026] The supporting plate 42 extends under the steel rails of the rail row, and supports and fixes the rail row by supporting the steel rails, so that the rail row is in a predetermined position;

[0027] The vertical rod 41 is located between the rail row and the steel mold, that is, the area where the side guard is cast, or the vertical rod 41 is located outside the steel mold;

[0028] When the vertical rod 41 is located between the rail row and the steel mold, during the process of dismantling the support frame 4, the vertical rod 41 is pulled out from the side stop, and mortar is poured into the missed holes and then smoothed.

[0029] Wherein, in the step 4, the grouting bag 5 is adhered to the bottom of the vibration damping pad 3 by double-sided tape, and the vibration damping pad is located in the middle of the grouting bag;

[0030] Preferably, when the vibration damping pad 3 is pasted in step 3, the grouting bag 5 is pasted under the vibration damping pad 3 simultaneously;

[0031] Alternatively, after the rail row is installed at a predetermined position, the grouting bag 5 is pasted under the vibration-damping pad 3 before executing step 4.

[0032] Wherein, the step 4 includes the following sub-steps:

[0033] Sub-step 4-1, check the vertical correspondence between the vibration damping pad 3, the grouting bag 5 and the groove 11 on the concrete base 1, and adjust the vibration damping pad 3 and the grouting bag (5) that are not in accurate correspondence;

[0034] Sub-step 4-2, using a grouting funnel to grout the grouting bag 5 from a high place, and continuously and dynamically squeezing the grouting port during the grouting process to promote the entry of grout;

[0035] Sub-step 4-3, after observing that the grouting opening of the grouting 5 is fully filled with mortar, use a nylon tie to tighten the grouting opening, and tighten the other end of the nylon tie to the rail fastener;

[0036] Sub-step 4-4, after the mortar strength in the grouting bag 5 reaches 7.5 MPa, cut off the excess part of the grouting bag opening and remove the support frame 4.

[0037] Wherein, the step 5 includes the following sub-steps:

[0038] Sub-step 5-1, arranging steel molds on the outer side of the rail row as a retaining wall for pouring, wherein the top surface of the steel molds is flush with the designed top surface of the side retaining platform of the concrete base, or the top surfaces of multiple steel molds are higher than the designed top surface of the side retaining platform of the concrete base by the same value;

[0039] Sub-step 5-2, filling the sleeper gap between two adjacent trapezoidal sleepers with a wooden mold or a wooden box to prevent concrete from entering the sleeper gap during secondary pouring;

[0040] Sub-step 5-3, check the integrity and reliability of the trapezoidal sleeper vibration damping pads, buffer pads and pearl cotton, replace them if damaged, adjust or supplement them if offset or falling off;

[0041] Sub-step 5-4, after checking the geometric state of the track again, perform secondary pouring, and perform surface finishing after the secondary pouring;

[0042] Sub-step 5-5, after the concrete strength of the side retaining platform reaches 7.5MPa, remove the steel formwork, remove debris and inspect, and repair defects.

[0043] The present invention also provides a trapezoidal sleeper system, which is obtained by the trapezoidal sleeper bottom-up grouting bag construction method described above;

[0044] Preferably, the system comprises, from top to bottom, a trapezoidal sleeper 2, a vibration-damping pad 3, a grouting bag 5 and a concrete base 1;

[0045] A groove 11 is provided on the concrete base 1, and the bottom of the grouting bag 5 is located in the groove 11.

[0046] The grouting bags 5 and the vibration damping pads 3 are all spot-laid;

[0047] The area of ​​the grouting bag 5 is slightly larger than that of the vibration damping pad 3, so that the vibration damping pad can be completely attached to the grouting bag 5, and there is no empty space under the vibration damping pad 3; the vibration damping pad 3 and the trapezoidal sleeper 2 are supported by the grouting bag 5, so that there is no hard contact between the trapezoidal sleeper 2 and the concrete base 1.

