Trapezoidal sleeper self-downward grouting bag construction method and trapezoidal sleeper system

Abstract

The application discloses a trapezoidal sleeper self-downward grouting bag construction method and a trapezoidal sleeper system. In the construction process of the method, a base is first poured and then a trapezoidal sleeper is paved, and then a grouting bag is pasted and poured; the grouting material in the grouting bag is hardened to provide support for the trapezoidal sleeper; and the construction mode of pouring a side edge retaining platform again is adopted, so that the adhesion of the bottom of the trapezoidal sleeper longitudinal beam and the base concrete is avoided, the need for a sleeving package is eliminated, the problems of honeycomb and uneven surface and empty hanging are eliminated, and the trapezoidal sleeper bottom is farther away from the base due to the point support of the grouting bag, so that the trapezoidal sleeper bottom is less likely to have a "hard collision" phenomenon and is easier to observe and maintain.

Description

Technical Field

[0001] This invention belongs to the field of rail transit pouring construction technology, specifically a method for bottom-up grouting bag construction of trapezoidal sleepers and a trapezoidal sleeper system. Background Technology

[0002] Polypropylene sheaths are commonly used as temporary isolation materials in the construction of trapezoidal sleeper tracks. While the construction process is relatively mature, shortcomings have been observed in their application. Due to their poor air permeability, polypropylene sheaths require highly skilled application techniques from the construction team and are time-consuming. Improper handling can cause wrinkles in the sheath at the bottom of the sleeper, leading to air bubbles at the contact point between the sleeper's vibration damping pad and the base concrete, resulting in honeycomb and pitted surfaces. Furthermore, issues such as unsupported suspension and direct contact with wall surfaces must be considered during construction.

[0003] "Open suspension" refers to the trapezoidal sleeper's vibration damping pads not being in full contact with the concrete track bed, affecting the transmission of the load on the upper part of the track. "Hard contact" means that the trapezoidal sleeper is in direct contact with the exposed concrete on the track bed, and the vibration damping pads and buffer pads cannot make full contact to dampen vibration, affecting the overall vibration damping effect of the trapezoidal sleeper.

[0004] Based on this, the inventors conducted in-depth research on track bed construction, considering the influence of isolation materials, and fundamentally solved the problems of honeycomb surface and empty suspension by directly connecting the trapezoidal sleeper vibration damping pads to the rigid base. As a result, a trapezoidal sleeper bottom-up grouting bag construction method and trapezoidal sleeper system were designed to solve the above problems. Summary of the Invention

[0005] To overcome the above problems, the inventors conducted in-depth research and designed a bottom-up grouting bag construction method and a trapezoidal sleeper system for trapezoidal sleepers. In this method, the base is poured first, then the trapezoidal sleepers are laid, followed by the pasting and grouting of the bags. The grout in the bags hardens and provides support for the trapezoidal sleepers. The side retaining platforms are then poured. This construction method avoids the adhesion between the bottom of the longitudinal beams of the trapezoidal sleepers and the concrete of the base. Therefore, there is no need to use a cover, eliminating honeycomb, pitted surfaces, and empty hanging problems. Furthermore, because the grouting bags provide point support, the distance between the sleeper bottom and the base is greater, making it less likely for the sleeper bottom to "collide" with the base and easier to observe and inspect. Thus, this invention is completed.

[0006] Specifically, the purpose of this invention is to provide a method for constructing trapezoidal sleepers using grouting bags from bottom to top, the method comprising the following steps:

[0007] Step 1: Tie the track bed reinforcement cage;

[0008] Step 2: Erect formwork on both sides of the track bed reinforcement cage and pour the track bed in one go, that is, pour the concrete base 1.

[0009] Step 3: Attach vibration damping pads 3, buffer pads and pearl cotton to the trapezoidal sleeper 2, assemble them into a track panel, and then install it to the predetermined position through the support frame 4.

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

[0011] Step 5: Set up a retaining wall on the outside of the track panel and carry out secondary pouring of the track bed, that is, pour the side retaining platform.

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

[0013] In step 2, after the concrete is poured, a groove 11 is pressed into the surface of the concrete base 1.

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

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

[0016] Step 3 includes the following sub-steps:

[0017] Sub-step 3-1: Place the vibration damping pad at the bottom of the trapezoidal sleeper longitudinal beam and place the buffer pad at the side of the trapezoidal sleeper longitudinal beam.

