High-speed railway curve super-high section ballastless track slab replacement method

Abstract

The application provides a high-speed rail curve super-high section ballastless track slab replacement method, and relates to the technical field of ballastless track structure repair, which comprises the following steps: early window: pre-planting threaded rod, pouring of leveling platform, chiseling of wide-narrow joint, clamping and limiting of track slab; current window: entry of track vehicle group, assembly of in-situ hoisting machine, loosening of fasteners and installation of rail shifting device, transverse rail shifting, lifting and removal of track slab, resetting of steel rail, temporary support, installation of rail shifting device, shifting of steel rail, cleaning of mortar layer, resetting of track slab, resetting of steel rail, temporary support, combination of track vehicle group, fine adjustment of track slab, re-pouring of mortar layer, and line recovery adjustment; subsequent window: chiseling of leveling platform, repair of inter-line sealing layer, track slab rebar planting in slab replacement area, pouring of wide-narrow joint, and track fine adjustment. The application overcomes the technical barrier that the current technology cannot replace the heavy CRTS II type slab, and realizes safe and rapid replacement of the slab ballastless track slab.

Description

Technical Field

[0001] This invention belongs to the field of railway ballastless track structure repair technology, and in particular relates to a method for replacing ballastless track slabs on ultra-high-speed curve sections of high-speed railways. Background Technology

[0002] With the completion and opening of ballastless track on important trunk high-speed railways such as the Beijing-Shanghai, Beijing-Shijiazhuang-Wuhan, and Harbin-Dalian lines, my country's high-speed railway network is gradually being built up, and ballastless track is being used on a large scale. Slab track structure is the main structural form adopted in my country's high-speed railway construction, mainly including CRTS I, II, and III slab track. Among them, CRTSⅠ type slab track is a slab track structure in which precast track slabs are laid on a cast-in-place reinforced concrete base, adjusted by a mortar filling layer, and limited by convex abutments; CRTSⅡ type slab track is a longitudinally connected slab track structure in which track slabs are laid on a field-spread concrete support layer (roadbed, tunnel) or a field-cast reinforced concrete base (bridge) with a cement asphalt mortar filling layer; CRTSⅢ type slab track is a slab track structure in which precast concrete track slabs with reserved connecting steel bars are laid on a cast-in-place reinforced concrete base or concrete support layer, and a self-compacting concrete filling layer is set in the middle. However, as the service life extends, under the combined effects of factors such as temperature stress, train load, environmental weathering, and inherent material deficiencies, some track slabs may develop cracks, chipping, or other deterioration, posing significant safety hazards. When the deterioration reaches a certain level, the damaged track slabs need to be replaced to ensure the safety, stability, and long-term durability of the ballastless track.

[0003] Because maintenance work on high-speed railway lines can only be carried out during designated maintenance windows, which are limited (generally only 4 hours), and because of the strict conditions for high-speed rail track access—with equipment size restricted by the dimensions of access doors and the height of the overhead contact line, large equipment cannot be used on the tracks—and because most high-speed railways are viaducts, reaching the track maintenance work site requires accessing the track via access doors and stairs spaced at intervals. The large number of tools involved further wastes time traveling to and from the work site and moving various tools, thus affecting the efficiency of maintenance work on operating high-speed railways. Given the limited maintenance window time and the complex track slab replacement process, it is crucial to adopt reliable technical solutions to ensure the temporary restoration of the line after the maintenance window ends and the timely reopening of the line. Therefore, how to safely and quickly replace slab track is an urgent problem to be solved in this field. Summary of the Invention

[0004] To address the aforementioned issues, this invention proposes a method for replacing ballastless track slabs in superelevated sections of high-speed railway curves. This innovative approach applies high-speed railway ballastless track slab replacement technology to superelevated curved sections, overcoming the technical barrier of replacing the heavier CRTS II type slabs, which is currently difficult with existing technology. This enables safe and rapid replacement of slab track slabs.

[0005] To achieve the above objectives, this invention discloses a method for replacing ballastless track slabs on ultra-high-speed railway curves, comprising:

[0006] During the initial maintenance window, two sets of leveling platforms were poured on both sides of the track slab to be replaced.

[0007] Remove the wide and narrow joints and side blocks between the track slab to be replaced and the adjacent track slab, and install a clamping and limiting device on the track slab to be replaced;

[0008] During the designated maintenance window, the railcar assembly enters the site, including: the first railcar driving the first fixed rail crane, the first rail flatcar, the second rail flatcar, the second fixed rail crane, and the second railcar connected to it in sequence into the construction area; the railcar assembly is then disassembled, and the first fixed rail crane and the second fixed rail crane are respectively fixed on the two sets of leveling platforms to form an in-situ hoisting unit; the first railcar, the first rail flatcar, the second rail flatcar, and the second railcar are then driven away from the construction area.