[0048] The beneficial effects of the present invention include:

[0049] (1) The present invention provides a bottom-up grouting bag construction method for a trapezoidal sleeper, wherein the trapezoidal sleeper track is point-supported, and a grouting bag that also provides point-support is pasted under the vibration-damping pad of the trapezoidal sleeper. After grouting and hardening of the grouting material, a reliable load transfer path of the vibration-damping pad-grouting bag-base is formed, and at the same time, the space at the bottom of the sleeper is increased, so that the phenomenon of "hard collision" between the bottom of the sleeper is less likely to occur, and the bottom of the sleeper is easier to observe and repair;

[0050] (2) The bottom-up grouting bag construction method of the trapezoidal sleeper provided by the present invention adopts the method of first pouring the base and then paving the trapezoidal sleeper, then pouring the grouting bag, the grouting material in the grouting bag solidifies and hardens to provide support for the trapezoidal sleeper, and finally pouring the side guard. This avoids the adhesion between the bottom of the trapezoidal sleeper longitudinal beam and the ballast concrete, so there is no need to set the wrapping sleeve, and the problems of honeycomb surface and empty hanging are eliminated;

[0051] (3) The present invention provides a bottom-up grouting bag construction method for trapezoidal sleepers. Below the grouting bags, a groove for limiting the position is provided on the concrete base, which provides horizontal constraints for the grouting bags and improves the stability of the trapezoidal sleepers. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 The overall logic diagram of the bottom-up grouting bag construction method for the trapezoidal sleeper provided by the present invention is shown;

[0053] Figure 2 A schematic diagram showing the structure of the method for constructing a trapezoidal sleeper with grouting bags from bottom to top provided by the present invention, when a rail row with grouting bags attached thereto is installed at a predetermined position through a support frame;

[0054] Figure 3 A schematic diagram showing the structure of the support frame in the bottom-up grouting bag construction method for trapezoidal sleepers provided by the present invention is shown;

[0055] Figure 4 A schematic diagram of the structure of the grouting bag after grouting in the bottom-up grouting bag construction method for the trapezoidal sleeper provided by the present invention is shown;

[0056] Figure 5 A side view of a grouting bag after grouting in the bottom-up grouting bag construction method for a trapezoidal sleeper provided by the present invention is shown;

[0057] Figure 6 A partial enlarged view of the grouting bag after grouting in the bottom-up grouting bag construction method for the trapezoidal sleeper provided by the present invention is shown;

[0058] Figure 7 A cross-sectional view of a trapezoidal sleeper system provided by the present invention is shown;

[0059] Figure 8 An enlarged cross-sectional view of a grouting bag of a trapezoidal sleeper system provided by the present invention is shown;

[0060] Fig. 9 A schematic structural diagram of a groove mold in a bottom-up grouting bag construction method for a trapezoidal sleeper provided by the present invention is shown.

[0061] Reference numerals

[0062] 1-Concrete base

[0063] 11-Groove

[0064] 2-Trapezoidal sleepers

[0065] 3-Vibration damping pad

[0066] 4-Support frame

[0067] 41-Pole

[0068] 411-External thread

[0069] 42-Supporting plate

[0070] 421-Sleeve

[0071] 5- Grouting Bag

[0072] 61-Steel Plate

[0073] 62-Square Steel Pipe

[0074] 63-Connection Block

[0075] 7- Rail DETAILED DESCRIPTION

[0076] The present invention will be further described in detail below through the accompanying drawings and embodiments. Through these descriptions, the characteristics and advantages of the present invention will become more clear and distinct.

[0077] The word "exemplary" is used exclusively herein to mean "serving as an example, embodiment, or illustration." Any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. Although various aspects of the embodiments are shown in the drawings, the drawings are not necessarily drawn to scale unless otherwise noted.

[0078] The present invention provides a bottom-up grouting bag construction method for a trapezoidal sleeper, such as Figure 1 As shown in , the method comprises the following steps:

[0079] Step 1: Tie up the track bed reinforcement cage.

[0080] Step 1 described in this application is carried out on the basis of the civil engineering structure. Specifically, step 1 includes the following sub-steps:

[0081] Sub-step 1-1: inspect and process the embedded reinforcement after the civil structure is handed over;

[0082] (1) Before the construction of the base, the sewage, construction waste and debris on the beam surface should be cleaned up, and the beam surface should be kept clean and moistened with water. No exposed water should be allowed to remain, to ensure that the base and the bridge structure can be connected as one. Before pouring the base, the embedded reinforcement on the beam surface should be processed, and the individual embedded reinforcement outside the trapezoidal sleeper base should be removed. The steel bars that are higher than the top surface of the trapezoidal sleeper base should be bent so that they can be poured into the base and meet the requirements for the thickness of the steel bar protective layer. The embedded reinforcement on the bridge deck should be kept in an inverted L shape perpendicular to the ground to increase the bonding strength between the base and the bridge deck, and should be insulated from the base reinforcement with insulating heat shrink tubing.

