Fabricated trapezoidal sleeper mold for ballast bed pouring and construction method using fabricated trapezoidal sleeper mold

Abstract

The invention discloses an assembly type trapezoidal sleeper mold for ballast bed pouring and a construction method using the same, the mold comprises a top mold, a bottom mold, a side mold and an end mold, the top mold, the bottom mold, the side mold and the end mold can be detachably combined, and after combination, a mold longitudinal beam of which the boundary dimension is basically consistent with that of a trapezoidal sleeper longitudinal beam can be obtained. Then the two mold longitudinal beams are fixedly connected into a trapezoidal sleeper mold with the boundary dimension basically consistent with that of the trapezoidal sleeper through the connecting steel pipes, then the mold track panel is assembled and placed above the ballast bed pouring position, namely, the preset placing position of the trapezoidal sleeper, and after ballast bed pouring is completed, the mold track panel can be taken down, and then the trapezoidal sleeper mold is formed. By means of the mold and the method, the phenomena of empty hoisting and hard-to-hard collision can be effectively avoided, use of isolation materials is omitted, the pasting and wrapping processes are reduced, and the cost is saved.

Description

Technical Field

[0001] The invention belongs to the technical field of rail transit casting construction, and specifically relates to an assembled trapezoidal sleeper mould for roadbed casting and a construction method using the same. Background Art

[0002] The construction quality of trapezoidal sleeper tracks directly affects the safety and stability of train operation, and also affects the vibration reduction effect of the line.

[0003] The traditional construction method of trapezoidal sleeper track is to first paste and wrap pearl cotton on the outer side and bottom of the trapezoidal sleeper, then assemble the trapezoidal sleeper rail, hoist, transport, and erect it to the predetermined position, then support the formwork and pour the ballast concrete, demould after the concrete strength reaches the standard, then fine-tune the track geometry, and finally deal with quality problems. During the concrete ballast pouring stage, due to factors such as the concealment of the contact part between the vibration damping pad of the trapezoidal sleeper and the ballast and the damage of the isolation material, as well as objective factors such as the low technical level of the construction team and the short construction period, some defects are difficult to eliminate in a timely and effective manner, so quality defects such as empty hoisting and "hard collision" often occur, affecting the vibration reduction effect of the trapezoidal sleeper and delaying the construction period.

[0004] Empty suspension refers to the situation that the vibration damping pad of the trapezoidal sleeper cannot fully contact with the concrete ballast bed. Figure 1 Partially empty as shown in Figure 2 The total empty suspension shown in the figure affects the transmission of load on the upper part of the ladder sleeper track;

[0005] "Hard-on-hard" means that the trapezoidal sleeper is in direct contact with the exposed concrete on the ballast bed, and the vibration-damping pad and the buffer pad cannot fully contact and reduce vibration, which affects the overall vibration-damping effect of the trapezoidal sleeper. Figure 3 and Figure 4 as shown in .

[0006] The main reasons for the empty suspension problem are poor concrete fluidity, inadequate vibration, and loose binding of the wrapping sleeve, which lead to bubbles in the contact area between the trapezoidal sleeper vibration damping pad and the ballast bed. The main reason for the "hard-on-hard" problem is that the wrapping and pasting of the isolation material do not meet the requirements or are damaged during the construction process, resulting in the adhesion of concrete to the main part of the trapezoidal sleeper when the ballast bed is poured.

[0007] Based on this, the inventors have conducted in-depth research on the ballast bed casting work, in the hope of designing an assembled trapezoidal sleeper mold for ballast bed casting and a construction method using the same that can solve the above-mentioned problems. Summary of the invention

[0008] In order to overcome the above problems, the inventors have conducted intensive research and designed an assembled trapezoidal sleeper mold for ballast bed casting and a construction method using the same. The mold includes a top mold, a bottom mold, a side mold and an end mold, and can be detachably combined. After the combination, a mold longitudinal beam having an outer size basically consistent with the trapezoidal sleeper longitudinal beam can be obtained. The two mold longitudinal beams are then consolidated into a trapezoidal sleeper mold having an outer size basically consistent with the trapezoidal sleeper through a connecting steel pipe, and then assembled into a mold rail row, which is placed above the ballast bed casting position, which is the predetermined placement position of the trapezoidal sleeper. After the ballast bed casting is completed, the mold rail row can be removed, thereby conveniently cleaning defects such as empty hanging and adhesion. The mold and method can effectively solve the problems of empty hanging and hard collision, and eliminate the use of isolation materials, reduce the pasting and wrapping processes, and save costs, thereby completing the present invention.