[0009] Loosen the fasteners of the ballastless track slab according to the predetermined fastener loosening length, install the rail shifting device, and use the rail shifting device to shift the rail laterally and limit its position.

[0010] Remove the clamping and limiting device of the track slab to be replaced, and use the in-situ hoisting unit to peel, lift and remove the track slab to be replaced;

[0011] The rail is reset and the rail-shifting device is removed. The loosened fasteners are screwed back in, and wooden sleepers are used to temporarily support the rail at the location of the track plate to be replaced.

[0012] The second railcar pushes the first railcar and the second railcar, so that the first railcar travels to the position of the rail slab to be replaced. The in-situ hoisting unit places the rail slab to be replaced on the first railcar. The second railcar continues to push, so that the second railcar is directly below the in-situ hoisting unit. The in-situ hoisting unit lifts the new rail slab on the second railcar.

[0013] The second railcar continues to push, causing the first and second railcars to leave the construction area. The fasteners of the ballastless track slab are loosened again according to the predetermined fastener loosening length. The rails at the positions of the track slabs to be replaced are then horizontally adjusted and limited.

[0014] The in-situ hoisting unit lowers the new track slab, installs the new track slab, resets the rails, removes the rail shifting equipment, and screws in the loosened fasteners.

[0015] As a further improvement of the present invention, during the initial window period, the actual locking rail temperature and the actual rail temperature are tested and compared to determine the fastener loosening length, thus obtaining the predetermined fastener loosening length.

[0016] As a further improvement of the present invention, the two sets of leveling platforms are symmetrical about the center line of the track to be replaced, which is perpendicular to the running direction.

[0017] As a further improvement of the present invention, during the initial window period, threaded rods are pre-installed on the support layer on the outer side at the location where the leveling platform needs to be poured, and then the leveling platform is poured based on the pre-installed threaded rods.

[0018] Both the first fixed rail crane and the second fixed rail crane are fixed to the leveling platform by bolt fixing devices.

[0019] As a further improvement of the present invention, after the new track slab is installed, the original hoisting unit is dismantled and restored to the first fixed track crane and the second fixed track crane. The first track crane and the second track crane both travel towards the middle construction area and meet the first fixed track crane, the first track flatcar, the second track flatcar, and the second fixed track crane in the middle one by one and recombine into a track car group. The second track car drives the track car group back.

[0020] As a further improvement of the present invention, the concrete of the wide and narrow joints between the front and rear of the track slab to be replaced is removed, the tension lock is released, and the concrete slag and debris in the wide joint are removed.

[0021] A clamping and limiting device is installed on both sides of the track plate to be replaced.

[0022] As a further improvement of the present invention, the rail shifting device includes a hydraulic jacking device and a slide rail;

[0023] The installation of the rail-mounting equipment includes:

[0024] A set of track-shifting equipment is installed on each of the two adjacent track plates to be replaced.

[0025] The hydraulic jacking device is installed between the first and second support platforms of the adjacent track slabs to be replaced, and the slide is installed between the support platforms next to the hydraulic jacking device.

[0026] As a further improvement of the present invention, the lateral adjustment and limiting of the rail by the rail-shifting device includes:

[0027] Use hydraulic jacking equipment to push the rails into place;

[0028] After the rail is pushed into place, it is fixed in place on the slide rail.

[0029] As a further improvement of the present invention, the track plate to be replaced is peeled off, lifted, and removed; including:

[0030] After removing the clamping and limiting device of the track plate to be replaced, clean the mortar at the fine adjustment claw position of the track plate to be replaced, and use a jack to lift the track plate to be replaced so that the track plate to be replaced is separated from the mortar layer.

[0031] Two sets of C-type lifting devices are installed on the track slab to be replaced. The two sets of C-type lifting devices are fastened to the track slab to be replaced. The track slab to be replaced is lifted by the in-situ hoisting unit, thus completing the lifting and removal of the track slab to be replaced.

[0032] As a further improvement of the present invention, the in-situ hoisting unit lowers the new track plate, installs the new track plate and resets the rail, removes the rail shifting device, and screws in the loosened fasteners; including:

[0033] After the new track slab is lifted, remove the temporary supporting wooden sleepers, clean the CA mortar layer under the location of the track slab to be replaced, and ensure that the top surface of the base plate under the location of the track slab to be replaced is flat and clean;

[0034] Pads are placed on the base plate and the support layer respectively, and the thickness of the pads is the same as the thickness of the mortar layer.

[0035] The in-situ hoisting unit places the new track slab on the pad and removes the track slab C-type hoisting tool;

[0036] Remove the guide rail equipment and slide rail, and screw back in the loosened fasteners within the construction area.