[0083] (2) Beam joint treatment: After the water retaining platform has been cast, check its size and steel bar position. If it exceeds the installation position of the trapezoidal sleeper, the concrete needs to be chiseled out and the steel bars need to be bent or cut to meet the installation requirements of the trapezoidal sleeper. The actual width data of the beam joint and the width of the water stop strip should be fed back to the designer before the installation of the ditch cover so as to match and combine the ditch covers between the connecting steel pipes on both sides of the sleeper joint.

[0084] Sub-step 1-2: Conduct benchmark survey and set-up to ensure that the beam surface elevation and track laying plane meet the laying conditions;

[0085] Conduct re-survey of the base mark and establish a foundation pile control network; before base treatment, construction personnel should use the track surface elevation as the reference line and measure the track structure height to ensure that the track geometry meets the requirements of the design drawings. The pre-embedded reinforcement of the bridge deck within the base range should be maintained in an inverted L shape perpendicular to the ground to achieve the purpose of assisting in limiting longitudinal displacement.

[0086] Sub-steps 1-3, laying running lines and installing running tracks, provide conditions for material delivery and laying of ladder sleepers.

[0087] Sub-steps 1-4 are to measure and draw lines to determine the position of the formwork support and the height of the base casting, and use this as a basis to adjust the position and height of the track bed reinforcement cage.

[0088] Sub-steps 1-5: After the processing of various types of ballast steel bars is completed, they are transported to the site in different categories and the ballast steel cages are tied.

[0089] Before laying the steel mesh, the construction workers should set pads under the steel mesh according to the requirements of the design drawings, and use the pads as a protective layer for the steel bars. The upper and lower bases are respectively equipped with longitudinal steel bars and welded to all the inner surface transverse steel bars in the structural section; at both ends of each section of the ballast, galvanized flat steel is welded to all the collection mesh steel bars, and connection terminals are led out on the left and right sides of the ballast for electrical connection and measurement.

[0090] The roadbed reinforcement binding is carried out according to general requirements. The reinforcement shall not be higher than the designed position. The thickness of the protective layer is 40mm. The height of the transverse reinforcement shall be adjusted according to the construction error of the beam surface.

[0091] Step 2, erecting formwork on both sides of the ballast steel cage to cast the ballast once, that is, casting the concrete base 1.

[0092] In step 2, after the formwork is installed, it is necessary to draw lines at the planned concrete pouring height. The side formwork must be installed firmly without any quality defects such as looseness, expansion, or leakage.

[0093] Preferably, after the concrete is poured, a groove 11 is pressed on the surface of the concrete base 1. Specifically, after the concrete is poured, Fig. 9 The groove mold shown in the figure is placed in correspondence with the position of the trapezoidal sleeper vibration damping pad, and then the surface is finished. Further, after the outer surface of the groove mold is oiled or wrapped with an isolation material, the groove mold is pressed into the concrete with a pressing depth of 1 cm.

[0094] In a preferred embodiment, the groove mold includes a steel plate 61, a square steel tube 62 and a connection block 63 for welding connection. The four corners of the steel plate are rounded, the thickness is 10mm, and the overall shape is an inverted trapezoid, that is, the bottom size of the steel plate is smaller than the top size.

[0095] The steel plate 61 is provided with two sizes. The two steel plates located at the ends of the square steel tube 62 are edge steel plates, with a bottom width of 120 mm, a top width of 140 mm, a bottom length of 580 mm, and a top length of 600 mm; the steel plate located in the middle of the square steel tube 62, that is, the other steel plates except the edge steel plates, has a bottom width of 220 mm, a top width of 240 mm, a bottom length of 580 mm, and a top length of 600 mm.

[0096] The steel plate is welded to the square steel tube 62 through a connecting block according to the spacing of the trapezoidal sleeper vibration damping pads to ensure the accuracy of the position of the limiting groove of the same ladder sleeper; the connecting block 63 in the present application raises the spacing between the square steel tube 62 and the steel plate 61, avoiding the contact between the square steel tube and the base concrete, thereby facilitating the removal of the groove mold.

[0097] After the base is cast, the working position of the groove mold is determined according to the relative position relationship between the preset trapezoidal sleeper and the base mold, and the trapezoidal sleeper and the vibration damping pad. Then the construction workers press the square steel pipe 62 until the top surface of the steel plate 61 is flush with the upper surface of the base. After the concrete of the base is finally set, the construction workers can manually grab and remove the groove mold.

[0098] The error requirements of the groove mold are: center line position ±5mm, length ±5mm, width ±5mm, and relative elevation between the steel plate and the top surface of the base 0~+5mm.

