Ballastless track guard wheel sleeper prefabricating method

Abstract

The invention relates to the technical field of ballastless tracks, in particular to a ballastless track wheel protection sleeper prefabricating method, which is different from the conventional wheel protection sleepers in which track sleepers and wheel protection rails are integrally designed, and the wheel protection sleepers are completely different from the conventional wheel protection sleepers as independent structures. The method comprises the steps of formwork designing and manufacturing, formwork splicing and size checking, fixing sleeve and spike installing, insulating steel reinforcement framework installing, concrete pouring, vibrating table vibrating, wheel protection sleeper demolding and sleeper maintaining. The method comprises the steps of formwork designing and manufacturing, formwork splicing and size checking, fixing sleeve and spike installing, insulating steel reinforcement framework installing, concrete pouring, vibrating table vibrating and tamping, wheel protection sleeper demolding and sleeper maintaining. The complete and scientific ballastless track guard wheel sleeper prefabricating construction technology is formed, and the technology is high in construction efficiency, controllable in quality, high in operability and capable of being widely applied and popularized.

Description

Technical Field

[0001] The invention relates to the technical field of ballastless track, in particular to a method for prefabricating wheel guard sleepers of ballastless track. Background Art

[0002] China's high-speed railway development has evolved from "three vertical and three horizontal" to the current "eight vertical and eight horizontal" high-speed railway network. Many railway lines are intertwined. To ensure that the newly built railways do not affect the completed or operational railway lines, the newly built railway lines crossing the existing high-speed railway tracks adopt the structure of cast-in-place ballastless track + wheel guard sleepers.

[0003] Ballastless track wheel guard sleepers are used for newly built railway lines crossing over existing high-speed railways, especially ballasted railway lines crossing over existing busy high-speed railway lines. The ballastless track structure is adopted to prevent ballast falling and causing high-speed railway driving safety, and wheel guard sleepers are added to the ballastless track structure. The sleepers and wheel guard sleepers are cast in place as a whole, which further ensures that the railway line below can also operate normally after a train derails due to an accident. Summary of the invention

[0004] The purpose of the present invention is to overcome the deficiencies of the prior art and provide a method for prefabricating a ballastless track wheel guard sleeper.

[0005] In order to achieve the above object, the technical solution adopted by the present invention is:

[0006] A method for prefabricating ballastless track wheel guard sleepers comprises the following steps:

[0007] (1) Template design and production steps: The template is designed with steel templates, and holes are opened at the corresponding positions to reserve the positions of the ballastless track guard rail sleeper sleeves. The center lines of the opening positions are at the same horizontal position, and the opening diameter is smaller than the diameter of the ballastless track guard rail sleeper sleeve. The length and width of the template meet the requirements, and its height is greater than the length of the embedded sleeve by 3 cm or more. In addition, whether there is a conflict with the ballastless track bed steel bars and whether the thickness of the guard rail concrete and the subsequent cast-in-place track bed concrete may cause cracks, etc. Otherwise, corresponding adjustments should be made;

[0008] (2) Template assembly and size verification steps: When assembling the template, the bottom should face upwards and the top surface of the guard rail sleeper should face downwards. The four-sided template should be assembled. After completion, the size of the guard rail template should be checked and verified to ensure that the size meets the requirements;

[0009] (3) Steps for installing the fixing sleeve and spikes: spray the template agent and place the four sleeper sleeves in the reserved holes. The installation sequence is as follows:

[0010] a. Install the embedded casing in the template;

[0011] b. Insert spikes into the reserved sleeve positions on the outside of the template, install gaskets and spring washers on the spikes, check the position of the embedded sleeves, check the dimensions including the centerline position and dimensions, the position and dimensions of the embedded sleeves from the template edge, and the distance between adjacent embedded sleeves. After confirming that they are correct, tighten the spikes with tools to make them basically fixed, recheck the position of the embedded sleeves, make fine adjustments, and tighten them with a torque wrench to the corresponding torque to ensure that the embedded sleeves are tightly attached to the template; it is not advisable to use electric wrenches to avoid deformation of the template caused by excessive torque;