[0009] Specifically, the object of the present invention is to provide an assembled trapezoidal sleeper mold for roadbed casting, the trapezoidal sleeper mold comprising:

[0010] Two mold longitudinal beams, the outer shape and size of the mold longitudinal beams are basically consistent with the trapezoidal sleeper longitudinal beams;

[0011] The mold longitudinal beam comprises a top mold 1, a bottom mold 2, a side mold and an end mold 4 which are detachably connected to each other;

[0012] A connecting steel pipe 5 is provided between the two longitudinal beams of the mould, and the two longitudinal beams of the mould are consolidated into one by the connecting steel pipe 1, so that the external shape and size of the obtained trapezoidal sleeper mould are basically consistent with the trapezoidal sleeper.

[0013] Among them, multiple trapezoidal sleeper molds are assembled into a 25m long mold rail row through rail consolidation, and the mold rail row is placed in the spatial position of the pre-installed trapezoidal sleeper rail row. After the strength of the poured ballast bed concrete reaches the standard, the mold rail row is removed, and then the empty hang and adhesion can be repaired.

[0014] The bottom mold 2 includes a bottom plate 21, which is a horizontally arranged flat plate. On the bottom plate 21, an outer side steel plate 22, an inner side steel plate 23 and two groups of end steel plates 24 connected end to end in a ring structure are arranged at the edge of the bottom plate 21;

[0015] On the bottom plate 21, transverse ribs 25 and longitudinal ribs 26 are also provided inside the annular structure;

[0016] On the bottom plate 21 , a boss longitudinal limiting plate 27 and a boss transverse limiting plate 28 are provided outside the outer side steel plate 22 .

[0017] Wherein, the side molds include side mold I31, side mold II32 and side mold III33;

[0018] The side mold I31 includes a side mold I inner plate 311 and a side mold I outer plate 312 which are parallel to each other and connected at the top. The gap between the side mold I inner plate 311 and the side mold I outer plate 312 is the side mold I gap.

[0019] When the side mold 131 is installed on the bottom mold 2, the outer side steel plate 22 is embedded in the gap of the side mold 1, and the bottom of the side mold 131 abuts against the bottom plate 21;

[0020] The side mold II 32 includes a side mold II inner plate 321 and a side mold II outer plate 322 which are parallel to each other and connected at the top. The gap between the side mold II inner plate 321 and the side mold II outer plate 322 is the side mold II gap.

[0021] When the side mold II 32 is installed on the bottom mold 2, the boss longitudinal limit plate 27 is embedded in the gap of the side mold II, and the bottom of the side mold II 32 abuts against the bottom plate 21;

[0022] The side mold III 33 comprises a side mold III inner plate 331 and a side mold III outer plate 332 which are parallel to each other and connected at the top and the side. The gap between the side mold III inner plate 331 and the side mold III outer plate 332 is the side mold III gap.

[0023] When the side mold III 33 is installed on the bottom mold 2 , the boss transverse limiting plate 28 is embedded in the gap of the side mold III, and the bottom of the side mold III 33 abuts against the bottom plate 21 .

[0024] The end mold 4 includes a horizontally arranged top plate 41, and an end mold inner plate 42, an end mold outer plate 43, two end mold core plates 44 and two end mold side plates 45 are arranged below the top plate 41.

[0025] The end mold inner plate 42, the end mold outer plate 43 and the end mold side plate 45 surround the end mold core plate 44;

[0026] The side of the end mold outer plate 43 is connected to the side of the end mold side plate 45;

[0027] A gap is left between the side of the end mold inner plate 42 and the side of the end mold side plate 45;

[0028] Each set of end steel plates 24 includes two steel plates parallel to each other, namely an inner steel plate and an outer steel plate;

[0029] When the end mold 4 is installed on the bottom mold 2, the inner steel plate is embedded between the end mold core plate 44 and the end mold inner plate 42, and the outer steel plate is embedded between the end mold core plate 44 and the end mold side plate 45.

[0030] The ends of the outer side steel plate 22 and the inner side steel plate 23 pass through the gap between the end mold inner plate 42 and the end mold side plate 45 , and are embedded between the end mold core plate 44 and the end mold side plate 45 .

[0031] The bottom of the end mold 4 abuts against the bottom plate 21 .

[0032] The top mold 1 includes a base plate 11, on which bosses 12 protruding upward are arranged at intervals, and the bosses 12 simulate the rail support platform;

[0033] The top mold 1 is installed on the top of the side mold and the end mold 4, and is fixed to the side mold and the end mold 4 by bolts.

[0034] The connecting steel pipe 5 includes a middle steel pipe 51, and side steel pipes 52 and a limiting plate 53 are arranged at both ends of the middle steel pipe 51;

[0035] When two longitudinal beams of the mold are connected by the connecting steel pipe 1, the two ends of the middle steel pipe 51 are overlapped on the inner side steel plate 23, and the inner side steel plate 23 is embedded between the side steel pipe 52 and the limit plate 53;

[0036] Preferably, a slot 54 is formed on the side steel pipe 52 , and the transverse ribs 25 are embedded in the slot 54 .