[0037] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0038] This invention optimizes construction organization, simplifies and concentrates construction procedures within two track maintenance windows, thereby reducing the number of procedures and tools required and improving construction efficiency. In addition, a reliable temporary transition scheme is adopted to ensure that the track can be opened on time after the track maintenance window ends, avoiding track closures that affect train punctuality.

[0039] This invention improves equipment performance and overcomes the technical barrier that current technologies mainly target the lighter CRTS I type plate, but are difficult to replace with the heavier CRTS II type plate.

[0040] This invention enhances the applicability of the equipment and innovatively applies the ballastless track slab replacement technology for high-speed railways to curved superelevation sections. Attached Figure Description

[0041] Figure 1 This is a flowchart of a method for replacing ballastless track slabs on ultra-high-altitude sections of high-speed railway curves, as disclosed in an embodiment of the present invention.

[0042] Figure 2 This is a schematic diagram of the planar leveling platform on the outer side of the track slab to be replaced, as disclosed in one embodiment of the present invention.

[0043] Figure 3 This is a schematic planar view of a pre-threaded rod disclosed in one embodiment of the present invention;

[0044] Figure 4 This is a schematic cross-sectional view of the leveling platform on the outer side of the track slab to be replaced, as disclosed in one embodiment of the present invention.

[0045] Figure 5 This is a schematic diagram of a railcar unit disclosed in one embodiment of the present invention;

[0046] Figure 6 This is a schematic diagram of the in-situ hoisting unit installation structure disclosed in one embodiment of the present invention;

[0047] Figure 7 This is a schematic diagram of the installation structure of the dialing device disclosed in one embodiment of the present invention;

[0048] Figure 8 This is a schematic diagram of a temporary support structure using wooden sleepers disclosed in one embodiment of the present invention;

[0049] Figure 9 This is a schematic diagram of lifting a new track slab on a second track flatcar, as disclosed in one embodiment of the present invention.

[0050] Figure 10 This is a plan view showing the arrangement of reinforcement bars for the new track slab after installation, according to one embodiment of the present invention.

[0051] Explanation of reference numerals in the attached figures:

[0052] 1. Track slab to be replaced; 2. Mortar layer; 3. Support layer; 4. Wide and narrow joints; 5. Pre-installed threaded rods; 6. Leveling platform; 7. Pressing and limiting device; 8. First track car; 9. Temporary support; 10. First fixed track crane; 11. New track slab; 12. Rebar pins; 13. First track flatcar; 14. Second track flatcar; 15. Second fixed track crane; 16. Second track car; 17. Hydraulic jacking equipment; 18. Slide rail; 19. Track slab C-type lifting device; 20. In-situ hoisting unit. Detailed Implementation

[0053] To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0054] The present invention will now be described in further detail with reference to the accompanying drawings:

[0055] like Figure 1 As shown, the present invention discloses a method for replacing ballastless track slabs on ultra-high-speed railway curves, comprising:

[0056] Initial window period:

[0057] like Figure 3 As shown, two sets of leveling platforms 6 are poured on both sides of the track slab 1 to be replaced;

[0058] Remove the wide and narrow joints 4 between the track slab to be replaced 1 and the adjacent track slab, as well as the side blocks, and install a clamping and limiting device on the track slab to be replaced 1, such as... Figure 4 As shown;

[0059] Sunlight window time of the day:

[0060] The railcar unit enters the site, such as Figure 5 As shown, the process includes: a first railcar 8 driving a first fixed rail crane 10, a first rail flatcar 13, a second rail flatcar 14, a second fixed rail crane 15, and a second railcar 16 connected to it sequentially into the construction area. The first railcar 8 should stop at a suitable lifting position for the first fixed rail crane 10 and the second fixed rail crane 15 on the line (this position is determined by the longitudinal slope, superelevation, and structures at the lifting point). Then, the railcar assembly is detached and transferred to a predetermined location, where the first fixed rail crane 10 and the second fixed rail crane 15 are respectively fixed onto two sets of leveling platforms 6. Figure 6 , 9 As shown, an in-situ hoisting unit is formed to move the first railcar 8, the first rail flatcar 13, the second rail flatcar 14, and the second railcar 16 away from the construction area;

[0061] Loosen the fasteners on the ballastless track slab according to the predetermined fastener loosening length, and install the track shifting device, such as... Figure 7 As shown, the rails are laterally shifted and limited using a rail shifting device;

[0062] Remove the clamping and limiting device of the track slab to be replaced 1, and use the in-situ hoisting unit to peel, lift and move the track slab to be replaced 1 out;

[0063] Reposition the rail and remove the rail-shifting device. Screw in the loosened fasteners and use wooden sleepers to temporarily support the rail at position 1 of the track slab to be replaced. Figure 8 As shown;

[0064] The second railcar 16 pushes the first railcar 13 and the second railcar 14, bringing the first railcar 13 to the position of the rail slab 1 to be replaced. The in-situ hoisting unit places the rail slab 1 to be replaced onto the first railcar 13. The second railcar 16 continues to push, positioning the second railcar 14 directly below the in-situ hoisting unit. The in-situ hoisting unit then lifts the new rail slab 11 from the second railcar 14. Figure 9 As shown;

[0065] The second track car 16 continues to push, causing the first track flat car 13 and the second track flat car 14 to leave the construction area. The fasteners of the ballastless track slab are loosened again according to the predetermined fastener loosening length. The rail at the position of the track slab to be replaced is then horizontally adjusted and limited.