[0012] (4) Steps for installing the insulated steel bar skeleton: The steel bars of the wheel guard rail sleepers of the ballastless track are made of insulating coated steel bars, which are cut and processed by steel bar processing equipment. During the steel bar processing, damage to the steel bar coating should be avoided. The processed steel bars are tied to the steel bar skeleton on the steel bar tying frame; the steel bar tying frame is processed according to the wheel guard rail steel bar layout drawing; concrete pads are tied at the bottom and around the steel bar skeleton to ensure that the thickness of the concrete protective layer is greater than 3 cm; the tied steel bar skeleton is manually lifted and placed into the mold;

[0013] (5) Concrete pouring steps: The concrete for the wheel guard sleeper of the ballastless track is the same as that for the ballastless track bed. The concrete mix ratio design of the ballastless track bed should be completed before the construction of the wheel guard sleeper of the ballastless track. The concrete is produced according to the mix ratio, transported to the site, poured into the mold, and the 8 poured formworks are manually lifted onto the vibration lift. The vibration is turned on for 30-45 seconds. The concrete is manually increased or decreased according to the vibration situation. The surface is manually cleaned and the formwork is lifted to the storage area for static storage;

[0014] (6) Steps for demoulding the wheel guard rail sleeper: After the initial setting of the wheel guard rail sleeper concrete, water curing shall be carried out in time. After the concrete reaches the demoulding strength, demoulding shall be carried out in time. First, the bolts around shall be removed, and the spikes, gaskets and spring washers shall be removed with a torque wrench. The template shall be turned 90° to completely separate the wheel guard rail from the template. After demoulding, clean up, assemble and apply demoulding agent for use.

[0015] (7) Maintenance and use steps of wheel guard rail sleepers: Cover the surface of the sleepers with maintenance materials such as geotextiles and sprinkle water to moisten them. The maintenance time of wheel guard rails should be ≥14 days, and it is best to maintain them for more than 28 days if conditions permit.

[0016] The present invention can be used to master the prefabrication construction technology of ballastless track wheel guard sleepers. The invention is easy to operate, convenient to assemble, and has high construction efficiency. It can combine the overall structural type of the ballastless track and the characteristics of later construction. The quality is controllable, the cost is low, the operability is strong, and it can be widely promoted and applied.

[0017] Preferably, the selection of ballastless track wheel guard rail formwork should be based on the construction process of the wheel guard rail sleeper itself, to meet quality requirements, and to facilitate construction. The steel formwork is selected mainly because it has high strength, and the embedded sleeve installation, spikes and other fasteners that fix the formwork should not cause deformation. The formwork consists of a base formwork, two longitudinal formworks, and two transverse formworks connected by bolts. 5cm high angle steels are added around the base membrane, and the height is greater than the exposed height of the spike bolts. This conforms to the production process, is easy to control quality, and is more convenient to demould.

[0018] Preferably, the steps of assembling the template and checking the dimensions are performed, and the steps of installing the fixing sleeves and spikes are performed.

[0019] Preferably, the template assembly and size verification steps are:

[0020] The order of template assembly is base membrane, longitudinal template, transverse template, after the bolt connection is completed, the size adjustment is completed and the bolts are tightened, the next set of templates are assembled after fine-tuning and verification.

[0021] Preferably, the steps of installing and fixing the sleeve and the spike are as follows: draw the longitudinal and transverse centerline positions of the embedded sleeve at the bottom mold position, place the sleeve on the inner side of the bottom mold, first put the spring washer on the spike, then install the gasket, insert it into the embedded sleeve from the outside of the bottom mold, measure the position of the embedded sleeve, preliminarily position it, fine-tune the precise positioning, and tighten the spike bolts.

[0022] Preferably, the prefabrication time of the wheel guard rail should be well planned and should be completed 28 days before the ballast concrete construction. The concrete shrinkage and creep of the wheel guard rail sleeper should be basically completed, and cracking is not likely to occur with the ballast concrete.

[0023] In summary, due to the adoption of the above technical solution, the beneficial effects of the present invention are:

[0024] 1. The present invention can be used to master the prefabrication construction technology of ballastless track wheel guard sleepers. It is easy to operate, convenient to assemble, and has high construction efficiency. It can combine the overall structural type of ballastless track and the characteristics of later construction. It has controllable quality, low cost, strong operability, and can be widely promoted and applied. BRIEF DESCRIPTION OF THE DRAWINGS

[0025] Figure 1 It is a framework diagram of the construction process flow of the present invention. DETAILED DESCRIPTION

[0026] The present invention is further described in detail below in conjunction with specific embodiments. However, this should not be understood as the scope of the above subject matter of the present invention being limited to the following embodiments, and all technologies realized based on the content of the present invention belong to the scope of the present invention.