[0037] The present invention also provides a construction method using the assembled trapezoidal sleeper mold for roadbed casting, wherein the assembled trapezoidal sleeper mold for roadbed casting described above is used;

[0038] Preferably, the method comprises the following steps:

[0039] Step 1, assembling a trapezoidal sleeper mold;

[0040] Step 2, assembling a plurality of trapezoidal sleeper molds into a 25 m long mold rail row by consolidating rails;

[0041] Step 3, hoisting, transporting and erecting the mold rail to the working position;

[0042] Step 4, supporting the formwork and pouring the roadbed concrete;

[0043] Step 5: After the concrete strength reaches the standard, remove the ballast formwork, take out the mold rails, and check and repair the bottom hanging and adhesion;

[0044] Step 6, lower the trapezoidal sleeper rail row to the installation position, and lay and install the trapezoidal sleeper;

[0045] Step 7, fine-tuning the geometric state, which includes track direction, track gauge, sag, and superelevation.

[0046] Among them, in step 6, the trapezoidal sleepers can be laid without the need for isolation material packaging and rail row assembly.

[0047] Among them, in step 5, after taking out the mold rail row, only the sleeper gaps between the trapezoidal sleeper molds need to be adjusted so that the sleeper can be reused.

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

[0049] (1) The assembled trapezoidal sleeper mold for roadbed casting and the construction method using the same provided by the present invention reduce the quality problems generated during the construction process and ensure the vibration reduction effect of the trapezoidal sleeper track;

[0050] (2) The assembled trapezoidal rail sleeper mold for roadbed casting provided by the present invention and the construction method using the same have the same rail assembly, hoisting, transportation and laying methods as the trapezoidal rail sleeper rail, which shortens the preparation time before construction and improves the construction efficiency;

[0051] (3) The present invention provides an assembled trapezoidal sleeper mold for roadbed casting and a construction method using the same, wherein the mold has a simple structure, is easy to install, has a light weight and is reusable, thereby eliminating the consumption of isolation and wrapping materials and reducing construction costs. BRIEF DESCRIPTION OF THE DRAWINGS

[0052] Figure 1 A schematic diagram of the structure when part of the empty hanging occurs in the existing construction scheme pointed out in the background technology of the present invention is shown;

[0053] Figure 2 A schematic diagram of the structure when all empty hangs are produced in the existing construction scheme pointed out in the background technology of the present invention is shown;

[0054] Figure 3 A schematic diagram of the structure when a pillow end hits a hard surface in the existing construction scheme pointed out in the background technology of the present invention is shown;

[0055] Figure 4 A schematic diagram of the structure when a pillow bottom hits a hard surface in the existing construction scheme pointed out in the background technology of the present invention is shown;

[0056] Figure 5 The overall structure schematic diagram of the assembled trapezoidal sleeper mold for roadbed casting provided by the present invention is shown;

[0057] Figure 6 A schematic structural diagram of a bottom mold in an assembled trapezoidal sleeper mold for casting a ballast provided by the present invention is shown;

[0058] Figure 7 A partial enlarged view of the assembled trapezoidal sleeper mold for ballast bed casting provided by the present invention is shown;

[0059] Figure 8A schematic structural diagram of a side mold I in an assembled trapezoidal sleeper mold for casting a ballast provided by the present invention is shown;

[0060] Fig. 9 A schematic structural diagram of a side mold II in an assembled trapezoidal sleeper mold for casting a ballast provided by the present invention is shown;

[0061] Fig.10 A schematic structural diagram of a side mold III in an assembled trapezoidal sleeper mold for casting a ballast provided by the present invention is shown;

[0062] Fig.11 A schematic structural diagram of a middle end mold of an assembled trapezoidal sleeper mold for casting a ballast provided by the present invention is shown;

[0063] Fig.12 A bottom view of the middle end mold of the assembled trapezoidal sleeper mold for casting the ballast provided by the present invention is shown;

[0064] Fig.13 A schematic diagram showing the structure of the connecting steel pipes in the assembled trapezoidal sleeper mould for ballast bed casting provided by the present invention;

[0065] Fig.14 The overall logic diagram of the construction method of the assembled trapezoidal sleeper mold for ballast bed casting provided by the present invention is shown.

