Prefabricated ballastless track and construction method thereof

Abstract

The application discloses an assembled ballastless track and a construction method thereof, and belongs to the technical field of ballastless tracks. The assembled ballastless track comprises prefabricated unit plates, leveling layers and lower foundations which are sequentially stacked along the vertical direction. The prefabricated unit plates are arranged side by side along the longitudinal direction of the track. The longitudinal ends of each prefabricated unit plate are provided with connecting pieces, and the connecting pieces of adjacent prefabricated unit plates are detachably connected. The assembled ballastless track is characterized in that the connecting pieces are arranged at the two ends of the prefabricated unit plates, and the adjacent prefabricated unit plates are detachably connected. The prefabricated unit plates can be quickly spliced and installed. The detachable connection not only makes the prefabricated units form a whole, but also enables the prefabricated unit plates to be quickly disassembled and replaced when a single or part of the prefabricated unit plates is damaged. The prefabricated unit plates are stably placed on the lower foundations, and the ballastless track can be quickly maintained and repaired.

Description

TECHNICAL FIELD

[0001] The present application belongs to the technical field of ballastless track, and particularly relates to a fabricated ballastless track and a construction method thereof. BACKGROUND

[0002] With the continuous advancement of the process of railway high-speed, ballastless track is widely used in high-speed railway, urban rail transit and regional railway due to its high smoothness, stability and small maintenance and repair workload. In recent years, the fabricated structure has been widely promoted due to its characteristics of saving construction period and being green and environmentally friendly.

[0003] The fabricated ballastless track is a new type of track structure combining the advantages of ballastless track and fabricated structure. The ballastless track structure is generally divided into unit type and longitudinal type. The unit ballastless track is convenient to maintain and repair, but it is necessary to ensure the stability of the ballastless track structure and the underlying foundation, and there is a problem that the unit plates cannot deform and coordinate with each other. The longitudinal ballastless track generally uses concrete to realize longitudinal connection, and the concrete structure needs to be re-poured and formed after damage, which is difficult to maintain and repair. SUMMARY

[0004] In view of one or more of the above defects or improvement needs of the prior art, the present application provides a fabricated ballastless track to solve the problems of inconvenient construction or difficult maintenance of the existing ballastless track.

[0005] To achieve the above-mentioned purpose, the present application provides a fabricated ballastless track, which comprises:

[0006] a prefabricated unit plate, a leveling layer and an underlying foundation which are sequentially stacked along the vertical direction;

[0007] Among them, the prefabricated unit plate is a plurality of units arranged side by side along the longitudinal direction of the track, the longitudinal ends of each prefabricated unit plate extend with a connecting piece, and the connecting pieces of adjacent two prefabricated unit plates are detachably connected.

[0008] As a further improvement of the present application, the connecting piece is an I-shaped steel, the I-shaped steel penetrates the prefabricated unit plate along the longitudinal direction, the two ends of the I-shaped steel form a first interface perpendicular to the longitudinal direction, a threaded hole is formed on the first interface, and adjacent two I-shaped steels are connected by a first screw.

[0009] As a further improvement of the present application, the part of the I-shaped steel extending out of the prefabricated unit plate forms a second interface perpendicular to the vertical direction, a threaded hole is vertically formed on the second interface, a second screw is threadedly connected in the threaded hole, and the second screw vertically connects the underlying foundation.

[0010] As a further improvement of the application, the first screw and the second screw are both multiple, and the projections of the first screw and the second screw in the vertical direction are arranged in staggered positions.

[0011] As a further improvement of the application, the part of the I-shaped steel penetrating into the prefabricated unit plate is roughened.

[0012] As a further improvement of the application, a solidification layer is further arranged below the part of the I-shaped steel protruding from the prefabricated unit plate, the lower end of the solidification layer is connected with the lower foundation, the upper end of the solidification layer is flush with the bottom end of the I-shaped steel, and the lower end of the second screw is fixedly connected with the solidification layer.