[0018] Sub-step 3-2: Attach the pearl cotton located at the bottom of the trapezoidal sleeper longitudinal beam between multiple vibration damping pads; attach the pearl cotton located on the side of the trapezoidal sleeper longitudinal beam between multiple buffer pads;

[0019] Sub-step 3-3: Assemble multiple trapezoidal sleepers 2 into a track panel;

[0020] Sub-steps 3-4 involve hoisting the rail panel above the concrete base 1, with a pair of support frames 4 placed every 1.5 to 3 meters to support the rail panel.

[0021] Sub-steps 3-5: Adjust the height of the rail panel using the support frame 4 so that the rail panel is exactly in the pre-installation position;

[0022] Sub-steps 3-6 involve fine-tuning the geometry of the track on the track panel using a fine-tuning trolley based on the pile control network.

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

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

[0025] A sleeve 421, which is fixed as a whole, is provided at one end of the support plate 42. An internal thread is provided in the sleeve 421, and the external thread 411 is screwed into the internal thread. By rotating the upright 41, the support plate 42 can be controlled to move back and forth along the axis of the upright 41.

[0026] The support plate 42 extends under the rail of the rail panel to support and fix the rail panel, so that the rail panel is in a predetermined position.

[0027] The upright 41 is located between the rail panel and the steel formwork, that is, in the area where the side retaining platform is cast, or the upright 41 is located outside the steel formwork;

[0028] When the upright 41 is located between the rail panel and the steel formwork, during the process of dismantling the support frame 4, the upright 41 is pulled out from the side platform, and mortar is poured into the missed hole and then smoothed out.

[0029] In step 4, the grouting bag 5 is attached to the bottom of the vibration damping pad 3 with double-sided adhesive tape, and the vibration damping pad is located in the middle of the grouting bag.

[0030] Preferably, when attaching the vibration damping pad 3 in step 3, the grouting bag 5 is simultaneously attached below the vibration damping pad 3;

[0031] Alternatively, after the track panel is installed in the predetermined position, the grouting bag 5 is pasted under the vibration damping pad 3 before performing step 4.

[0032] Step 4 includes the following sub-steps:

[0033] Sub-step 4-1: Check the upper and lower correspondence of the vibration damping pad 3, the grouting bag 5 and the groove 11 on the concrete base 1, and adjust the vibration damping pad 3 and the grouting bag (5) if they are not in accurate.

[0034] Sub-step 4-2: Use a grouting funnel to grout the grouting bag 5 from a height. During the grouting process, continuously and dynamically squeeze the grouting port to promote the entry of grout.

[0035] Sub-step 4-3: After observing that the grouting port of the grouting bag 5 is fully filled with mortar, use nylon cable ties to tie the grouting port tightly, and pull the other end of the nylon cable ties taut and tie it to the rail fastener.

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

[0037] Step 5 includes the following sub-steps:

[0038] Sub-step 5-1: Arrange steel molds on the outside of the track panel as retaining walls for pouring. The top surface of the steel molds is flush with the designed top surface of the side retaining platform of the concrete base, or the top surfaces of multiple steel molds are at the same height above the designed top surface of the side retaining platform of the concrete base.

[0039] Sub-step 5-2: Fill the gap between two adjacent trapezoidal sleepers with wooden molds or boxes to prevent concrete from entering the gap during secondary pouring.

[0040] Sub-step 5-3: Check the integrity and reliability of the trapezoidal sleeper vibration damping pads, buffer pads and pearl cotton. Replace them if any damage is found, and adjust or replenish them if any offset or detachment is found.

[0041] Sub-step 5-4: After re-checking the track geometry, perform secondary pouring, followed by surface finishing.

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

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

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

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

[0046] Both the grouting bag 5 and the vibration damping pad 3 are laid at points;

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

[0048] The beneficial effects of this invention include:

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

[0050] (2) The trapezoidal sleeper bottom-up grouting bag construction method provided by the present invention adopts the following construction method: first pour the base and then lay the trapezoidal sleeper, then pour the grouting bag, the grouting material in the grouting bag solidifies and hardens to provide support for the trapezoidal sleeper, and finally pour the side abutment. This avoids the adhesion between the bottom of the trapezoidal sleeper longitudinal beam and the track bed concrete. Therefore, it does not need to be wrapped with a cover, thus eliminating the problems of honeycomb surface and empty hanging.