[0066] Reference numerals

[0067] 1-Top mold

[0068] 11-Substrate

[0069] 12-Boss

[0070] 2- Bottom mold

[0071] 21- Bottom plate

[0072] 22-Outer side steel plate

[0073] 23-Inner side steel plate

[0074] 24-End steel plate

[0075] 25- Transverse ribs

[0076] 26-Longitudinal ribs

[0077] 27-Boss longitudinal limit plate

[0078] 28- Boss lateral limit plate

[0079] 31-Side mold I

[0080] 311-Side mold I inner plate

[0081] 312-Side mold I outer panel

[0082] 313-Side mold I threaded through hole

[0083] 32-Side mold II

[0084] 321-Side mold II inner plate

[0085] 322-Side mold II outer panel

[0086] 323-Side mold II threaded through hole

[0087] 33-Side mold III

[0088] 331-Side mold III inner plate

[0089] 332-Side mold III outer panel

[0090] 333-Side mold III threaded through hole

[0091] 4-end mold

[0092] 41-Top plate

[0093] 42-end mold inner plate

[0094] 43-End mold outer plate

[0095] 44-end mold core plate

[0096] 45-end mold side plate

[0097] 5-Connecting steel pipe

[0098] 51-Middle steel pipe

[0099] 52-Side steel pipe

[0100] 53-Limiting plate

[0101] 54-Slot

[0102] 61-Buffer

[0103] 62-Vibration Damping Pad

[0104] 63-Ballast

[0105] 64-Partially empty

[0106] 65-All empty

[0107] 66-Exposed concrete DETAILED DESCRIPTION

[0108] The present invention will be further described in detail below through the accompanying drawings and embodiments. Through these descriptions, the characteristics and advantages of the present invention will become more clear and distinct.

[0109] The word "exemplary" is used exclusively herein to mean "serving as an example, embodiment, or illustration." Any embodiment described herein as "exemplary" is not necessarily to be construed as preferred or advantageous over other embodiments. Although various aspects of the embodiments are shown in the drawings, the drawings are not necessarily drawn to scale unless otherwise noted.

[0110] The present invention provides an assembled trapezoidal sleeper mold for roadbed casting, such as Figure 5 As shown in , the trapezoidal sleeper mold includes: two mold longitudinal beams, the outer shape and size of the mold longitudinal beams are basically consistent with the trapezoidal sleeper longitudinal beams;

[0111] The mold longitudinal beam comprises a top mold 1, a bottom mold 2, a side mold and an end mold 4 which are detachably connected to each other;

[0112] A connecting steel pipe 5 is provided between the two longitudinal beams of the mould, and the two longitudinal beams of the mould are consolidated into one by the connecting steel pipe 1, so that the external shape and size of the obtained trapezoidal sleeper mould are basically consistent with the trapezoidal sleeper.

[0113] Preferably, a plurality of the trapezoidal sleeper moulds are assembled into a 25m long mould rail row by consolidating rails, and the mould rail row is placed in the spatial position of the pre-installed trapezoidal sleeper rail row. After the strength of the cast ballast bed concrete reaches the standard, the mould rail row is removed, thereby repairing empty hanging and adhesion.

[0114] In a preferred embodiment, Figure 6 and Figure 7 As shown in the figure, the bottom mold 2 includes a bottom plate 21, which is a horizontally arranged flat plate. On the bottom plate 21, an outer side steel plate 22, an inner side steel plate 23 and two groups of end steel plates 24 connected end to end in a ring structure are arranged at the edge of the bottom plate 21;

[0115] On the bottom plate 21, transverse ribs 25 and longitudinal ribs 26 are also arranged inside the annular structure; the transverse ribs 25 and longitudinal ribs 26 are consolidated into an integral structure with each other, and a certain gap is left between the outer side steel plate 22, the inner side steel plate 23 and the two groups of end steel plates 24 to facilitate the installation of the side mold and the end mold 4.

[0116] On the bottom plate 21 , a boss longitudinal limit plate 27 and a boss transverse limit plate 28 are arranged outside the outer side steel plate 22 to form a structure similar to a limit boss, wherein two longitudinal limit plates 27 are arranged, which are respectively located on both sides of the boss transverse limit plate 28 .

[0117] The heights of the vertical plates arranged on the bottom plate 21 are consistent.

[0118] In a preferred embodiment, Figure 5 , Figure 8 , Fig. 9, Fig.10 As shown in , the side mold includes side mold I31, side mold II32 and side mold III33;

[0119] The side mold I31 includes a side mold I inner plate 311 and a side mold I outer plate 312 which are parallel to each other and connected at the top. The gap between the side mold I inner plate 311 and the side mold I outer plate 312 is the side mold I gap. The side mold I31 can be obtained by bending a steel plate or by splicing and welding multiple steel plates.

[0120] When the side mold 131 is installed on the bottom mold 2, the outer side steel plate 22 is embedded in the gap of the side mold 1, and the bottom of the side mold 131 abuts against the bottom plate 21;

[0121] A threaded through hole is opened on the inner plate 311 of the side mold I of the side mold I31, which is denoted as the side mold I threaded through hole 313, and a threaded blind hole is arranged on the outer plate 312 of the side mold I. Correspondingly, a through hole is opened in the side steel plate 22, so that the bolt can pass through the inner plate 311 of the side mold I and the side steel plate 22 and then be screwed into the threaded blind hole, thereby completing the detachable connection between the side mold I31 and the side steel plate 22.