[0013] As a further improvement of the application, a grouting hole is further arranged on the prefabricated unit plate, a grouting gap is left between the prefabricated unit plate and the lower foundation, and the leveling layer is formed by pouring concrete through the grouting hole.

[0014] As a further improvement of the application, a damping layer is further arranged between the prefabricated unit plate and the lower foundation.

[0015] The application also includes a construction method of the prefabricated ballastless track, which is used for the construction arrangement of the prefabricated ballastless track, and includes the following steps.

[0016] S1, checking the smoothness of the lower foundation, and installing a limiting sleeve at the set position of the lower foundation;

[0017] S2, setting the installation position of the prefabricated unit plate on the lower foundation, and installing the prefabricated unit plate through tooling;

[0018] S3, arranging a screw to pass through the prefabricated unit plate and be fixed to the limiting sleeve, and screwing the screw to make the prefabricated unit plate reach the set elevation;

[0019] S4, arranging the next prefabricated unit plate beside the previous prefabricated unit plate, and longitudinally connecting the adjacent prefabricated unit plates through screws;

[0020] S5, installing a formwork around the prefabricated unit plate, pouring concrete through the grouting hole on the surface of the prefabricated unit plate, and forming a leveling layer between the prefabricated unit plate and the lower foundation through the concrete;

[0021] S6, testing the flatness and elevation of the prefabricated unit plate, and continuously laying the unit plates along the longitudinal direction of the track when the flatness and elevation of the prefabricated unit plate are within the set error.

[0022] As a further improvement of the application, after step S4, the method further includes: installing a formwork at the joint of the adjacent prefabricated unit plates, pouring concrete between the two prefabricated unit plates, and adjusting the pouring amount of the concrete to make the upper layer of the concrete contact the lower surface of the connecting piece.

[0023] The above technical features can be combined with each other as long as they do not conflict with each other.

[0024] Overall, compared with the prior art, the above technical solutions conceived by the present application have the beneficial effects including:

[0025] (1) The assembled ballastless track of the present application realizes the rapid splicing and installation of the prefabricated unit plate by providing connecting pieces at both ends of the prefabricated unit plate and detachably connecting adjacent prefabricated unit plates. In addition to forming a whole by the detachable connection of the prefabricated unit, the rapid disassembly and replacement of the prefabricated unit plate are realized when a single or part of the prefabricated unit plate is damaged, thereby ensuring the stable placement of the prefabricated unit plate on the lower foundation and realizing the rapid maintenance and repair of the ballastless track.

[0026] (2) The assembled ballastless track of the present application realizes the rapid connection and fixation of the prefabricated unit plate by longitudinally penetrating an I-beam in the prefabricated unit plate, forming a first interface in the longitudinal direction of the I-beam, and connecting the I-beams of adjacent prefabricated unit plates by a first screw. The threaded connection form ensures the stable connection of the prefabricated unit plate while realizing the rapid disassembly and replacement of adjacent prefabricated unit plates. At the same time, a second interface is provided on the I-beam, and the I-beam is connected to the lower foundation by a second screw. The second screw connection form allows the prefabricated unit plate to be adjusted in elevation by the corresponding screw, realizes the installation and construction of the prefabricated unit plate according to the set size, and ensures the stable connection of the prefabricated unit plate and the lower foundation, thereby improving the stability of the assembled ballastless track.

[0027] (3) The assembled ballastless track of the present application realizes the stable connection of the second screw and the lower foundation without fixing the I-beam by pouring a solidified layer between adjacent prefabricated unit plates and adjusting the solidified layer, thereby further improving the stability of the prefabricated unit plate on the lower foundation without affecting the disassembly of the prefabricated unit plate, and ensuring the disassembly and stability of the prefabricated unit plate.