[0051] (3) The trapezoidal sleeper bottom-up grouting bag construction method provided by the present invention provides a groove for limiting the grouting bag on the concrete base below the grouting bag, which provides horizontal constraint for the grouting bag and improves the stability of the trapezoidal sleeper. Attached Figure Description

[0052] Figure 1 This invention provides an overall logic diagram of the bottom-up grouting bag construction method for trapezoidal sleepers.

[0053] Figure 2 This diagram illustrates the structure of a rail panel with grouting bags attached to it when it is installed in a predetermined position using a support frame in the bottom-up grouting bag construction method for trapezoidal sleepers provided by the present invention.

[0054] Figure 3 This diagram shows a structural schematic of the support frame in the bottom-to-top grouting bag construction method for trapezoidal sleepers provided by the present invention.

[0055] Figure 4 This diagram illustrates the structure of the grouting bag after grouting in the bottom-up grouting bag construction method for trapezoidal sleepers provided by the present invention.

[0056] Figure 5 This shows a side view of the grouting bag after grouting in the trapezoidal sleeper grouting bag construction method from bottom to top provided by the present invention.

[0057] Figure 6 This image shows a partial enlarged view of the grouting bag after grouting in the trapezoidal sleeper grouting bag construction method provided by the present invention.

[0058] Figure 7 This invention provides a cross-sectional view of the trapezoidal sleeper system.

[0059] Figure 8 This shows an enlarged cross-sectional view of the grouting bag in the trapezoidal sleeper system provided by the present invention;

[0060] Figure 9 This diagram illustrates the structure of the groove mold in the bottom-up grouting bag construction method for trapezoidal sleepers provided by the present invention.

[0061] Figure Labels

[0062] 1- Concrete base

[0063] 11-groove

[0064] 2-Trapezoidal sleepers

[0065] 3-Vibration damping pad

[0066] 4-Support frame

[0067] 41-Upright pole

[0068] 411 - External Thread

[0069] 42-Supporting plate

[0070] 421-Sleeve

[0071] 5- Grouting Bag

[0072] 61-steel plate

[0073] 62-square steel pipe

[0074] 63-Connecting Block

[0075] 7-Rail Detailed Implementation

[0076] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments. Through these descriptions, the features and advantages of the present invention will become clearer and more apparent.

[0077] The term “exemplary” as used herein means “serving as an example, embodiment, or illustration.” Any embodiment illustrated herein as “exemplary” is not necessarily to be construed as superior to or better than other embodiments. Although various aspects of embodiments are shown in the accompanying drawings, the drawings are not necessarily drawn to scale unless specifically indicated otherwise.

[0078] This invention provides a method for constructing trapezoidal sleepers using grouting bags from bottom to top, such as... Figure 1 As shown, the method includes the following steps:

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

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

[0081] Sub-step 1-1: After the handover of the civil structure, inspect and process the embedded reinforcement bars;

[0082] (1) Before the base construction, the sewage, construction waste and debris on the beam surface should be cleaned to ensure that the beam surface is clean and moistened with water, and there should be no standing water to ensure that the base and the bridge structure can be connected as one. Before the base is poured, the pre-embedded reinforcement on the beam surface should be treated. Individual pre-embedded reinforcement outside the trapezoidal sleeper base should be cut off. Reinforcing bars with a height higher than the top surface of the trapezoidal sleeper base should be bent so that they are poured into the base and meet the requirements of the reinforcement protective layer thickness. The pre-embedded reinforcement on the bridge deck should be kept in an inverted L-shape perpendicular to the ground to increase the bonding force between the base and the bridge deck, and should be insulated from the base reinforcement with insulated heat shrink tubing.

[0083] (2) Beam joint treatment: The water-retaining platform has been poured. Check its size and the position of the reinforcing bars. If it exceeds the installation position of the trapezoidal sleeper, the concrete needs to be removed and the reinforcing bars need to be bent or cut off to meet the installation of the trapezoidal sleeper. The actual width data of the beam joint and the width of the waterstop should be fed back to the designer before the installation of the ditch cover so as to match and combine the ditch cover between the connecting steel pipes on both sides of the sleeper joint.

[0084] Sub-steps 1-2 involve surveying and setting out benchmarks to ensure that the beam elevation and track laying plane meet the laying conditions.

[0085] Benchmark re-measurement and establishment of a foundation pile control network are required. Before foundation treatment, construction personnel should use the rail surface elevation as a baseline to measure the height of the track structure, ensuring that the track geometry meets the design drawings. Within the base area, the bridge deck embedded reinforcement should be kept perpendicular to the ground in an inverted L-shape to help limit longitudinal displacement.