[0027] Unless otherwise specified, in the description of the specific embodiments of the present invention, the terms indicating the orientation or position relationship such as "up", "down", "left", "right", "center", "inside", "outside", etc. are all based on the expression of the orientation or position relationship shown in the drawings, or are the orientation or position relationship when the invented product / equipment / device is usually used. These terms of orientation or position relationship are only for the convenience of describing the scheme of the present invention or simplifying the description in the specific embodiments, so as to facilitate the technicians to quickly understand the scheme, and do not indicate or imply that a specific device / component / element must have a specific orientation, or be constructed and operated in a specific position relationship, and therefore cannot be understood as a limitation on the present invention.

[0028] In addition, if the terms "horizontal", "vertical", "overhanging", "parallel" and the like appear, it does not mean that the corresponding devices / components / elements are required to be absolutely horizontal or vertical or overhanging or parallel, but may be slightly tilted or have deviations. For example, "horizontal" only means that its direction is more horizontal than "vertical", and does not mean that the structure must be completely horizontal, but may be slightly tilted. Alternatively, it can be simplified to mean that the corresponding devices / components / elements are set in directions such as "horizontal", "vertical", "overhanging", "parallel", etc., and can have an error / deviation of ±10% relative to the corresponding direction setting, more preferably an error / deviation within ±8%, more preferably an error / deviation within ±6%, more preferably an error / deviation within ±5%, and more preferably an error / deviation within ±4%. As long as the corresponding device / component / element is within the error / deviation range, it can still achieve its role in the scheme of the present invention.

[0029] In addition, the expressions “first”, “second”, “third”, etc., which appear in the terms, are merely used to distinguish the description of the same or similar components and should not be understood as emphasizing or implying the relative importance of specific components.

[0030] In addition, in the description of the embodiments of the present invention, "several", "plurality" and "a number" represent at least 2. It can be any number such as 2, 3, 4, 5, 6, 7, 8, 9, and even more than 9.

[0031] In addition, in the description of the technical solution of the present invention, unless otherwise clearly specified / defined / restricted, the terms "set", "install", "connect", "connected", "provided with", "laid", and "arranged" should be understood in a broad sense, for example, it can be a fixed connection, a detachable connection, or an integral connection, and can be welding, riveting, bolting, threading, and other commonly used connection means in the field. This connection can be a mechanical connection, an electrical connection, or a communication connection; it can be a direct connection, or an indirect connection through an intermediate medium, and it can be the internal connection of two elements.

[0032] Example 1

[0033] like Figure 1 As shown, a method for prefabricating ballastless track wheel guard sleepers adopted in this embodiment comprises the following steps:

[0034] a. Template design and production

[0035] The template is designed with steel template, and holes are opened at corresponding positions to reserve positions for the ballastless track wheel guard sleeper sleeves. The center lines of the opening positions are at the same horizontal position, and the diameter of the opening is smaller than the diameter of the ballastless track wheel guard sleeper sleeve. The length and width of the template meet the requirements, and its height is 3 cm or more greater than the length of the embedded sleeve. It should be considered whether there is a conflict with the ballastless track bed steel bars and whether the thickness of the wheel guard rail concrete and the subsequent cast-in-place track bed concrete may cause cracks, etc. Otherwise, corresponding adjustments should be made.

[0036] b. Template assembly and size verification

[0037] When assembling the template, the bottom should face upwards and the top of the guard rail sleeper should face downwards. The four-sided template should be assembled. After completion, the size of the guard rail template should be checked and verified to ensure that the size meets the requirements;

[0038] c. Install the fixing sleeve and spikes

[0039] Spray the template agent and place the 4 sleeper casings in the reserved holes. The installation sequence is:

[0040] Install the embedded casing in the template;

[0041] Insert spikes at the reserved sleeve position outside the template, install gaskets and spring washers on the spikes, check the position of the embedded sleeve, check the dimensions including the centerline position and dimensions, the position and dimensions of the embedded sleeve from the template edge, and the distance between adjacent embedded sleeves. After confirming that they are correct, tighten the spikes with tools to make them basically fixed, recheck the position of the embedded sleeve, make fine adjustments, and tighten with a torque wrench to the corresponding torque to ensure that the embedded sleeve is tightly attached to the template; it is not advisable to use an electric wrench to avoid deformation of the template caused by excessive torque;