[0122] The side mold II 32 includes a side mold II inner plate 321 and a side mold II outer plate 322 which are parallel to each other and connected at the top. The gap between the side mold II inner plate 321 and the side mold II outer plate 322 is the side mold II gap. The side mold II 32 can be obtained by bending a steel plate or by splicing and welding multiple steel plates.

[0123] When the side mold II 32 is installed on the bottom mold 2, the boss longitudinal limit plate 27 is embedded in the gap of the side mold II, and the bottom of the side mold II 32 abuts against the bottom plate 21;

[0124] A threaded through hole is opened on the side mold II inner plate 321 of the side mold II32, which is recorded as the side mold II threaded through hole 323, and a threaded blind hole is arranged on the side mold II outer plate 322. Correspondingly, a through hole is opened in the boss longitudinal limit plate 27, so that the bolt can pass through the side mold II inner plate 321 and the boss longitudinal limit plate 27 and then be screwed into the threaded blind hole, thereby completing the detachable connection between the side mold II32 and the boss longitudinal limit plate 27.

[0125] The side mold III33 comprises a side mold III inner plate 331 and a side mold III outer plate 332 which are parallel to each other and connected at the top and the side, that is, the side mold III33 is a plate-like structure with five closed sides and an open bottom; the gap between the side mold III inner plate 331 and the side mold III outer plate 332 is the side mold III gap, and the side mold III33 can be obtained by splicing and welding multiple steel plates;

[0126] When the side mold III 33 is installed on the bottom mold 2 , the boss transverse limiting plate 28 is embedded in the gap of the side mold III, and the bottom of the side mold III 33 abuts against the bottom plate 21 .

[0127] A threaded through hole is opened on the side mold III inner plate 331 of the side mold III33, which is recorded as the side mold III threaded through hole 333, and a threaded blind hole is arranged on the side mold III outer plate 332. Correspondingly, a through hole is opened in the boss transverse limit plate 28, so that the bolt can pass through the side mold III inner plate 331 and the boss transverse limit plate 28 and then be screwed into the threaded blind hole, thereby completing the detachable connection between the side mold III33 and the boss transverse limit plate 28.

[0128] Bolt holes are provided at the tops of the side molds I31, II32 and III33 for connection with the top mold bolts.

[0129] In a preferred embodiment, Fig.11 and Fig.12 As shown in the figure, the end mold 4 includes a horizontally arranged top plate 41, and an end mold inner plate 42, an end mold outer plate 43, two end mold core plates 44 and two end mold side plates 45 are arranged below the top plate 41, and are fixed together by welding;

[0130] The end mold inner plate 42, the end mold outer plate 43 and the end mold side plate 45 surround the end mold core plate 44 and are connected to each other to form a ring structure that is approximately rectangular.

[0131] The two end mold core plates 44 are parallel to each other and have the same size.

[0132] The side of the end mold outer plate 43 is connected to the side of the end mold side plate 45;

[0133] A gap is left between the side of the end mold inner plate 42 and the side of the end mold side plate 45 to facilitate the passage of the outer side steel plate 22 and the inner side steel plate 23;

[0134] Each group of end steel plates 24 includes two parallel steel plates, namely an inner steel plate and an outer steel plate; when assembling the rails and the sleepers, in order to accurately control the width of the sleeper seam, an adjustment block is usually added between the end molds of two adjacent sleepers, resulting in the end molds and the end steel plates being subjected to relatively greater force. Based on this, the end steel plates and end molds in the present application are configured as a double-layer structure to ensure that there is no deformation during long-term use and to increase the service life.

[0135] When the end mold 4 is installed on the bottom mold 2, the inner steel plate is embedded between the end mold core plate 44 and the end mold inner plate 42, and the outer steel plate is embedded between the end mold core plate 44 and the end mold side plate 45.

[0136] The ends of the outer side steel plate 22 and the inner side steel plate 23 pass through the gap between the end mold inner plate 42 and the end mold side plate 45 , and are embedded between the end mold core plate 44 and the end mold side plate 45 .

[0137] The bottom of the end mold 4 abuts against the bottom plate 21 .

[0138] A bolt hole is provided at the top of the end mold 4 for screwing and fixing with the top mold 1 , and the bolt hole is located between the two end mold core plates 44 .

[0139] In a preferred embodiment, Figure 5 As shown in , the top mold 1 includes a base plate 11, on which bosses 12 protruding upward are arranged at intervals, and the bosses 12 simulate the rail support platform;

[0140] The top mold 1 is installed on the top of the side mold and the end mold 4 and is fixed to the side mold and the end mold 4 by bolts, that is, bolt holes are opened at the end and side of the base plate 11.