[0086] Sub-steps 1-3 involve laying the running line and erecting the running rail to provide conditions for material entry and ladder sleeper laying.

[0087] Sub-steps 1-4 involve measuring and stringing lines to determine the formwork support position and base pouring height, and then adjusting the position and height of the track bed reinforcement cage based on these measurements.

[0088] Sub-steps 1-5: After the various types of track bed steel bars are processed, they are classified and transported to the site for binding of the track bed steel bar cages.

[0089] Before laying the reinforcing mesh, construction workers should place spacers under the reinforcing mesh according to the design drawings, using the spacers as a protective layer for the reinforcing bars. The upper and lower base layers are respectively equipped with longitudinal reinforcing bars, which are welded to all the inner surface transverse reinforcing bars within the structural section. At both ends of each track bed section, galvanized flat steel is welded to all the collecting mesh reinforcing bars, and then connection terminals are led out on the left and right sides of the track bed for electrical connection and measurement.

[0090] The track bed reinforcement binding shall be carried out in accordance with conventional requirements. The reinforcement shall not be higher than the design position, and the protective layer thickness shall be 40mm. The height of the transverse reinforcement shall be adjusted according to the construction error of the beam surface.

[0091] Step 2: Erect formwork on both sides of the track bed reinforcement cage and pour the track bed in one go, that is, pour the concrete base 1.

[0092] In step 2, after the formwork is installed, a line needs to be drawn at the planned pouring height of the concrete. The side formwork must be installed firmly and there should be no quality defects such as loosening, bulging, or leakage.

[0093] Preferably, after the concrete is poured, a groove 11 is pressed into the surface of the concrete base 1. Specifically, after the concrete is poured, the groove 11 is pressed into the surface of the concrete base 1. Figure 9 The groove mold shown is placed corresponding to the trapezoidal sleeper vibration damping pad, and then the surface is finished. Further, after applying oil or wrapping the outside of the groove mold with insulating material, the groove mold is pressed into the concrete to a depth of 1 cm.

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

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

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

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

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

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

[0100] Preferably, the groove 11 has a depth of 1cm and its length and width are the same as those of the grouting bag, so that the grouting bag is just embedded in the groove, providing positioning and limiting for the grouting bag 5, and improving the overall stability and reliability of the sleeper system.

[0101] Step 3: Attach vibration damping pads 3, buffer pads, and pearl cotton to the trapezoidal sleeper 2, assemble them into a track panel, and then install it to the predetermined position using the support frame 4; (e.g., ...) Figure 2 As shown;

[0102] Step 3 includes the following sub-steps:

[0103] Sub-step 3-1: Place the vibration damping pad at the bottom of the trapezoidal sleeper longitudinal beam and place the buffer pad at the side of the trapezoidal sleeper longitudinal beam.

[0104] Sub-step 3-2: Attach the pearl cotton located at the bottom of the trapezoidal sleeper longitudinal beam between multiple vibration damping pads; attach the pearl cotton located on the side of the trapezoidal sleeper longitudinal beam between multiple buffer pads;

[0105] In this application, when pasting pearl cotton, it is necessary to apply adhesive to the outer side of the longitudinal beam of the ladder sleeper and paste sheet pearl cotton, and paste strip pearl cotton on the outer side of the bottom of the ladder sleeper. It is not necessary to wrap or cover it. After pasting is completed and checked to be correct, it is stacked on the site for hoisting.

[0106] The pasted trapezoidal sleepers are transported to the vicinity of the work surface by a flatbed transport vehicle. A gantry crane is used to lift the trapezoidal sleepers to the designated laying position, and the sleepers are slowly lowered to the designated laying position.

[0107] During storage and transportation, trapezoidal sleepers should be placed on temporary platforms and stacked horizontally (bottom down), with a maximum stacking of 6 layers. The stacking area should be hardened to ensure it is flat and firm. The number of stacking layers should not exceed 6, and after the isolation material is applied, it should not exceed 4 layers. Wooden blocks no smaller than (100×100) mm should be placed horizontally between layers. These blocks should be placed between the vibration damping pads and the embedded sleeves (near the ends of the trapezoidal sleepers). After the isolation material is applied, the blocks can only be located at the bottom vibration damping pad position; therefore, the width of the blocks should not be less than 200 mm, and the length should not be less than the width of the longitudinal beam. Each layer of blocks should be aligned vertically and perpendicular to the longitudinal direction of the trapezoidal sleeper.