[0066] The in-situ hoisting unit lowers the new track slab 11, installs the new track slab 11, resets the rails, removes the rail shifting equipment, and screws in the loosened fasteners.

[0067] in,

[0068] During the initial track maintenance window, the actual locking rail temperature and the actual rail temperature are tested and compared to determine the fastener loosening length, thus obtaining the predetermined fastener loosening length.

[0069] The two sets of leveling platforms are symmetrical about the centerline of the track to be replaced, which is perpendicular to the running direction.

[0070] During the initial window period, threaded rods 5 are pre-installed at the location of the leveling platform 6 to be poured and on the outer support layer 3, and then the leveling platform 6 is poured based on the pre-installed threaded rods 5.

[0071] Both the first fixed rail crane 10 and the second fixed rail crane 15 are fixed to the leveling platform 6 by bolt fixing devices.

[0072] When using wooden sleepers to temporarily support the rail at the position of the track slab to be replaced, the temporary support 9 uses wooden sleepers with a cross section of 220mm×260mm and a length of 3m, and the clear distance between the wooden sleepers is 110-180cm.

[0073] When the in-situ hoisting unit 20 controls the new track slab 11 to fall into place, it can precisely control and supplement with measuring facilities to ensure that the positioning accuracy of the new track slab 11 meets the requirements, thus eliminating the need for fine adjustment of the new track slab 11.

[0074] Furthermore,

[0075] After the new track slab 11 is installed, the original hoisting unit 20 is dismantled and the first fixed track crane 10 and the second fixed track crane 15 are restored. The first track car 8 and the second track car 16 both travel to the middle construction area and meet the first fixed track crane 10, the first track flat car 13, the second track flat car 14 and the second fixed track crane 15 in the middle one by one and reassemble into a track car group. The second track car 16 drives the track car group back.

[0076] Remove the concrete from the front and rear wide and narrow joints 4 of the track slab to be replaced, loosen the tension lock, and remove the concrete slag and debris from the wide joint.

[0077] Install clamping and limiting devices 7 on both sides of the track slab 1 to be replaced. Specifically, the track slab is clamped and limited to the left and right. Three clamping and limiting devices are set on each side of a single track slab to prevent the track slab from shifting laterally during the transition operation.

[0078] Furthermore,

[0079] (1) The rail-shifting equipment includes a hydraulic jacking device 17 and a slide rail 18; the rail-shifting installation equipment includes:

[0080] Install a set of track shifting equipment on each of the two adjacent track plates 1 to be replaced;

[0081] The hydraulic jacking device is installed between the first and second support platforms of the adjacent track slab 1 to be replaced, and the slide rail 18 is installed between the support platforms next to the hydraulic jacking device.

[0082] (2) Laterally shifting and limiting the rails using a rail shifting device, including:

[0083] The hydraulic jacking device 17 is used to push the rail into place.

[0084] After the rail is pushed into place, it is fixed on the slide rail 18.

[0085] (3) Peel off, lift and remove the track slab 1 to be replaced; including:

[0086] After removing the clamping and limiting device of the track plate to be replaced 1, clean the mortar at the fine adjustment claw position of the track plate to be replaced 1, and use a jack to lift the track plate to be replaced 1 so that the track plate to be replaced 1 is separated from the mortar layer 2.

[0087] Two sets of track slab C-type lifting devices are installed on the track slab to be replaced 1. The two sets of track slab C-type lifting devices are fastened to the track slab to be replaced 1. The lifting device of the in-situ hoisting unit 20 is connected to the two sets of track slab C-type lifting devices to lift the track slab to be replaced, thus completing the lifting and removal of the track slab to be replaced 1.

[0088] in,

[0089] The two sets of C-type track slab lifting tools can be connected to the lifting holes or anchor bolt holes of the track slab 1 to be replaced, or they can be fixed to the side of the track slab using specific tooling.

[0090] Furthermore,

[0091] The lifting device of the in-situ hoisting unit 20 can precisely control the lifting or lowering of the track slab; the lifting device can be powered or manually operated.

[0092] The in-situ hoisting unit 20 has a protective device to prevent the track slab from falling during the lifting or lowering of the track slab 1 to be replaced; it also has a mechanical protective device to prevent the track slab from falling during the transportation of the track slab.