[0042] d. Install the insulation steel frame

[0043] The steel bars of the wheel guard rail sleepers of ballastless track are made of insulating coated steel bars, which are cut and processed by steel bar processing equipment. During the steel bar processing, damage to the steel bar coating should be avoided. The processed steel bars are tied to the steel bar skeleton on the steel bar tying frame; the steel bar tying frame is processed according to the wheel guard rail steel bar layout drawing; concrete pads are tied at the bottom and around the steel bar skeleton to ensure that the thickness of the concrete protective layer is greater than 3cm; the tied steel bar skeleton is manually lifted and placed into the mold;

[0044] e. Pouring concrete

[0045] The ballastless track wheel guard sleeper concrete uses the same concrete as the ballastless track bed. The ballastless track bed concrete mix ratio design work should be completed before the construction of the ballastless track wheel guard sleeper. The concrete is produced according to the mix ratio, the concrete is transported to the site, the concrete is poured into the mold, and the 8 poured templates are manually lifted to the vibration lift. The vibration is turned on for 30-45 seconds. The concrete is manually increased or decreased according to the vibration situation. The surface is manually cleaned and the template is lifted to the storage area for static storage;

[0046] f. Demoulding of wheel guard sleepers

[0047] After the initial setting of the wheel guard rail sleeper concrete, water curing shall be carried out in time. After the concrete reaches the demoulding strength, demoulding shall be carried out in time. First, the bolts around shall be removed, and the spikes, gaskets and spring washers shall be removed with a torque wrench. The template shall be turned 90° to completely separate the wheel guard rail from the template. After demoulding, clean up, assemble and apply demoulding agent for use.

[0048] g. Maintenance and use of wheel guard sleepers

[0049] Cover the sleeper surface with maintenance materials such as geotextiles and sprinkle water for maintenance. The wheel guard rail maintenance time should be ≥14 days, and it is best to maintain it for more than 28 days if conditions permit.

[0050] In short, if Figure 1 As shown, the overall process of the present invention is as follows: template design and production → template assembly and size verification → installation of fixed sleeves and spikes → installation of insulating steel frame → pouring concrete → vibration table vibration → wheel guard rail demoulding → sleeper maintenance and use. The present invention can master the prefabrication construction technology of wheel guard rail sleepers for ballastless track. It is easy to operate, easy to assemble, and has high construction efficiency. It can combine the overall structural type of ballastless track and the characteristics of later construction, etc. It has controllable quality, low cost, strong operability, and can be widely promoted and applied.

[0051] The above are only preferred embodiments of the present invention and are not intended to limit the present invention. Any modifications, equivalent substitutions and improvements made within the spirit and principles of the present invention should be included in the protection scope of the present invention.