[0108] Trapezoidal sleeper hoisting: hoisting slings must be used for stable hoisting, and there should be no fewer than 4 hoisting points (selected at the connecting steel pipes). Pay attention to the protection of the finished trapezoidal sleepers.

[0109] Sub-step 3-3: Assemble multiple trapezoidal sleepers 2 into a track panel;

[0110] Sub-steps 3-4 involve hoisting the rail panel above the concrete base 1, with a pair of support frames 4 placed every 1.5-3m to support the rail panel. Specifically, preliminary positioning is performed based on the surveyed track plane, longitudinal profile, and curve superelevation. Then, temporary tooling support frames are arranged at 1.5-3m intervals along the direction of the rail panel. After rough adjustment, the support frames are used to raise and fix the rail panel. During rough adjustment, a track gauge is used to control the rails next to the benchmark.

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

[0112] Sub-steps 3-5: Adjust the height of the rail panel using the support frame 4 so that the rail panel is exactly in the pre-installation position;

[0113] Sub-steps 3-6 involve fine-tuning the geometry of the track on the track panel using a fine-tuning trolley based on the pile control network.

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

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

[0116] A sleeve 421, which is fixed as a whole, is provided at one end of the support plate 42. An internal thread is provided in the sleeve 421, and the external thread 411 is screwed into the internal thread. By rotating the upright 41, the support plate 42 can be controlled to move back and forth along the axis of the upright 41.

[0117] Preferably, the support plate 42 extends under the rail 7 of the rail panel to support and fix the rail panel, so that the rail panel is in a predetermined position.

[0118] The upright 41 is located between the rail panel and the steel formwork, that is, in the area where the side retaining platform is cast, or the upright 41 is located outside the steel formwork;

[0119] When the upright 41 is located between the rail panel and the steel formwork, during the process of dismantling the support frame 4, the upright 41 is pulled out from the side platform, and mortar is poured into the missed hole and then smoothed out.

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

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

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

[0123] Preferably, when pasting the vibration damping pad 3 in step 3, the grouting bag 5 is simultaneously pasted below the vibration damping pad 3; in this pasting scheme, the pasting process is more convenient and faster, and easier to operate;

[0124] Alternatively, after the track panel is installed in the predetermined position, the grouting bag 5 can be pasted under the vibration damping pad 3 before performing step 4. In this pasting method, the pasting position is more accurate, avoiding wear on the grouting bag during track panel assembly and hoisting, and the grouting bag is less likely to be damaged.

[0125] The grouting port of the grouting bag is located inside the trapezoidal sleeper.

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

[0127] Sub-step 4-1: Check the vertical alignment of the vibration damping pad 3, grouting bag 5 and the groove 11 on the concrete base 1, and adjust any misaligned vibration damping pads 3 and grouting bags 5; ensure that the vibration damping pad is centered on the grouting bag.

[0128] Sub-step 4-2: Use a grouting funnel to grout the grouting bag 5 from a height. During the grouting process, continuously and dynamically squeeze the grouting port to promote the entry of grout.

[0129] In sub-step 4-3, after observing that the grouting port of grouting bag 5 is fully filled with mortar, use nylon cable ties to tie the grouting port tightly, and pull the other end of the nylon cable tie taut and tie it to the rail fastener; the state after grouting is as follows. Figure 4 , Figure 5 and Figure 6 As shown;

[0130] In sub-step 4-4, after the mortar strength in the grouting bag 5 reaches 7.5 MPa, cut off the excess part of the grouting bag opening and remove the support frame 4. In actual work, since the pouring time of the grouting bag and the side retaining platform is roughly the same, and the solidification speed of the mortar in the grouting bag is higher than that of the concrete in the side retaining platform, it is only necessary to ensure that the concrete strength of the side retaining platform reaches 7.5 MPa before proceeding with the operation in sub-step 4-4.

[0131] Step 5: Set up a retaining wall on the outside of the track panel and carry out secondary pouring of the track bed, that is, pour the side retaining platform.

[0132] The track bed in this application includes a base at the bottom and a side retainer above the side of the base.

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

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

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

[0136] Sub-step 5-2: Fill the gap between two adjacent trapezoidal sleepers with wooden molds or boxes to prevent concrete from entering the gap during secondary pouring.