[0099] After the trapezoidal sleeper 2 is installed in place, the groove 11 is located directly below the vibration damping pad 3 of the trapezoidal sleeper 2;

[0100] Preferably, the groove 11 is 1 cm deep, and its length and width are consistent with those of the grouting bag, so that the grouting bag can be just embedded in the groove, providing positioning and limiting for the grouting bag 5, and improving the overall stability and reliability of the sleeper system.

[0101] Step 3, stick the vibration damping pad 3, the buffer pad and the pearl cotton on the trapezoidal sleeper 2, assemble the rail row and install it to the predetermined position through the support frame 4; Figure 2 As shown in;

[0102] The step 3 includes the following sub-steps:

[0103] Sub-step 3-1, laying the vibration-damping pad 1 point on the bottom of the trapezoidal sleeper longitudinal beam, and laying the buffer pad point on the side of the trapezoidal sleeper longitudinal beam;

[0104] Sub-step 3-2, sticking the pearl cotton at the bottom of the trapezoidal sleeper longitudinal beam between multiple vibration damping pads; sticking the pearl cotton at the side of the trapezoidal sleeper longitudinal beam between multiple buffer pads;

[0105] In this application, when pasting pearl cotton, it is necessary to apply glue to the outer side of the ladder sleeper longitudinal beam to paste the sheet pearl cotton, and paste the strip pearl cotton on the outer side of the bottom of the ladder sleeper. No wrapping set is required. After pasting is completed and checked, it is stacked on the site for hoisting;

[0106] Transport the pasted trapezoidal sleepers to the vicinity of the working surface via a flatbed transport vehicle, use a gantry crane to lift the trapezoidal sleepers to the designated laying position, and slowly lower the sleepers to the designated laying position.

[0107] During the storage and transportation process, a temporary platform should be set up for the trapezoidal sleepers, and they should be stacked horizontally (bottom down), with a maximum of 6 layers. The stacking site should be hardened to ensure that it is flat and solid. The number of stacking layers should not exceed 6 layers, and should not exceed 4 layers after the isolation material is pasted; between the layers, a cushion of not less than (100×100) mm should be placed horizontally, and the cushion should be placed between the vibration-damping pad and the embedded casing (close to the end of the trapezoidal sleeper). After the isolation material is pasted, the cushion can only be located at the bottom of the vibration-damping pad. The width of the cushion should not be less than 200 mm, and the length should not be less than the width of the longitudinal beam. Each layer of cushions should be aligned up and down and kept vertical to the longitudinal direction of the trapezoidal sleeper.

[0108] Lifting of trapezoidal sleepers: Lifting belts must be used for smooth lifting, and there must be no less than 4 lifting points (selected at the connecting steel pipes). Pay attention to the protection of the finished trapezoidal sleepers.

[0109] Sub-step 3-3, assembling a plurality of trapezoidal sleepers 2 into a rail row;

[0110] Sub-step 3-4, hoist the rail above the concrete base 1, arrange a pair of support frames 4 every 1.5 to 3 meters, and support the rail through the support frames; specifically, perform preliminary positioning according to the measured line plane, longitudinal section and curve superelevation, and then arrange temporary tooling support frames at intervals of 1.5 to 3 meters along the direction of the rail, and use the support frames to lift and fix after rough adjustment; during rough adjustment, the rails beside the base mark are controlled by a track ruler;

[0111] The spacing between support frames should ensure the stability of the track geometry of the ladder sleepers; the support frames for straight sections should be perpendicular to the line direction, and the support frames for curved sections should be perpendicular to the line tangent direction.

[0112] Sub-step 3-5, adjusting the height position of the rail row by the support frame 4 so that the rail row is just in the pre-installation position;

[0113] Sub-step 3-6, through the fine-tuning trolley, the geometric state of the track on the track arrangement is fine-tuned as a whole based on the pile control network.

[0114] Preferably, if Figure 3 As shown in , the support frame 4 includes a vertically arranged upright pole 41 and a horizontally arranged supporting plate 42;

[0115] An external thread 411 is provided in the middle of the vertical rod 41;

[0116] A sleeve 421 fixed as an integral body is provided at one end of the support plate 42 , an internal thread is provided in the sleeve 421 , and the external thread 411 is screwed together with the internal thread, and the support plate 42 can be controlled to reciprocate along the axis direction of the vertical pole 41 by rotating the vertical pole 41 .

[0117] Preferably, the support plate 42 extends under the steel rail 7 of the rail row, and supports and fixes the rail row by supporting the steel rail 7, so that the rail row is in a predetermined position;

[0118] The vertical rod 41 is located between the rail row and the steel mold, that is, the area where the side guard is cast, or the vertical rod 41 is located outside the steel mold;

[0119] When the vertical rod 41 is located between the rail row and the steel mold, during the process of dismantling the support frame 4, the vertical rod 41 is pulled out from the side stop, and mortar is poured into the missed holes and then smoothed.