[0028] (4) The assembled ballastless track of the present application realizes the stable placement of the prefabricated unit plate on the lower foundation by providing a grouting hole on the prefabricated unit plate and pouring a leveling layer through the grouting hole, thereby ensuring the installation accuracy and use accuracy of the prefabricated unit plate. In addition, a damping layer is provided between the prefabricated unit plate and the lower foundation to improve the service life of the prefabricated unit plate. BRIEF DESCRIPTION OF DRAWINGS

[0029] Figure 1 is a schematic view of the overall structure of the assembled ballastless track in the embodiment of the present application;

[0030] Figure 2 isFigure 1 Enlarged view of the connection at A;

[0031] Figure 3 is the overall structure schematic diagram of the connection in the embodiment of the present application.

[0032] In all the drawings, the same reference signs refer to the same technical features, in particular:

[0033] 1, prefabricated unit board; 2, lower foundation; 3, connection; 4, first interface; 5, second interface; 6, grouting hole; 7, damping layer. DETAILED DESCRIPTION

[0034] In order to make the objectives, technical solutions and advantages of the present application clearer, the present application will be further described in detail below with reference to the drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the present application and should not be used to limit the present application. In addition, the technical features involved in each embodiment of the present application described below can be combined with each other as long as there is no conflict.

[0035] In the description of the present application, it should be understood that the terms "center", "longitudinal", "transverse", "length", "width", "thickness", "upper", "lower", "front", "rear", "left", "right", "vertical", "horizontal", "top", "bottom", "inner", "outer", "clockwise", "counterclockwise", "axial", "radial", "circumferential" and the like indicate the orientation or positional relationship based on the orientation or positional relationship shown in the drawings, and are only used to facilitate the description of the present application and simplify the description, and therefore cannot be understood as indicating or implying that the devices or elements referred to must have a particular orientation, be constructed and operated in a particular orientation, and therefore cannot be understood as limiting the present application.

[0036] In addition, the terms "first", "second" are only used for description purposes, and cannot be understood as indicating or implying relative importance or implicitly indicating the number of the technical features indicated. Therefore, the features defined with "first", "second" can explicitly or implicitly include at least one of the features. In the description of the present application, the meaning of "multiple" is at least two, for example, two, three, etc., unless otherwise specifically limited.

[0037] In this invention, unless otherwise explicitly specified and limited, the terms "installation," "connection," "linking," and "fixing," etc., should be interpreted broadly. For example, they can refer to a fixed connection, a detachable connection, or an integral part; they can refer to a mechanical connection or an electrical connection; they can refer to a direct connection or an indirect connection through an intermediate medium; they can refer to the internal communication of two components or the interaction between two components, unless otherwise explicitly limited. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0038] In this invention, unless otherwise explicitly specified and limited, "above" or "below" the second feature can mean that the first feature is in direct contact with the second feature, or that the first feature is in indirect contact with the second feature through an intermediate medium. Furthermore, "above," "over," and "on top" of the second feature can mean that the first feature is directly above or diagonally above the second feature, or simply that the first feature is at a higher horizontal level than the second feature. "Below," "below," and "under" the second feature can mean that the first feature is directly below or diagonally below the second feature, or simply that the first feature is at a lower horizontal level than the second feature.

[0039] Example:

[0040] Please see Figures 1-3 In a preferred embodiment of the present invention, the prefabricated ballastless track includes prefabricated unit plates 1, a leveling layer and a lower foundation 2 stacked vertically in sequence; wherein the prefabricated unit plates 1 are multiple prefabricated units arranged side by side in sequence along the longitudinal direction of the track, and each prefabricated unit plate 1 has a connector 3 extending from both ends in the longitudinal direction, and the connector 3 of two adjacent prefabricated unit plates 1 is detachably connected.

[0041] Specifically, this application mainly modifies the design of the prefabricated unit plate 1 to form connectors 3 at both ends of the prefabricated unit plate 1, and realizes the connection of the prefabricated unit plate 1 through a detachable connection. When the rail train is running, the prefabricated unit plate 1 is connected as a whole through the connectors 3 to realize the normal operation of the rail train. When a prefabricated unit plate 1 is damaged, the connectors 3 can be quickly disassembled to realize the disassembly and replacement of one or part of the prefabricated unit plate 1, so as to realize the rapid maintenance of ballastless track.