[0137] Sub-step 5-3: Check the integrity and reliability of the trapezoidal sleeper vibration damping pads, buffer pads and pearl cotton. Replace them if any damage is found, and adjust or replenish them if any offset or detachment is found.

[0138] Sub-step 5-4: After re-checking the track geometry, perform secondary pouring, and then smooth and finish the surface after secondary pouring; preferably, before pouring, the trapezoidal sleepers, rails and fasteners are protectively wrapped.

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

[0140] During concrete pouring, concrete should be poured along both sides of the sleeper. Due to the very small distance between the sides and the formwork, construction workers should reasonably control the pouring speed and flow rate to prevent concrete from overflowing the formwork. Vibration should be carried out promptly during the pouring process, with enhanced vibration near the vibration damping pads and limiting protrusions. After pouring, the surface should be smoothed and cured promptly. Concrete can only be poured from the outer formwork to the outer part of the sleeper.

[0141] After the above procedures are completed, before the concrete initially sets, the construction personnel should promptly smooth the concrete surface. During smoothing, ensure the surface is smooth and flat, and the concrete of the retaining wall should not be higher than the surface of the ladder sleeper; its height should ideally be consistent with the upper surface of the vibration damping pad. Simultaneously, clean the laitance from the surfaces of the fasteners, support frames, and rails.

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

[0143] In sub-step 5-5, the removal of debris also includes the removal of pearl cotton, wherein a cleaning tool consisting of a crescent hook, a short straight hook, and a blade is used to cut, hook, and remove the pearl cotton.

[0144] The pearl cotton in this application is mainly used to protect and insulate the trapezoidal sleepers, ensuring that the poured concrete does not come into direct contact with the trapezoidal sleepers during the pouring process, thus avoiding hard-on-hard contact.

[0145] In this application, experimental concrete is cured under the same conditions near the sleeper system to periodically measure its strength. When the strength of the experimental concrete reaches a predetermined value, such as 7.5 MPa, the strength of the poured concrete is considered to have reached that predetermined value, thus allowing subsequent cleaning work to proceed.

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

[0147] When pouring the concrete base, the allowable deviation for the flatness of the surface at the installation location of the drainage ditch cover is 3mm / m, and the elevation is 0 to -5mm, to ensure the quality of the cover installation. The drainage ditch cover should be installed firmly and should not be warped or loose. If the track contractor finds a significant deviation between the construction error of the beam joint and the design value during construction, it should promptly report this to the design unit and adjust the drainage ditch cover at the beam joint accordingly.

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

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

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

[0151] Both the grouting bag 5 and the vibration damping pad 3 are laid at points;

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

[0153] Example

[0154] The track bed was poured and trapezoidal sleepers were laid on a 1000-meter experimental section, specifically following these steps: Figure 1 As shown;

[0155] Step 1: Tie the track bed reinforcement cage;

[0156] Step 2: Erect formwork on both sides of the track bed reinforcement cage and pour the track bed in one go, that is, pour the concrete base 1.

[0157] Step 3: Attach vibration damping pads 3, buffer pads and pearl cotton to the trapezoidal sleeper 2, assemble them into a track panel, and then install it to the predetermined position through the support frame 4.

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

[0159] Step 5: Set up a retaining wall on the outside of the track panel and carry out secondary pouring of the track bed, that is, pour the side retaining platform; among them, Step 4 and Step 5 are carried out simultaneously.

[0160] Repeat steps 1 to 5 above to pour and lay the next 25-meter track bed.

[0161] During construction, a construction team of 10 people participated in the entire process, completing the pouring of the track bed and laying of trapezoidal sleepers on a 1000-meter experimental section in 232 hours. The completed track bed and laid trapezoidal sleepers were assessed as having excellent construction quality, with no quality issues requiring post-construction processing. Therefore, construction of adjacent tracks could proceed immediately after the pouring was completed. The total construction time plus quality control time was 232 hours. The labor, time, and material costs were 1.38 million yuan.

[0162] Comparative Example

[0163] The track bed was poured and trapezoidal sleepers were laid on a 1000-meter experimental section, and the following steps were taken:

[0164] Step 1: Attach pearl cotton to the outside of the trapezoidal sleeper;

[0165] Step 2, package the kit;

[0166] Step 3: Assemble multiple trapezoidal sleeper molds into a 25m long rail panel by securing them to the rails;

[0167] Step 4: Hoist, transport, and erect the track panels to the work location;

[0168] Step 5: Set up the formwork and pour the track bed concrete;

[0169] Step 6: Remove the track bed formwork after the concrete has reached the required strength.