[0120] Since the support plate 42 is located above the trapezoidal sleeper, the support plate 42 will not interfere with the steel mold and the side stop for secondary pouring.

[0121] Step 4, grouting the grouting bag 5 at the bottom of the vibration damping pad 3;

[0122] In step 4, the grouting bag 5 is adhered to the bottom of the vibration damping pad 3 by double-sided tape, and the vibration damping pad is located in the middle of the grouting bag;

[0123] Preferably, when the vibration damping pad 3 is pasted in step 3, the grouting bag 5 is pasted under the vibration damping pad 3 simultaneously; in such a pasting scheme, the pasting process is more convenient and quick, and easy to operate;

[0124] Alternatively, after the rail is installed at the predetermined position, the grouting bag 5 is pasted under the vibration damping pad 3 before executing step 4. In such a pasting scheme, the pasting position is more accurate, and the wear of the grouting bag during the rail assembly and hoisting process is avoided, and the grouting bag is not easily damaged.

[0125] The grouting opening of the grouting bag is located on the inner side of the trapezoidal sleeper.

[0126] Preferably, step 4 includes the following sub-steps:

[0127] Sub-step 4-1, check the correspondence between the vibration damping pad 3, the grouting bag 5 and the groove 11 on the concrete base 1, and adjust the vibration damping pad 3 and the grouting bag 5 that are not in accurate correspondence; ensure that the vibration damping pad is pasted in the center of the grouting bag;

[0128] Sub-step 4-2, using a grouting funnel to grout the grouting bag 5 from a high place, and continuously and dynamically squeezing the grouting port during the grouting process to promote the entry of grout;

[0129] Sub-step 4-3, after observing that the grouting opening of the grouting bag 5 is fully filled with mortar, use a nylon tie to tighten the grouting opening, and tighten the other end of the nylon tie to the rail fastener; the state after grouting is as follows Figure 4 , Figure 5 and Figure 6 As shown in;

[0130] Sub-step 4-4, after the mortar strength in the grouting bag 5 reaches 7.5MPa, cut off the excess part of the grouting bag mouth and remove the support frame 4. In the actual working process, since the pouring time of the grouting bag and the side guard is generally not much different, and the mortar in the grouting bag solidifies faster than the concrete of the side guard, it is only necessary to ensure that the concrete strength of the side guard reaches 7.5MPa before the operation in sub-step 4-4 can be carried out;

[0131] Step 5: Set up a retaining wall on the outside of the track and cast the ballast bed for the second time, that is, cast the side retaining platform.

[0132] The roadbed in the present application includes a base at the bottom and side guards located above the side of the base.

[0133] In the present application, the steps 4 and 5 may be performed in any order, that is, step 5 may be performed first and then step 4; step 4 may be performed first and then step 5; or step 4 and step 5 may be performed simultaneously.

[0134] Preferably, the step 5 includes the following sub-steps:

[0135] Sub-step 5-1, arrange steel molds on the outside of the track as retaining walls for pouring, the top surface of the steel molds is flush with the designed top surface of the side retaining platform of the concrete base, or the top surfaces of multiple steel molds are the same height above the designed top surface of the side retaining platform of the concrete base; so as to facilitate the control of the flatness of the concrete surface of the base.

[0136] Sub-step 5-2, filling the sleeper gap between two adjacent trapezoidal sleepers with a wooden mold or a wooden box to prevent concrete from entering the sleeper gap during secondary pouring;

[0137] Sub-step 5-3, check the integrity and reliability of the trapezoidal sleeper vibration damping pads, buffer pads and pearl cotton, replace them if damaged, adjust or supplement them if offset or falling off;

[0138] Sub-step 5-4, after checking the geometric state of the track again, a second pouring is performed, and the surface is finished after the second pouring; preferably, before pouring, the trapezoidal sleepers, rails and fasteners are protectively wrapped;

[0139] In sub-step 5-4, if the concrete can be transported to the construction site by pumping, it should be pumped directly. If it cannot be transported to the construction site by pumping, a rail flatbed truck can be used to transport the hopper to the construction site, and then a gantry crane on the running rail can be used to transport the hopper for pouring.