[0093] The in-situ hoisting unit 20 can lift the track slab to a certain height. The lifting height is determined by the line superelevation, track slab type, track structure type, and the longitudinal transport and intersection method of the new and old track slabs along the line. This height is not less than 40 cm.

[0094] (4) The in-situ hoisting unit lowers the new track slab 11, installs the new track slab 11 and resets the rails, removes the rail shifting equipment, and screws in the loosened fasteners; including:

[0095] After the new track slab 11 is lifted, remove the wooden sleepers of the temporary support 9, and remove the CA mortar layer 2 under the position of the track slab to be replaced 1 to ensure that the top surface of the base plate under the position of the track slab to be replaced 1 is flat and clean.

[0096] Pads are set on the base plate and the support layer 3 respectively, and the thickness of the pads is the same as the thickness of the mortar layer 2.

[0097] The in-situ hoisting unit places the new track slab 11 on the pad and removes the track slab C-type lifting device 19;

[0098] Remove the guide rail equipment and slide rail 18, and screw in the loosened fasteners within the construction area. Example

[0099] Under the influence of temperature stress and train fatigue loads, multiple transverse cracks and diagonal cracks appeared on the lateral sides of a CRTSⅡ type track on a high-speed railway bridge section, necessitating replacement and repair. The construction process for track slab replacement using this patented technology is as follows: Figure 1 As shown, the specific content is as follows:

[0100] During the initial window of opportunity, preparatory work is carried out:

[0101] 1) Locking rail temperature test and initial data acquisition

[0102] The actual locking rail temperature is tested using a seamless track actual locking rail temperature detection system. The actual temperature of the rail is also tested and compared with the actual locking rail temperature to determine the fastener loosening length. Monitoring sensors are then installed.

[0103] 2) Determining and marking the location of the track slab

[0104] The plane and elevation positions of the damaged track slab are measured and marked. The damaged track slab is the track slab to be replaced 1. The data of the relative position between the track slab to be replaced 1 and the adjacent track slabs are recorded.

[0105] 3) Re-inspection of the rebar installation status of the track slab in the replacement area

[0106] A follow-up inspection was conducted on the rebar installation status of the track slabs in the construction area. Since the rebar installation in the replacement area and on both sides of the track slabs has been completed, no anchorage zone was designated this time.

[0107] 4) Pre-installed threaded rod 5

[0108] like Figure 2 As shown, threaded rods are inserted into the support layers 3 on both sides of the track slab to be replaced by drilling holes. The drilling should be perpendicular to the support layer 3, and the center position of a set of threaded rods should be aligned with the transverse center position of the leveling platform 6 to be poured. The holes are cleaned, and after injecting the anchoring adhesive, the threaded rods are inserted, with an error of ±5mm. After the leveling platform 6 is poured, threaded rods are inserted into the leveling platforms 6 on both sides of the track slab to be replaced, as well as into the inter-line and external sealing layers. When inserting threaded rods into the inter-line and external sealing layers, the drilling should be perpendicular to the sealing layer, and the center position of a set of threaded rods should be aligned with the transverse center position of the leveling platform 6.

[0109] 5) Leveling platform 6 pouring

[0110] like Figure 3 , 4 As shown, at the locations of the pre-installed threaded rods 5 on both sides of the track slab 1 to be replaced, four leveling platforms 6 are poured, two between the lines and two on the outer side. The top surface height of these platforms is generally 150mm lower than the top of the inner rail. The elevation of the top surface of the leveling platforms 6 is measured and controlled during pouring, ensuring that the top surfaces of the support concrete are on the same horizontal plane and flat.

[0111] 6) Removal of wide and narrow joints 4 and side blocks

[0112] Remove the damaged concrete from the front and rear wide and narrow joints of the track slab to be replaced, loosen the tension lock, and remove concrete debris and slag from the wide joint.

[0113] 7) Clamping limit of track plate 1 to be replaced

[0114] Tightening and limiting devices are installed on both sides of the track slab to be replaced 1 to clamp and limit the left and right sides of the track slab to be replaced 1. Three tightening and limiting devices are set on each side of a single track slab to be replaced 1 to prevent the track slab to be replaced 1 from shifting laterally during the transition operation.

[0115] During the designated window of opportunity, the implementation phase will take place:

[0116] 1) Railcar group enters the site

[0117] like Figure 5 As shown, the railcar formation is as follows: First railcar 8 + First fixed rail crane 10 + First rail flatcar 13 + Second rail flatcar 14 + Second fixed rail crane 15 + Second railcar 16. The railcar group is driven by the first railcar 8, departing from the station and entering from the up line, stopping at the position on the up line where the track slab to be replaced is located. After a power outage, the railcar group is disengaged. After disengagement, the first railcar 8 first leaves the construction area, while the second railcar 16 and the flatcar leave the construction section after the hoisting unit 20 is installed in its original location.