[0170] Step 7: Fine-tune the geometry, which includes track orientation, gauge, sagittal, and superelevation.

[0171] Step 8: Address quality issues.

[0172] Repeat steps 1 to 8 above to pour and lay the next 25-meter track bed.

[0173] During construction, a construction team of 10 people participated in the entire process, spending 228 hours to complete the pouring of the track bed and laying of trapezoidal sleepers on a 1000-meter experimental section. The quality of the completed track bed and laid trapezoidal sleepers was assessed as qualified, with 19 quality issues requiring rectification. The rectification time was 34 hours, bringing the total construction time plus rectification time to 262 hours. The cost of manpower, time, and materials was 1.5 million yuan.

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

[0175] The present invention has been described above with reference to preferred embodiments; however, these embodiments are merely exemplary and illustrative. Various substitutions and modifications can be made to the present invention based on these embodiments, all of which fall within the scope of protection of the present invention.

Claims

1. A method for constructing trapezoidal railway sleepers using bottom-up grouting bags, characterized in that, The method includes the following steps: Step 1: Tie the track bed reinforcement cage; Step 2: Erect formwork on both sides of the track bed reinforcement cage and pour the track bed in one go, that is, pour the concrete base (1). In step 2, after the concrete is poured, a groove (11) is pressed on the surface of the concrete base (1). After the trapezoidal sleeper (2) is installed in place, the groove (11) is located directly below the vibration damping pad (3) of the trapezoidal sleeper (2); The groove (11) is 1 cm deep and its length and width are the same as those of the grouting bag. After the concrete is poured, the groove mold is placed according to the trapezoidal sleeper vibration damping pad, and then the surface is finished; after the groove mold is coated with oil or wrapped with isolation material, the groove mold is pressed into the concrete to a depth of 1cm. The groove mold includes a steel plate (61), a square steel pipe (62), and a connecting block (63) for welding connection; the four corners of the steel plate are rounded, the thickness is 10mm, and the overall shape is an inverted trapezoid, that is, the bottom surface dimension of the steel plate is smaller than the top surface dimension; The steel plate (61) is provided in two sizes. The two steel plates located at the ends of the square steel tube (62) are edge steel plates with a bottom width of 120mm, a top width of 140mm, a bottom length of 580mm, and a top length of 600mm. The steel plate located in the middle of the square steel tube (62), that is, the other steel plates except for the edge steel plates, has a bottom width of 220mm, a top width of 240mm, a bottom length of 580mm, and a top length of 600mm. Step 3: Attach vibration damping pads (3), buffer pads and pearl cotton to the trapezoidal sleepers (2), assemble them into rail panels, and then install them to the predetermined position through the support frame (4); Step 3 includes the following sub-steps: Sub-step 3-1: Place the vibration damping pad (3) at the bottom of the trapezoidal sleeper longitudinal beam and place the buffer pad at the side of the trapezoidal sleeper longitudinal beam; Sub-step 3-2: Attach the pearl cotton located at the bottom of the trapezoidal sleeper longitudinal beam between multiple vibration damping pads; attach the pearl cotton located on the side of the trapezoidal sleeper longitudinal beam between multiple buffer pads; Sub-step 3-3: Assemble multiple trapezoidal sleepers (2) into a track panel; Sub-steps 3-4 involve hoisting the rail panel above the concrete base (1) and arranging a pair of support frames (4) every 1.5-3m to support the rail panel. Sub-steps 3-5: Adjust the height of the rail panel using the support frame (4) so ​​that the rail panel is in the pre-installation position; Sub-steps 3-6 involve fine-tuning the geometry of the track on the track panel using a fine-tuning trolley based on the pile control network. The support frame (4) includes a vertically arranged upright (41) and a horizontally arranged support plate (42). An external thread (411) is provided in the middle of the upright (41). A sleeve (421) is fixed as one piece at one end of the support plate (42). An internal thread is provided in the sleeve (421). The external thread (411) is screwed into the internal thread. By rotating the upright (41), the support plate (42) can be controlled to move back and forth along the axis of the upright (41). Step 4: Grout the grouting bag (5) at the bottom of the vibration damping pad (3); Step 5: Set up a retaining wall on the outside of the track panel and carry out secondary pouring of the track bed, that is, pour the side retaining platform.