[0141] In a preferred embodiment, Fig.13 As shown in , the connecting steel pipe 5 includes a middle steel pipe 51, and side steel pipes 52 and limit plates 53 are provided at both ends of the middle steel pipe 51;

[0142] When two longitudinal beams of the mold are connected by the connecting steel pipe 1, the two ends of the middle steel pipe 51 are overlapped on the inner side steel plate 23, and the inner side steel plate 23 is embedded between the side steel pipe 52 and the limit plate 53;

[0143] Preferably, a slot 54 is opened on the side steel pipe 52 , and the transverse rib 25 is embedded in the slot 54 , so as to further limit the connection of the steel pipe 5 .

[0144] Preferably, a plurality of connecting steel pipes 5 are provided, for example, three connecting steel pipes 5 are evenly arranged in each trapezoidal sleeper mould.

[0145] Bolt holes or through holes are provided on the side steel pipe 52 and the limiting plate 53 , and correspondingly, bolt holes or through holes are also provided on the inner side steel plate 23 , so that the connecting steel pipe 5 and the bottom mold 2 can be fixed together by bolts.

[0146] The present invention also provides a construction method using an assembled trapezoidal sleeper mold for roadbed casting, such as Fig.14 As shown in, the method uses the assembled trapezoidal sleeper mold for roadbed casting described above; preferably, the method comprises the following steps:

[0147] Step 1, assembling a trapezoidal sleeper mold; in step 1, the following sub-steps are specifically included:

[0148] Sub-step 1, placing the bottom mold 2 on a flat ground;

[0149] Sub-step 2, sequentially installing the side mold and the end mold 4, and after the installation is completed, fixing the side mold and the end mold 4 to the bottom mold 2 by bolts;

[0150] Sub-step 3, hoisting the top mold 1, aligning it accurately, and fixing the top mold 1 with the side mold and the end mold 4 by bolts;

[0151] Sub-step 4, installing the connecting steel pipe 5, and fixing the connecting steel pipe 5 to the bottom mold 2 by bolts.

[0152] Step 2, assembling a plurality of trapezoidal sleeper molds into a 25 m long mold rail row by consolidating rails;

[0153] Step 3, hoisting, transporting and erecting the mold rail to the working position;

[0154] Step 4, supporting the formwork and pouring the roadbed concrete;

[0155] Step 5: After the concrete strength reaches the standard, remove the ballast formwork, take out the mold rails, check and repair the bottom hanging and adhesion, so as to eliminate the defects such as hanging and hard contact;

[0156] Step 6: lower the trapezoidal sleeper rail row to the installation position, lay and install the trapezoidal sleepers; then install the rail fasteners and tighten the spike bolts;

[0157] Step 7, fine-tuning the geometric state, which includes track direction, track gauge, sag, and superelevation.

[0158] Preferably, in step 6, the trapezoidal sleepers can be laid without packaging with insulating materials and assembling the rail rows.

[0159] Preferably, in step 5, after taking out the mold rail row, only the sleeper gaps between the trapezoidal sleeper molds need to be adjusted for reuse.

[0160] Example

[0161] The ballast bed was poured and the trapezoidal sleepers were laid on the 1000-meter test section. The following steps were used:

[0162] Step 1, assemble as Figure 5 , Figure 6 , Figure 7 , Figure 8 , Fig. 9 , Fig.10 , Fig.11 , Fig.12 and Fig.13 The trapezoidal sleeper mold shown in the figure specifically includes the following sub-steps:

[0163] Sub-step 1, placing the bottom mold 2 on a flat ground;

[0164] Sub-step 2, sequentially installing the side mold and the end mold 4, and after the installation is completed, fixing the side mold and the end mold 4 to the bottom mold 2 by bolts;

[0165] Sub-step 3, hoisting the top mold 1, aligning it accurately, and fixing the top mold 1 with the side mold and the end mold 4 by bolts;

[0166] Sub-step 4, installing the connecting steel pipe 5, and fixing the connecting steel pipe 5 to the bottom mold 2 by bolts.

[0167] Step 2, assembling a plurality of trapezoidal sleeper molds into a 25 m long mold rail row by consolidating rails;

[0168] Step 3, hoisting, transporting and erecting the mold rail to the working position;

[0169] Step 4, supporting the formwork and pouring the roadbed concrete;

[0170] Step 5: After the concrete strength reaches the standard, remove the ballast formwork, take out the mold rails, and check and repair the bottom hanging and adhesion;

[0171] Step 6, lowering the trapezoidal sleeper rail row to the installation position, laying and installing the trapezoidal sleepers, and the trapezoidal sleepers are not packaged with isolation materials; then laying and installing rail fasteners, and tightening spike bolts;

[0172] Step 7, fine-tuning the geometric state, which includes track direction, track gauge, sag, and superelevation.