[0140] During the concrete pouring process, the material is discharged along the two sides of the sleeper. Since the distance between the side and the formwork is very small, the construction personnel should reasonably control the discharge speed and discharge flow to prevent the concrete from overflowing the formwork, and vibrate the concrete in time during the pouring process. The vibration should be strengthened near the vibration-damping pad and the limit boss. After pouring, the surface should be plastered and maintained in time. Concrete can only be discharged from the outer formwork to the outer side of the sleeper.

[0141] After the above process is completed, before the concrete begins to set, the construction personnel should promptly perform surface treatment on the concrete surface. The surface should be smooth and flat, and the concrete of the platform should not be higher than the surface of the ladder sleeper, and the height should be consistent with the upper surface of the vibration damping pad. At the same time, clean the floating slurry on the fasteners, support frames, and rail surfaces.

[0142] Sub-step 5-5, after the concrete strength of the side retaining platform reaches 7.5MPa, remove the steel formwork, remove debris and inspect, and repair defects.

[0143] In sub-step 5-5, the debris removal also includes removing the pearl cotton, wherein the cleaning tools consisting of a crescent hook, a short straight hook, and a blade are used to cut, hook, and pick out the pearl cotton respectively.

[0144] The pearl cotton in this application is mainly used to protect and isolate the trapezoidal sleepers, ensuring that the poured concrete will not come into direct contact with the trapezoidal sleepers during the pouring process to avoid hard collisions.

[0145] In this application, near the sleeper system, experimental concrete is cured under the same curing conditions to measure the strength regularly. When the strength of the experimental concrete reaches a predetermined value, such as 7.5 MPa, it can be considered that the strength of the poured concrete has reached the predetermined value, so that subsequent cleaning work can be carried out.

[0146] The present application also includes step 6, measuring the clear distance between adjacent trapezoidal sleeper beams and the distance from the base to the top of the steel beam, and designing the width combination and height of the ditch cover accordingly.

[0147] When pouring the concrete base, the allowable deviation of the smoothness of the surface of the ditch cover installation area is 3mm / m, and the elevation is 0-5mm to ensure the installation quality of the cover. The ditch cover should be installed firmly without warping or loosening. If the rail contractor finds that the construction error of the beam joint deviates greatly from the design value during the construction process, it should promptly feedback to the design unit and adjust the ditch cover at the beam joint in time.

[0148] The present application also provides a ladder sleeper system, such as Figure 7 and Figure 8 As shown in , the system is obtained by the bottom-up grouting bag construction method of the trapezoidal sleeper described above;

[0149] Preferably, the system comprises, from top to bottom, a trapezoidal sleeper 2, a vibration-damping pad 3, a grouting bag 5 and a concrete base 1;

[0150] A groove 11 is provided on the concrete base 1, and the bottom of the grouting bag 5 is located in the groove 11.

[0151] The grouting bags 5 and the vibration damping pads 3 are all spot-laid;

[0152] The area of ​​the grouting bag 5 is slightly larger than that of the vibration damping pad 3, so that the vibration damping pad can be completely attached to the grouting bag 5, and there is no empty space under the vibration damping pad 3; the vibration damping pad 3 and the trapezoidal sleeper 2 are supported by the grouting bag 5, so that there is no hard contact between the trapezoidal sleeper 2 and the concrete base 1.

[0153] Example

[0154] The ballast bed was poured and the trapezoidal sleepers were laid on the 1000-meter test section. The following steps were used: Figure 1 As shown in;

[0155] Step 1, tying the track bed reinforcement cage;

[0156] Step 2, erecting formwork on both sides of the ballast steel cage to cast the ballast once, i.e., casting the concrete base 1;

[0157] Step 3, sticking the vibration damping pad 3, the buffer pad and the pearl cotton on the trapezoidal sleeper 2, assembling the rail row and installing it to the predetermined position through the support frame 4;

[0158] Step 4, grouting the grouting bag 5 at the bottom of the vibration damping pad 3;

[0159] Step 5, setting up a retaining wall outside the track row and performing secondary pouring of the ballast bed, i.e. pouring the side retaining platform; wherein, step 4 and step 5 are performed simultaneously.

[0160] Repeat steps 1 to 5 above to cast and lay the next 25-meter ballast.