[0042] Specifically, the prefabricated unit panel 1 of this application is prefabricated in a factory according to set standards. It has an overall plate-like structure, and pairs of pads are set on the top of the plate-like structure for placing rails and fixing rail fasteners to achieve stable arrangement of the rails. The plate-like structure below can be a solid reinforced concrete block, a lightweight structure with holes, or a plate with grooves on the bottom.

[0043] Further, as a preferred embodiment of the present application, the connecting piece 3 in the present application is an I-beam, which penetrates the prefabricated unit plate 1 along the longitudinal direction and extends out of the prefabricated unit plate 1 at both ends, and a first joint surface 4 perpendicular to the longitudinal direction is formed at both ends of the I-beam, and a threaded hole is formed on the first joint surface 4, and adjacent two I-beams are connected by a first screw. In order to realize the detachable connection between adjacent prefabricated unit plates 1, the I-beam is arranged in the prefabricated unit plate 1, and both ends of the I-beam extend out of the prefabricated unit plate 1 for connection, and the first joint surface 4 is formed at both ends of the adjacent I-beam, and the first screw is used to realize the connection between the two first joint surfaces 4, and the reliable connection between the adjacent prefabricated unit plates 1 is completed. When a single or part of the prefabricated unit plates 1 is damaged and needs to be replaced, the adjacent prefabricated unit plates 1 can be separated by removing the first screw.

[0044] Further, as a preferred embodiment of the present application, the part of the I-beam extending out of the prefabricated unit forms a second joint surface 5 perpendicular to the vertical direction, a threaded hole is vertically formed on the second joint surface 5, a second screw is threadedly connected in the threaded hole, and the second screw is vertically connected to the lower foundation 2. Although the prefabricated unit plate 1 can realize the longitudinal connection of the prefabricated unit plate 1 by the cooperation of the first joint surface 4 and the first screw, the connection with the lower foundation 2 is not stable enough, so the present application correspondingly provides the second joint surface 5, and the I-beam is connected to the lower foundation 2 below by the second screw. Specifically, the second screw in the present application not only realizes the stable connection between the prefabricated unit plate 1 and the lower foundation 2, but also can realize the elevation adjustment of the prefabricated unit plate 1 by adjusting the part of the second screw extending into the lower foundation 2, so that the prefabricated unit plate 1 is installed at the set position. Correspondingly, a limiting sleeve is installed on the lower foundation 2 in the present application, and the cooperation of the second screw and the limiting sleeve realizes the fixation of the second screw and the elevation adjustment of the prefabricated unit plate 1.

[0045] Further, as a preferred embodiment of the present application, the first screw and the second screw are both multiple, and the projections of the first screw and the second screw on the vertical direction are arranged in a staggered manner. When the first screw is used to realize the connection between adjacent prefabricated units, and the second screw is used to realize the connection between the prefabricated unit plate 1 and the lower foundation 2, since the first screw is arranged along the longitudinal direction and the second screw is arranged along the vertical direction, and both of them are connected to the part of the I-beam extending out of the prefabricated unit plate 1, in order to avoid the interference between the first screw and the second screw, the present application correspondingly adjusts the position of the threaded hole on the I-beam to arrange the projections of the first screw and the second screw on the vertical direction in a staggered manner, so as to realize the stable arrangement of the first screw and the second screw.

[0046] Further, as a preferred embodiment of the present application, the part of the I-shaped steel penetrating into the prefabricated unit plate 1 is roughened. Since the main body of the prefabricated unit plate 1 is a concrete structure, and the I-shaped steel is a metal material, one is non-metal and the other is metal, there is an interface separation at the joint of the two, in order to ensure the stable arrangement of the I-shaped steel in the prefabricated unit plate 1, the surface of the I-shaped steel is roughened to increase the contact area between the I-shaped steel and the prefabricated unit plate 1 and improve the connection stability. Preferably, the I-shaped steel is provided with reinforcing ribs extending in the horizontal and vertical directions, and the reinforcing ribs are penetrated into the prefabricated unit plate 1 to further improve the connection stability.