[0118] Assemble in-situ hoisting unit 20

[0119] like Figure 6 As shown, the outriggers on both sides of the rail cranes on the first fixed rail crane 10 and the second fixed rail crane 15 are placed at the longitudinal center positions on the two sets of leveling platforms 6 and fixed with bolts. Then, the crossbeams and lifting gears are assembled, and diagonal bracing is applied to both sides of the two rail cranes. After assembly, fine adjustments are made to ensure that the crossbeam of the in-situ lifting unit 20 is horizontal and perpendicular to the centerline of the track.

[0120] 3) Loosen the fasteners and install the guide rail device.

[0121] An automatic composite clamp is used to sequentially remove and store the fasteners within a certain range before and after the track plate replacement. Simultaneously with fastener removal, a hydraulic jacking device 17 is installed between the first and second support platforms of adjacent track plates on both sides of the track plate to be replaced; a total of two sets are installed. Figure 7 As shown, slide rail 18 is first installed next to the adjacent jacking device, and a set of slide rail 18 is installed on each of the other track plates.

[0122] 4) Horizontal guide rail

[0123] After the composite clamp removes the fasteners to a certain distance, the hydraulic jacking device 17 is used to jack the rail. The rail is jacked into place according to the jacking requirements. After it is in place, the rail is fixed on the slide rail 18.

[0124] 5) The track slab is peeled off, lifted, and removed.

[0125] Remove the clamping device of the track slab to be replaced, remove the mortar from the fine-tuning claw position of the track slab to be replaced, and use a jack to lift the track slab to be replaced and separate it from the mortar layer 2. Install the track slab C-type lifting tool 19, and use an in-situ hoist to lift the old track slab. Take care to protect the rails during the lifting and lowering of the old track slab.

[0126] 6) Rail repositioning and temporary support 9

[0127] like Figure 8 As shown, after the old track slab is lifted, the rails are reset, the rail shifting equipment and slide rail 18 are removed, and an automatic composite clamp is used to screw in the loosened fasteners of the replacement section. At the same time, wooden sleepers are used to temporarily support the rails at the location of the track slab to be replaced.

[0128] 7) The track flatcar is positioned and the new track slab is lifted.

[0129] like Figure 9 As shown, the second railcar 16 pushes the first railcar 13 to the position of the plate to be replaced. The in-situ hoist places the old rail plate on the first railcar 13. Then the second railcar 16 moves so that the second railcar 14 carrying the new rail plate 11 is directly below the in-situ hoisting unit 20. The in-situ hoisting unit 20 lifts the new rail plate 11.

[0130] 8) The railcar moves away and the rails are separated.

[0131] The second railcar 16 pulls the first rail flatbed and the second rail flatcar 14 out of the construction position. After removing the composite clamps and fasteners to a certain distance, the hydraulic jacking equipment 17 is used to jack the rails. The rails are jacked into place according to the jacking requirements. After they are in place, the rails are limited and fixed on the slide rail 18.

[0132] 9) Cleaning of mortar layer 2

[0133] After the track slab is hoisted, the wooden sleepers of the temporary support 9 are removed. Using tools such as electric picks, blowers, and grinders, the CA mortar layer 2 under the track slab is removed to ensure that the top surface of the base plate is flat and clean.

[0134] 10) Reset the new track slab 11

[0135] After the mortar layer 2 is cleaned, the new track slab 11 is lowered and reset using the in-situ hoisting unit 20. Spacers are placed between the track slab and the support layer 3, with the same thickness as the mortar layer 2. The track crane places the new track slab 11 on the spacers and removes the track slab C-type lifting device 19.

[0136] 11) Rail repositioning

[0137] After the new track slab 11 is installed, the rails are reset, the rail shifting equipment and slide rail 18 are removed, and the loosened fasteners of the replacement section are screwed back in using an automatic composite clamp.

[0138] 12) Railcar combination

[0139] The first railcar 8 and the second railcar 16 on both sides travel to the plate-changing position and are combined. At the same time, the in-situ hoisting unit 20 is dismantled, loaded onto the vehicle, and finally the railcar returns.

[0140] 13) Fine-tuning of track slabs and re-grouting of mortar layer 2

[0141] After fine-tuning, tightening, cleaning, and sealing of the track slab edges, polymer cement mortar can be poured. The fine-tuning and correction device under the track slab is removed once the mortar reaches a minimum compressive strength of 1 MPa. The spatial condition of the track slab is re-measured after the filling mortar is poured. The deviation between the elevation adjustment and the design elevation adjustment after track slab pouring is -0.5 mm, and the allowable deviation for the centerline adjustment is 1 mm, which meets the allowable range.

[0142] 14) Line restoration and adjustment

[0143] The loosened fasteners before and after the plate replacement were screwed back in in the original order using an automatic composite clamp. The track inspection trolley was used to test the section with loosened fasteners, and the track condition met the operational requirements.