[0161] During the construction process, a construction team of 10 people participated in the construction work, which took 232 hours to complete the work of pouring the ballast and laying the trapezoidal sleepers on the 1,000-meter test section. The ballast and the trapezoidal sleepers obtained by the construction were tested and their construction quality was evaluated as excellent, with no quality problems that needed to be processed later. Therefore, after the pouring was completed, the adjacent tracks could be constructed. The construction time + quality processing time was 232 hours. The cost of manpower, time and materials used was 1.38 million yuan;

[0162] Comparative Example

[0163] The ballast bed was poured and the trapezoidal sleepers were laid on the 1000-meter test section. The following steps were used:

[0164] Step 1, paste pearl cotton on the outside of the trapezoidal sleeper;

[0165] Step 2, set the wrapping cover;

[0166] Step 3, assembling a plurality of trapezoidal sleepers through steel rails into a 25m long rail row;

[0167] Step 4: hoist, transport and install the rails to the working location;

[0168] Step 5, supporting the formwork and pouring the roadbed concrete;

[0169] Step 6: Remove the roadbed formwork after the concrete strength reaches the standard.

[0170] Step 7, fine-tuning the geometric state, wherein the geometric state includes track direction, track gauge, sag, and superelevation;

[0171] Step 8: Deal with quality issues.

[0172] Repeat the above steps 1 to 8 to cast and lay the next 25-meter ballast.

[0173] During the construction process, a construction team of 10 people participated in the construction work, which took 228 hours to complete the 1,000-meter test section of the roadbed casting and the laying of trapezoidal sleepers. The roadbed and the laid trapezoidal sleepers were inspected and the construction quality was evaluated as qualified. There were 19 quality problems that needed to be dealt with, and the quality processing time was 34 hours. The construction time + quality processing time was 262 hours. The cost of manpower, time and materials used was 1.5 million yuan.

[0174] It can be seen from the above embodiments and comparative examples that the bottom-up grouting bag construction method for trapezoidal sleepers provided in the present application can not only improve the construction quality, but also shorten the construction time and improve the construction efficiency.

[0175] The present invention has been described above in conjunction with preferred embodiments, but these embodiments are only exemplary and serve only as an illustration. On this basis, the present invention may be subjected to a variety of substitutions and improvements, all of which fall within the scope of protection of the present invention.

Claims

1. A bottom-up grouting bag construction method for trapezoidal sleepers, characterized in that: The method comprises the following steps: Step 1, tying the track bed reinforcement cage; Step 2, erecting formwork on both sides of the ballast steel cage to cast the ballast once, i.e., casting the concrete base (1); Step 3, affixing vibration-damping pads (3), buffer pads and pearl cotton to the trapezoidal sleepers (2), assembling the rail row and installing it to a predetermined position through a support frame (4); Step 4, grouting the grouting bag (5) at the bottom of the vibration damping pad (3); Step 5: Set up a retaining wall on the outside of the track and cast the ballast bed for the second time, that is, cast the side retaining platform.

2. The bottom-up grouting bag construction method for trapezoidal sleepers according to claim 1 is characterized in that: In this method, The steps 4 and 5 may be performed in any order, that is, step 5 may be performed first and then step 4; step 4 may be performed first and then step 5; or step 4 and step 5 may be performed simultaneously.

3. The bottom-up grouting bag construction method for trapezoidal sleepers according to claim 1 is characterized in that: In this method, In step 2, after the concrete is poured, a groove (11) is pressed on the surface of the concrete base (1). After the trapezoidal rail sleeper (2) is installed in place, the groove (11) is located directly below the vibration damping pad (3) of the trapezoidal rail sleeper (2); Preferably, the groove (11) has a depth of 1 cm, and its length and width are consistent with those of the grouting bag.

4. The bottom-up grouting bag construction method for trapezoidal sleepers according to claim 1 is characterized in that: In this method, The step 3 includes the following sub-steps: Sub-step 3-1, laying the vibration-damping pad (1) on the bottom of the trapezoidal sleeper longitudinal beam, and laying the buffer pad on the side of the trapezoidal sleeper longitudinal beam; Sub-step 3-2, sticking the pearl cotton at the bottom of the trapezoidal sleeper longitudinal beam between multiple vibration damping pads; sticking the pearl cotton at the side of the trapezoidal sleeper longitudinal beam between multiple buffer pads; Sub-step 3-3, assembling a plurality of trapezoidal sleepers (2) into a track row; Sub-step 3-4, hoisting the rail row to the top of the concrete base (1), arranging a pair of support frames (4) every 1.5 to 3 meters, and supporting the rail row through the support frames; Sub-step 3-5, adjusting the height of the rail row by means of the support frame (4) so ​​that the rail row is just in the pre-installation position; Sub-step 3-6, through the fine-tuning trolley, the geometric state of the track on the track arrangement is fine-tuned as a whole based on the pile control network.