[0047] Further, as a preferred embodiment of the present application, the part of the I-shaped steel penetrating into the prefabricated unit plate 1 is roughened. Since the main body of the prefabricated unit plate 1 is a concrete structure, and the I-shaped steel is a metal material, one is non-metal and the other is metal, there is an interface separation at the joint of the two, in order to ensure the stable arrangement of the I-shaped steel in the prefabricated unit plate 1, the surface of the I-shaped steel is roughened to increase the contact area between the I-shaped steel and the prefabricated unit plate 1 and improve the connection stability. Preferably, the I-shaped steel is provided with reinforcing ribs extending in the horizontal and vertical directions, and the reinforcing ribs are penetrated into the prefabricated unit plate 1 to further improve the connection stability.

[0048] Further, as a preferred embodiment of the present application, the prefabricated unit plate 1 in the application is also provided with a grouting hole 6, and a grouting gap is left between the prefabricated unit plate 1 and the lower foundation 2, and the leveling layer is formed by pouring concrete through the grouting hole 6. The prefabricated unit plate 1 and the lower foundation 2 are both completed in advance, which makes it impossible for the prefabricated unit plate 1 to be perfectly combined with the lower foundation 2, and the elevation of the prefabricated unit plate 1 and the lower foundation 2 is also adjusted by the second screw, which makes a gap exist between the prefabricated unit plate 1 and the lower foundation 2, and the stable arrangement of the prefabricated unit plate 1 on the lower foundation 2 cannot be realized by the second screw structure alone. In order to ensure the stable operation of the track train, a leveling layer needs to be formed between the prefabricated unit plate 1 and the lower foundation 2, which on the one hand ensures the planeness and elevation of the prefabricated unit plate 1, and on the other hand transmits the force received by the prefabricated unit plate 1 to the lower foundation 2 through the leveling layer, thereby ensuring the stable use of the assembled ballastless track.

[0049] Further preferably, a damping layer 7 is further arranged between the prefabricated unit plate 1 and the lower foundation 2 in the application, and the damping layer 7 is prepared in a rubber structure and is used for absorbing vibration and improving the service life of the prefabricated unit plate 1.

[0050] Further, based on the assembled ballastless track in the application, the application further includes a construction method of the assembled ballastless track, which includes the following steps:

[0051] S1, check the smoothness of the lower foundation 2, and install a limiting sleeve at a set position of the lower foundation 2; since a leveling layer needs to be arranged between the lower foundation 2 and the prefabricated unit plate 1 later, the smoothness of the lower foundation 2 here is mainly used to clean the surface of the lower foundation 2 and remove some sharp protrusions and the like;

[0052] S2, set the installation position of the prefabricated unit plate 1 on the lower foundation 2, and install the prefabricated unit plate 1 through a tool;

[0053] S3, set the screw to pass through the prefabricated unit plate 1 and be fixed to the limiting sleeve, and rotate the screw to make the prefabricated unit plate 1 reach the set elevation;

[0054] S4, set the next prefabricated unit plate 1 beside the previous prefabricated plate, and use the screw to longitudinally connect the adjacent prefabricated unit plates 1;

[0055] S5, install a formwork around the prefabricated unit plate 1, pour concrete through the grouting hole 6 on the surface of the prefabricated unit plate 1, and form a leveling layer between the prefabricated unit plate 1 and the lower foundation 2 by the concrete;

[0056] S6, test the planeness and elevation of the prefabricated unit plate 1, when the planeness and elevation of the prefabricated unit plate 1 are within the set error, continuously lay the prefabricated unit plate 1 along the longitudinal direction of the track to form the assembled ballastless track.