2. The method for constructing trapezoidal sleepers using grouting bags from bottom to top according to claim 1, characterized in that, In this method, Steps 4 and 5 can be performed in any order; that is, step 5 can be executed first, followed by step 4; step 4 can be executed first, followed by step 5; or steps 4 and 5 can be executed simultaneously.

3. The method for constructing trapezoidal sleepers using grouting bags from bottom to top according to claim 1, characterized in that, In this method, The support plate (42) extends under the rail of the rail panel and supports and fixes the rail panel by supporting the rail, so that the rail panel is in a predetermined position; The upright (41) is located between the rail panel and the steel formwork, i.e., in the area where the side retaining platform is cast, or the upright (41) is located outside the steel formwork; When the upright (41) is located between the rail panel and the steel formwork, during the process of dismantling the support frame (4), the upright (41) is pulled out from the side platform, and mortar is poured into the missed hole and then smoothed.

4. The method for constructing trapezoidal sleepers using grouting bags from bottom to top according to claim 1, characterized in that, In this method, In step 4, the grouting bag (5) is attached to the bottom of the vibration damping pad (3) with double-sided tape, and the vibration damping pad is located in the middle of the grouting bag; Alternatively, after the track panel is installed in the predetermined position, the grouting bag (5) is pasted under the vibration damping pad (3) before performing step 4.

5. The method for constructing trapezoidal sleepers using grouting bags from bottom to top according to claim 1, characterized in that, When pasting the vibration damping pad (3) in step 3, the grouting bag (5) is simultaneously pasted below the vibration damping pad (3).

6. The method for constructing trapezoidal sleepers using grouting bags from bottom to top according to claim 1, characterized in that, In this method, Step 4 includes the following sub-steps: Sub-step 4-1: Check the upper and lower correspondence of the groove (11) on the vibration damping pad (3), grouting bag (5) and concrete base (1), and adjust the vibration damping pad (3) and grouting bag (5) that are not in sync. Sub-step 4-2: Use a grouting funnel to grout the grouting bag (5) from a high place. During the grouting process, continuously and dynamically squeeze the grouting port to promote the entry of grout. Sub-step 4-3: After observing that the grouting port of the grouting bag (5) is fully filled with mortar, use nylon cable ties to tie the grouting port tightly, and pull the other end of the nylon cable ties to tie it to the rail fastener. Sub-step 4-4: After the mortar strength in the grouting bag (5) reaches 7.5MPa, cut off the excess part of the grouting bag opening and remove the support frame (4).

7. The method for constructing trapezoidal sleepers using grouting bags from bottom to top according to claim 1, characterized in that, In this method, Step 5 includes the following sub-steps. Sub-step 5-1: Arrange steel formwork on the outside of the track panel as a retaining wall for pouring. The top surface of the steel formwork is flush with the designed top surface of the side retaining platform of the concrete base, or the top surfaces of multiple steel formworks are at the same height above the designed top surface of the side retaining platform of the concrete base. Sub-step 5-2: Fill the gap between two adjacent trapezoidal sleepers with wooden molds or boxes to prevent concrete from entering the gap during secondary pouring. Sub-step 5-3: Check the integrity and reliability of the trapezoidal sleeper vibration damping pads, buffer pads and pearl cotton. Replace them if any damage is found, and adjust or replenish them if any offset or detachment is found. Sub-step 5-4: After re-checking the track geometry, perform secondary pouring, followed by surface finishing. Sub-step 5-5: After the concrete strength of the side retaining platform reaches 7.5MPa, remove the steel formwork, clear away debris, and inspect and repair any defects.

8. A trapezoidal sleeper system, characterized in that, The system is obtained by the bottom-up grouting bag construction method for trapezoidal sleepers as described in any one of claims 1 to 7; The system consists of trapezoidal sleepers (2), vibration damping pads (3), grouting bags (5), and concrete bases (1) from top to bottom. A groove (11) is provided on the concrete base (1), and the bottom of the grouting bag (5) is located in the groove (11). Both the grouting bag (5) and the vibration damping pad (3) are dotted; The area of ​​the grouting bag (5) is slightly larger than that of the vibration damping pad (3), so that the vibration damping pad can be completely attached to the grouting bag (5) and there is no empty space under the vibration damping pad (3); the grouting bag (5) supports the vibration damping pad (3) and the trapezoidal sleeper (2), so that there is no hard contact between the trapezoidal sleeper (2) and the concrete base (1).

Images