[0173] The sleeper gaps between the trapezoidal sleeper moulds can be further adjusted and the above steps 3 to 7 can be repeated to cast and lay the next 25-meter ballast.

[0174] During the construction process, a construction team of 10 people participated in the construction work, which took 108 hours to complete the work of pouring the ballast and laying the trapezoidal sleepers on the 1,000-meter test section. The ballast and the trapezoidal sleepers obtained by the construction were tested and the construction quality was evaluated as excellent, with no quality problems that needed to be dealt with later. Therefore, the adjacent tracks could be constructed after the pouring was completed. The construction time + quality problem handling time was 108 hours. The cost of manpower, time and materials used was 1.25 million yuan (including the depreciation cost of the trapezoidal sleeper mold).

[0175] Comparative Example

[0176] The ballast bed was poured and the trapezoidal sleepers were laid on the 1000-meter test section. The following steps were used:

[0177] Step 1, paste pearl cotton on the outside of the trapezoidal sleeper;

[0178] Step 2, set the wrapping cover;

[0179] Step 3, assembling a plurality of trapezoidal sleepers through steel rails into a 25m long rail row;

[0180] Step 4: hoist, transport and install the rails to the working location;

[0181] Step 5, supporting the formwork and pouring the roadbed concrete;

[0182] Step 6: Remove the roadbed formwork after the concrete strength reaches the standard.

[0183] Step 7, fine-tuning the geometric state, wherein the geometric state includes track direction, track gauge, sag, and superelevation;

[0184] Step 8: Deal with quality issues.

[0185] Repeat the above steps 1 to 8 to cast and lay the next 25-meter ballast.

[0186] During the construction process, a construction team of 10 people participated in the construction work, which took 106 hours to complete the 1,000-meter test section of the roadbed casting and the laying of trapezoidal sleepers. The roadbed and the laid trapezoidal sleepers were tested and the construction quality was evaluated as qualified. There were 19 quality problems that needed to be dealt with. The quality problem handling time was 24 hours, and the construction time + quality problem handling time was 130 hours. The cost of manpower, time and materials used was 1.35 million yuan.

[0187] It can be seen from the above embodiments and comparative examples that the assembled trapezoidal sleeper mold for roadbed casting and the construction method using the same provided in the present application can not only reduce construction costs, but also improve construction quality, shorten construction time, and improve construction efficiency.

[0188] The present invention has been described above in conjunction with preferred embodiments, but these embodiments are only exemplary and serve only as an illustration. On this basis, the present invention may be subjected to a variety of substitutions and improvements, all of which fall within the scope of protection of the present invention.

Claims

1. An assembled trapezoidal sleeper mould for roadbed casting, characterized in that: The trapezoidal sleeper mould includes: Two mold longitudinal beams, the outer shape and size of the mold longitudinal beams are basically consistent with the trapezoidal sleeper longitudinal beams; The mold longitudinal beam comprises a top mold (1), a bottom mold (2), a side mold and an end mold (4) which are detachably connected to each other; A connecting steel pipe (5) is arranged between the two longitudinal beams of the mould, and the two longitudinal beams of the mould are consolidated into one body through the connecting steel pipe (1), so that the external shape and size of the obtained trapezoidal sleeper mould are basically consistent with the trapezoidal sleeper.

2. The assembled trapezoidal sleeper mold for roadbed casting according to claim 1 is characterized in that: A plurality of the trapezoidal sleeper moulds are assembled into a 25m long mould rail row through rail consolidation, and the mould rail row is placed in the spatial position of the pre-installed trapezoidal sleeper rail row. After the strength of the cast ballast bed concrete reaches the standard, the mould rail row is removed to repair the empty hang and adhesion.

3. The assembled trapezoidal sleeper mold for roadbed casting according to claim 1, characterized in that: The bottom mold (2) comprises a bottom plate (21), which is a horizontally arranged flat plate. On the bottom plate (21), an outer side steel plate (22), an inner side steel plate (23) and two groups of end steel plates (24) connected end to end to form a ring structure are arranged at the edge of the bottom plate (21); On the bottom plate (21), transverse ribs (25) and longitudinal ribs (26) are also arranged inside the annular structure; On the bottom plate (21), a boss longitudinal limiting plate (27) and a boss transverse limiting plate (28) are arranged outside the outer side steel plate (22).