[0144] During the subsequent maintenance window, restoration work will be carried out.

[0145] 1) Remove the leveling platform 6

[0146] Using tools such as electric picks and manual labor, the leveling platform 6 was chiseled away. After chiseling, the concrete debris was packed into woven bags, the reinforcing bars were removed, and the debris was cleaned up and transported away.

[0147] 2) Reinforcing bar installation in the track slab replacement area

[0148] Rebar is installed in the track slab of the replacement area. Holes are drilled perpendicular to the track slab surface, and rebar is installed using pins. The rebar arrangement is as follows: Figure 10 As shown.

[0149] 3) Pouring of wide and narrow joints 4

[0150] Clean the track slab joints and grouting holes, and moisten them. Use C55 concrete to connect the track slabs longitudinally and fill the holes. At narrow joints, the concrete pouring height should be about 60mm below the upper edge of the track slab.

[0151] After the mortar reaches a strength of 9 MPa and the narrow joint concrete reaches a strength of 20 MPa, the tension bars in the track slab are installed sequentially. Finally, concrete is used to fill and compact the joints and grouting holes, ensuring the concrete surface is flush with the track slab and maintaining a clean appearance.

[0152] 4) Track fine-tuning.

[0153] Fine-tune the rails to meet the smoothness requirements.

[0154] Advantages of this invention:

[0155] This invention utilizes a combination of railcars, rail-mounted gantry cranes, and rail flatcars to replace track slabs in superelevated curved sections of bridges within two to three maintenance windows. The railcar combination of railcar-rail-mounted gantry crane-rail-flatcar-rail-mounted gantry crane-railcar achieves seamless integration of old slab removal and new slab installation, reducing tooling scale while maintaining operational efficiency. This method is flexible and reliable; two rail-mounted gantry cranes work as a group, ensuring precision and safety during hoisting while avoiding limiting devices, electrical boxes, and other equipment present in special sections such as bridges. Furthermore, the pre-set leveling platform ensures stable operation of the rail-mounted gantry cranes under superelevated curved conditions. This method is quick, practical, reliable, cost-effective, and highly applicable, enabling the replacement of heavy CRTSⅡ type ballastless track slabs within maintenance windows without cutting the rails. This method departs from the traditional approach of replacing lighter CRTSⅠ track slabs by cutting rails or using gantry cranes. It solves the problems of low overall replacement efficiency caused by the numerous track window procedures and long inter-procedure times inherent in the traditional method. This new method not only enables track slab replacement on superelevated curves but also significantly improves construction efficiency, ensuring completion within two to three track windows. Safe and reliable temporary supports are installed during construction to ensure trains can run at 80 km / h after the track window closes, guaranteeing smooth track operation and safe operation.

[0156] This invention optimizes construction organization, simplifies and concentrates construction procedures within two track maintenance windows, thereby reducing the number of procedures and tools required and improving construction efficiency. In addition, a reliable temporary transition scheme is adopted to ensure that the track can be opened on time after the track maintenance window ends, avoiding track closures that affect train punctuality.

[0157] This invention improves equipment performance and overcomes the technical barrier that current technologies mainly target the lighter CRTS I type plate, but are difficult to replace with the heavier CRTS II type plate.

[0158] This invention enhances the applicability of the equipment and innovatively applies the ballastless track slab replacement technology for high-speed railways to curved superelevation sections.

[0159] The above are merely preferred embodiments of the present invention and are not intended to limit the present invention. Various modifications and variations can be made to the present invention by those skilled in the art. Any modifications, equivalent substitutions, improvements, etc., made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

1. A method for replacing ballastless track slabs on ultra-high-altitude sections of high-speed railway curves, characterized in that: During the initial skylight period, two sets of leveling platforms were poured on both sides of the track slab to be replaced. Remove the wide and narrow joints and side blocks between the track slab to be replaced and the adjacent track slab, and install a clamping and limiting device on the track slab to be replaced; During the designated maintenance window, the railcar assembly enters the site, including: the first railcar driving the first fixed rail crane, the first rail flatcar, the second rail flatcar, the second fixed rail crane, and the second railcar connected to it in sequence into the construction area; the railcar assembly is then disassembled, and the first fixed rail crane and the second fixed rail crane are respectively fixed on the two sets of leveling platforms to form an in-situ hoisting unit; the first railcar, the first rail flatcar, the second rail flatcar, and the second railcar are then driven away from the construction area. Loosen the fasteners of the ballastless track slab according to the predetermined fastener loosening length, install the rail shifting device, and use the rail shifting device to shift the rail laterally and limit its position. Remove the clamping and limiting device of the track slab to be replaced, and use the in-situ hoisting unit to peel, lift and remove the track slab to be replaced; The rail is reset and the rail-shifting device is removed. The loosened fasteners are screwed back in, and wooden sleepers are used to temporarily support the rail at the location of the track plate to be replaced. The second railcar pushes the first railcar and the second railcar, so that the first railcar travels to the position of the rail slab to be replaced. The in-situ hoisting unit places the rail slab to be replaced on the first railcar. The second railcar continues to push, so that the second railcar is directly below the in-situ hoisting unit. The in-situ hoisting unit lifts the new rail slab on the second railcar. The second railcar continues to push, causing the first and second railcars to leave the construction area. The fasteners of the ballastless track slab are loosened again according to the predetermined fastener loosening length. The rails at the positions of the track slabs to be replaced are then horizontally adjusted and limited. The in-situ hoisting unit lowers the new track slab, installs the new track slab, resets the rails, removes the rail shifting equipment, and screws in the loosened fasteners.