5. The bottom-up grouting bag construction method for trapezoidal sleepers according to claim 4 is characterized in that: In this method, The support frame (4) comprises a vertically arranged upright pole (41) and a horizontally arranged supporting plate (42); An external thread (411) is provided in the middle of the vertical rod (41); A sleeve (421) fixed to one end of the support plate (42) is provided, and an internal thread is provided in the sleeve (421). The external thread (411) is screwed together with the internal thread, and the support plate (42) can be controlled to reciprocate along the axis of the vertical rod (41) by rotating the vertical rod (41).

6. The bottom-up grouting bag construction method for trapezoidal sleepers according to claim 5 is characterized in that: In this method, The support plate (42) extends under the steel rails of the rail row, and supports and fixes the rail row by supporting the steel rails, so that the rail row is in a predetermined position; The vertical rod (41) is located between the rail row and the steel mold, that is, the area where the side baffle is cast, or the vertical rod (41) is located outside the steel mold; When the vertical rod (41) is located between the rail row and the steel mold, in the process of removing the support frame (4), the vertical rod (41) is pulled out from the side stop, and mortar is poured into the missing holes and then smoothed.

7. The bottom-up grouting bag construction method for trapezoidal sleepers according to claim 1 is characterized in that: In this method, In step 4, the grouting bag (5) is adhered to the bottom of the vibration damping pad (3) by means of double-sided tape, and the vibration damping pad is located in the middle of the grouting bag; Preferably, when the vibration damping pad (3) is pasted in step 3, the grouting bag (5) is pasted under the vibration damping pad (3) simultaneously; Alternatively, after the rail row is installed at a predetermined position, the grouting bag (5) is pasted below the vibration-damping pad (3) before executing step 4.

8. The bottom-up grouting bag construction method for trapezoidal sleepers according to claim 1 is characterized in that: In this method, The step 4 includes the following sub-steps: Sub-step 4-1, checking the correspondence between the vibration-damping pad (3), the grouting bag (5) and the groove (11) on the concrete base (1), and adjusting the vibration-damping pad (3) and the grouting bag (5) that are not in accurate correspondence; Sub-step 4-2, using a grouting funnel to grout the grouting bag (5) from a high position, and continuously and dynamically squeezing the grouting opening during the grouting process to facilitate the entry of grout; Sub-step 4-3, after observing that the grouting opening of the grouting bag (5) is fully filled with mortar, use a nylon tie to tighten the grouting opening, and tighten the other end of the nylon tie to the rail fastener; Sub-step 4-4, after the mortar strength in the grouting bag (5) reaches 7.5 MPa, cut off the excess portion of the grouting bag opening and remove the support frame (4).

9. The bottom-up grouting bag construction method for trapezoidal sleepers according to claim 1 is characterized in that: In this method, The step 5 includes the following sub-steps: Sub-step 5-1, arranging steel molds on the outer side of the rail row as a retaining wall for pouring, wherein the top surface of the steel molds is flush with the designed top surface of the side retaining platform of the concrete base, or the top surfaces of multiple steel molds are higher than the designed top surface of the side retaining platform of the concrete base by the same value; Sub-step 5-2, filling the sleeper gap between two adjacent trapezoidal sleepers with a wooden mold or a wooden box to prevent concrete from entering the sleeper gap during secondary pouring; Sub-step 5-3, check the integrity and reliability of the trapezoidal sleeper vibration damping pads, buffer pads and pearl cotton, replace them if damaged, adjust or supplement them if offset or falling off; Sub-step 5-4, after checking the geometric state of the track again, perform secondary pouring, and perform surface finishing after the secondary pouring; Sub-step 5-5, after the concrete strength of the side retaining platform reaches 7.5MPa, remove the steel formwork, remove debris and inspect, and repair defects.

10. A ladder sleeper system, characterized in that: The system is obtained by the bottom-up grouting bag construction method for trapezoidal sleepers as described in any one of claims 1 to 9; Preferably, the system comprises, from top to bottom, a ladder-shaped sleeper (2), a vibration-damping pad (3), a grouting bag (5) and a concrete base (1); Wherein, a groove (11) is provided on the concrete base (1), and the bottom of the grouting bag (5) is located in the groove (11). The grouting bag (5) and the vibration damping pad (3) are both spot-laid; The area of ​​the grouting bag (5) is slightly larger than the area of ​​the vibration-damping pad (3), so that the vibration-damping pad can be completely attached to the grouting bag (5) and there is no empty space below the vibration-damping pad (3); the vibration-damping pad (3) and the trapezoidal rail sleeper (2) are supported by the grouting bag (5), so that there is no hard-on-hard contact between the trapezoidal rail sleeper (2) and the concrete base (1).

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