Claims

1. A method for prefabricating ballastless track wheel guard sleepers, characterized in that: The following steps are included: (1) It includes the steps of template design and production: the template is designed with steel template, and holes are opened at the corresponding positions to reserve the positions of the ballastless track guard rail sleeper sleeves. The center lines of the opening positions are at the same horizontal position, and the opening diameter is smaller than the diameter of the ballastless track guard rail sleeper sleeves. The length and width of the template meet the requirements, and its height is greater than the length of the embedded sleeve by 3 cm or more. In addition, whether there is a conflict with the ballastless track bed steel bars and whether the thickness of the guard rail concrete and the subsequent cast-in-place track bed concrete may cause cracks, etc., otherwise corresponding adjustments should be made; (2) Template assembly and size verification steps: When assembling the template, the bottom should face upwards and the top surface of the guard rail sleeper should face downwards. The four-sided template should be assembled. After completion, the size of the guard rail template should be checked and verified to ensure that the size meets the requirements; (3) Steps for installing the fixing sleeve and spikes: spray the template agent and place the four sleeper sleeves in the reserved holes. The installation order is: a. Install the embedded casing in the template; b. Insert spikes into the reserved sleeve positions on the outside of the template, install gaskets and spring washers on the spikes, check the position of the embedded sleeves, check the dimensions including the centerline position and dimensions, the position and dimensions of the embedded sleeves from the template edge, and the distance between adjacent embedded sleeves. After confirming that they are correct, tighten the spikes with tools to make them basically fixed, recheck the position of the embedded sleeves, make fine adjustments, and tighten them with a torque wrench to the corresponding torque to ensure that the embedded sleeves are tightly attached to the template; it is not advisable to use electric wrenches to avoid deformation of the template caused by excessive torque; (4) Steps for installing the insulated steel bar skeleton: The steel bars of the wheel guard rail sleepers of the ballastless track are made of insulating coated steel bars, which are cut and processed by steel bar processing equipment. During the steel bar processing, damage to the steel bar coating should be avoided. The processed steel bars are tied to the steel bar skeleton on the steel bar tying frame; the steel bar tying frame is processed according to the wheel guard rail steel bar layout drawing; concrete pads are tied at the bottom and around the steel bar skeleton to ensure that the thickness of the concrete protective layer is greater than 3 cm; the tied steel bar skeleton is manually lifted and placed into the mold; (5) Concrete pouring steps: The concrete for the wheel guard sleeper of the ballastless track is the same as that for the ballastless track bed. The concrete mix ratio design of the ballastless track bed should be completed before the construction of the wheel guard sleeper of the ballastless track. The concrete is produced according to the mix ratio, transported to the site, poured into the mold, and the 8 poured formworks are manually lifted onto the vibration lift. The vibration is turned on for 30-45 seconds. The concrete is manually increased or decreased according to the vibration situation. The surface is manually cleaned and the formwork is lifted to the storage area for static storage; (6) Steps for demoulding the wheel guard rail sleeper: After the initial setting of the wheel guard rail sleeper concrete, water curing shall be carried out in time. After the concrete reaches the demoulding strength, demoulding shall be carried out in time. First, the bolts around shall be removed, and the spikes, gaskets and spring washers shall be removed with a torque wrench. The formwork shall be turned 90° to completely separate the wheel guard rail from the formwork. After demoulding, clean up, assemble, and apply release agent for equipment; (7) Maintenance and use steps of wheel guard rail sleepers: Cover the surface of the sleepers with maintenance materials such as geotextiles and sprinkle water to moisten them. The maintenance time of wheel guard rails should be ≥14 days, and it is best to maintain them for more than 28 days if conditions permit.

2. A method for prefabricating ballastless track wheel guard sleepers according to claim 1, characterized in that: Template design and production steps: The selection of ballastless track wheel guard sleeper templates should be based on the construction process of the wheel guard rail itself, quality requirements, and ease of construction. The steel template is selected mainly because it has high strength, and the embedded casing installation, spikes and other fasteners that fix the template should not be deformed. The template consists of a bottom template, two longitudinal templates, and two horizontal templates connected by bolts. 5cm high angle steels are added around the bottom membrane, and the height is greater than the exposed height of the spike bolts, which conforms to the production process, is easy to control the quality, and is more convenient to demould.

3. The method for prefabricating ballastless track wheel guard sleepers according to claim 1, characterized in that: Steps for assembling the template and checking its dimensions, and installing the fixing sleeves and spikes.

4. A method for prefabricating ballastless track wheel guard sleepers according to claim 3, characterized in that: Template assembly and size verification steps: The order of template assembly is base membrane, longitudinal template, transverse template, after the bolt connection is completed, the size adjustment is completed and the bolts are tightened, the next set of templates are assembled after fine-tuning and verification.

5. The method for prefabricating ballastless track wheel guard sleepers according to claim 3, characterized in that: Steps for installing and fixing sleeves and spikes: Draw the longitudinal and transverse centerline positions of the embedded sleeves on the bottom mold, place the sleeves on the inside of the bottom mold, first put the spring washers on the spikes, then install the gaskets, insert them into the embedded sleeves from the outside of the bottom mold, measure the position of the embedded sleeves, preliminarily position them, fine-tune the precise positioning, and tighten the spike bolts.

6. The method for prefabricating ballastless track wheel guard sleepers according to claim 1, characterized in that: The prefabrication time of the wheel guard rail should be well planned and should be completed 28 days before the ballast concrete construction. The concrete shrinkage and creep of the wheel guard rail sleeper should be basically completed and cracking is not likely to occur with the ballast concrete.

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