2. The method for replacing ballastless track slabs on superelevation sections of high-speed railway curves according to claim 1, characterized in that: During the initial track maintenance window, the actual locking rail temperature and the actual rail temperature are tested and compared to determine the fastener loosening length, thus obtaining the predetermined fastener loosening length.

3. The method for replacing ballastless track slabs on superelevation sections of high-speed railway curves according to claim 1, characterized in that: The two sets of leveling platforms are symmetrical about the centerline of the track to be replaced, which is perpendicular to the direction of operation.

4. The method for replacing ballastless track slabs on superelevation sections of high-speed railway curves according to claim 1, characterized in that: During the initial window period, threaded rods are pre-installed on the location of the leveling platform to be poured and on the outer support layer, and then the leveling platform is poured based on the pre-installed threaded rods; Both the first fixed rail crane and the second fixed rail crane are fixed to the leveling platform by bolt fixing devices.

5. The method for replacing ballastless track slabs on superelevation sections of high-speed railway curves according to claim 1, characterized in that: After the new track slab is installed, the original hoisting unit will be dismantled and replaced with the first fixed track crane and the second fixed track crane. The first track crane and the second track crane will both travel towards the middle construction area and meet the first fixed track crane, the first track flatcar, the second track flatcar, and the second fixed track crane in the middle one by one and recombine into a track car group. The second track car will then drive the track car group back.

6. The method for replacing ballastless track slabs on superelevation sections of high-speed railway curves according to claim 1, characterized in that: Remove the concrete from the wide and narrow joints of the track slab to be replaced, loosen the tension lock, and remove the concrete slag and debris from the wide joint. A clamping and limiting device is installed on both sides of the track plate to be replaced.

7. The method for replacing ballastless track slabs on superelevation sections of high-speed railway curves according to claim 1, characterized in that: The rail shifting device includes a hydraulic jacking device and a slide rail; The installation of the rail-mounting equipment includes: A set of track-shifting equipment is installed on each of the two adjacent track plates to be replaced. The hydraulic jacking device is installed between the first and second support platforms of the adjacent track slabs to be replaced, and the slide is installed between the support platforms next to the hydraulic jacking device.

8. The method for replacing ballastless track slabs on superelevation sections of high-speed railway curves according to claim 7, characterized in that: The method of laterally adjusting and limiting the rails using a rail-adjusting device includes: Use hydraulic jacking equipment to push the rails into place; After the rail is pushed into place, it is fixed in place on the slide rail.

9. The method for replacing ballastless track slabs on superelevation sections of high-speed railway curves according to claim 1, characterized in that: Peeling, lifting, and removing the track slab to be replaced; including: After removing the clamping and limiting device of the track plate to be replaced, clean the mortar at the fine adjustment claw position of the track plate to be replaced, and use a jack to lift the track plate to be replaced so that the track plate to be replaced is separated from the mortar layer. Two sets of C-type lifting devices are installed on the track slab to be replaced. The two sets of C-type lifting devices are fastened to the track slab to be replaced. The track slab to be replaced is lifted by the in-situ hoisting unit, thus completing the lifting and removal of the track slab to be replaced.

10. The method for replacing ballastless track slabs on superelevation sections of high-speed railway curves according to claim 1, characterized in that: The in-situ hoisting unit lowers the new track slab, installs the new track slab, resets the rails, removes the rail shifting equipment, and screws in the loosened fasteners; including: After the new track slab is lifted, remove the temporary supporting wooden sleepers, clean the CA mortar layer under the location of the track slab to be replaced, and ensure that the top surface of the base plate under the location of the track slab to be replaced is flat and clean; Pads are placed on the base plate and the support layer respectively, and the thickness of the pads is the same as the thickness of the mortar layer. The in-situ hoisting unit places the new track slab on the pad and removes the track slab C-type hoisting tool; Remove the guide rail equipment and slide rail, and screw back in the loosened fasteners within the construction area.

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