[0057] The construction method of the assembled ballastless track in the application has a simple construction mode and can realize stable setting of the prefabricated unit during connection, quick disassembly during disassembly, and quick installation, stable operation, and quick maintenance of the assembled ballastless track.

[0058] Further, the step S4 further includes installing a formwork at the joint of the adjacent prefabricated unit plates 1, pouring concrete between the two prefabricated unit plates 1, and adjusting the pouring amount of the concrete so that the upper layer of the concrete is in contact with the lower surface of the connecting piece 3. Here, the joint of the adjacent prefabricated unit plates 1 mainly refers to the part of the I-beam extending out of the prefabricated unit plate 1, and by adjusting the pouring amount of the concrete, the second screw is fixed on the basis of not fixing the I-beam.

[0059] Optionally, the construction method of the assembled ballastless track in the application can be applied to various construction environments. When the construction is performed on a bridge, the lower foundation 2 is a beam surface; when the construction is performed in a tunnel, the lower foundation 2 is an upward backfill layer; and when the construction is performed on a roadbed, the lower foundation 2 is a concrete base plate.

[0060] Those skilled in the art will easily understand that the above description is only the preferred embodiment of the present application and is not intended to limit the present application. Any modification, equivalent replacement, and improvement within the spirit and principle of the present application shall be included in the protection scope of the present application.

Claims

1. A prefabricated ballastless track, characterized in that, The utility model relates to a prefabricated unit plate and a method for installing the same, and relates to the field of track construction. The prefabricated unit plate, the leveling layer and the lower foundation are sequentially stacked in the vertical direction. The connecting piece is an I-shaped steel, which penetrates the prefabricated unit plate in the longitudinal direction, and the two ends of the I-shaped steel form a first abutting surface perpendicular to the longitudinal direction. The first screw and the second screw are both multiple, and the projections of the first screw and the second screw in the vertical direction are arranged in a staggered manner.

2. The assembled ballastless track according to claim 1, characterized in that, The part of the I-shaped steel penetrating the prefabricated unit plate is roughened.

3. The assembled ballastless track according to claim 1, characterized in that, The part of the I-shaped steel protruding from the prefabricated unit plate is further provided with a solidification layer.

4. The assembled ballastless track according to claim 1, characterized in that, The prefabricated unit plate is further provided with a grouting hole, and a grouting gap is left between the prefabricated unit plate and the lower foundation.

5. The assembled ballastless track according to any one of claims 1-4, characterized in that, The prefabricated unit plate and the lower foundation are further provided with a damping layer.

6. The assembled ballastless track according to any one of claims 1-4, characterized in that, The method comprises the following steps:

7. A construction method for prefabricated ballastless track, used for the construction layout of prefabricated ballastless track as described in any one of claims 1 to 6, characterized in that, S1, checking the smoothness of the lower foundation, and installing a limiting sleeve at the set position of the lower foundation; S2, setting the installation position of the prefabricated unit plate on the lower foundation, and installing the prefabricated unit plate through a tool; S3, passing a screw through the prefabricated unit plate and fixing it to the limiting sleeve, and rotating the screw to make the prefabricated unit plate reach the set elevation; S4, setting the next prefabricated unit plate beside the previous prefabricated unit plate, and longitudinally connecting the adjacent prefabricated unit plates through a screw; S5, installing a formwork around the prefabricated unit plate, pouring concrete through the grouting hole on the surface of the prefabricated unit plate, and forming a leveling layer between the prefabricated unit plate and the lower foundation; S6, testing the flatness and elevation of the prefabricated unit plate, and continuously laying the prefabricated unit plate in the longitudinal direction of the track when the flatness and elevation of the prefabricated unit plate are within the set error. After step S4, the method further comprises the following steps: installing a formwork at the abutting position of the adjacent prefabricated unit plates, pouring concrete between the two prefabricated unit plates, and adjusting the amount of concrete poured to make the upper layer of the concrete contact the lower surface of the connecting piece.

8. The construction method of the assembled ballastless track according to claim 7, characterized in that, ​

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