4. The assembled trapezoidal sleeper mold for roadbed casting according to claim 3 is characterized in that: The side mold comprises a side mold I (31), a side mold II (32) and a side mold III (33); The side mold I (31) comprises a side mold I inner plate (311) and a side mold I outer plate (312) which are parallel to each other and connected at the top, and the gap between the side mold I inner plate (311) and the side mold I outer plate (312) is the side mold I gap. When the side mold I (31) is installed on the bottom mold (2), the outer side steel plate (22) is embedded in the gap of the side mold I, and the bottom of the side mold I (31) abuts against the bottom plate (21); The side mold II (32) comprises a side mold II inner plate (321) and a side mold II outer plate (322) which are parallel to each other and connected at the top, and the gap between the side mold II inner plate (321) and the side mold II outer plate (322) is the side mold II gap. When the side mold II (32) is installed on the bottom mold (2), the boss longitudinal limit plate (27) is embedded in the gap of the side mold II, and the bottom of the side mold II (32) abuts against the bottom plate (21); The side mold III (33) comprises a side mold III inner plate (331) and a side mold III outer plate (332) which are parallel to each other and connected at the top and the side. The gap between the side mold III inner plate (331) and the side mold III outer plate (332) is the side mold III gap. When the side mold III (33) is installed on the bottom mold (2), the boss transverse limit plate (28) is embedded in the gap of the side mold III, and the bottom of the side mold III (33) abuts against the bottom plate (21).

5. The assembled trapezoidal sleeper mold for roadbed casting according to claim 3, characterized in that: The end mold (4) comprises a horizontally arranged top plate (41), and an end mold inner plate (42), an end mold outer plate (43), two end mold core plates (44) and two end mold side plates (45) are arranged below the top plate (41). Wherein, the end mold inner plate (42), the end mold outer plate (43) and the end mold side plate (45) surround the end mold core plate (44); The side of the end mold outer plate (43) is connected to the side of the end mold side plate (45); A gap is left between the side of the end mold inner plate (42) and the side of the end mold side plate (45); Each set of end steel plates (24) comprises two steel plates parallel to each other, namely an inner steel plate and an outer steel plate; When the end mold (4) is installed on the bottom mold (2), the inner steel plate is embedded between the end mold core plate (44) and the end mold inner plate (42), and the outer steel plate is embedded between the end mold core plate (44) and the end mold side plate (45). The ends of the outer side steel plate (22) and the inner side steel plate (23) pass through the gap between the end mold inner plate (42) and the end mold side plate (45), and are embedded between the end mold core plate (44) and the end mold side plate (45); The bottom of the end mold (4) abuts against the bottom plate (21).

6. The assembled trapezoidal sleeper mold for roadbed casting according to claim 3, characterized in that: The top mold (1) comprises a base plate (11), on which bosses (12) protruding upward are arranged at intervals, and the bosses (12) simulate the rail support platform; The top mold (1) is installed on the top of the side mold and the end mold (4), and is fixed to the side mold and the end mold (4) by bolts.

7. The assembled trapezoidal sleeper mold for roadbed casting according to claim 3, characterized in that: The connecting steel pipe (5) comprises a middle steel pipe (51), and side steel pipes (52) and limiting plates (53) are arranged at both ends of the middle steel pipe (51); When two longitudinal beams of the mold are connected by the connecting steel pipe (1), the two ends of the middle steel pipe (51) are overlapped on the inner side steel plate (23), and the inner side steel plate (23) is embedded between the side steel pipe (52) and the limit plate (53); Preferably, a slot (54) is provided on the side steel pipe (52), and the transverse rib (25) is embedded in the slot (54).

8. A construction method using an assembled trapezoidal sleeper mould for roadbed casting, characterized in that: The method utilizes the assembled trapezoidal sleeper mold for ballast bed casting as claimed in any one of claims 1 to 7; Preferably, the method comprises the following steps: Step 1, assembling a trapezoidal sleeper mold; Step 2, assembling a plurality of trapezoidal sleeper molds into a 25 m long mold rail row by consolidating the rails; Step 3, hoisting, transporting and setting up the mold rail to the working position; Step 4, supporting the formwork and pouring the roadbed concrete; Step 5: After the concrete strength reaches the standard, remove the ballast formwork, take out the mold rails, and check and repair the bottom hanging and adhesion; Step 6, lower the trapezoidal sleeper rail row to the installation position, and lay and install the trapezoidal sleeper; Step 7, fine-tuning the geometric state, which includes track direction, track gauge, sag, and superelevation.

9. The construction method of using the assembled trapezoidal sleeper mold for ballast bed casting according to claim 8, characterized in that: In step 6, the trapezoidal sleepers can be laid without packaging with insulating materials and assembly of rail panels.

10. The construction method of using the assembled trapezoidal sleeper mold for ballast bed casting according to claim 8, characterized in that: In step 5, after taking out the mold rail row, only the sleeper gaps between the trapezoidal sleeper molds need to be adjusted for reuse.

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