Full-assembled monolithic track structure and its temporary supporting mechanism for coal loading line of silo

Abstract

The present application relates to a kind of silo coal loading line full assembly type monolithic track structure and its temporary supporting mechanism, temporary supporting mechanism is vertically arranged between prefabricated small unit track slab and prefabricated base, including prefabricated pier, pier limiting sleeve, connecting steel plate, limiting sleeve anchoring screw rod and limiting sleeve anchoring bolt;Limiting sleeve anchoring screw rod is respectively embedded to the bottom surface of prefabricated small unit track slab and the top surface of prefabricated base;The exposed part of limiting sleeve anchoring screw rod passes through the round hole arranged on connecting steel plate and is anchored, fixed connecting steel plate;Pier limiting sleeve is fixed to connecting steel plate, and the top and bottom of prefabricated pier are inserted into two pier limiting sleeves respectively.The present application meets the requirements of narrow space and skylight point construction of silo coal loading line, avoids the delay of construction period caused by the strength period of cast-in-place structure, and the temporary supporting mechanism used meets the functions of track slab fine adjustment and temporary support, ensuring the implementability of assembly type ballastless track structure in maintenance skylight.

Description

Technical Field

[0001] This invention relates to the field of ballastless track technology for dedicated railway lines, specifically to a fully assembled integral track bed structure for silo coal loading lines and its temporary support mechanism. Background Technology

[0002] Railway transportation, characterized by high efficiency, large capacity, and strong planning capabilities, has become the main mode of coal transportation. Dedicated railway lines are a crucial measure for addressing the "last mile" problem in railway transportation and building a high-quality logistics infrastructure network. However, due to their lower operating speeds and the widespread use of ballasted track, these lines frequently suffer from defects during operation. These include coal slag spilling onto the track bed, track bed contamination and compaction, mud pumping and frost heave in the roadbed, frequent occurrences of empty red light zones, and the need for acidic liquids to be sprayed for antifreeze and dust suppression. Furthermore, the lack of washing facilities for ballasted track leads to severe corrosion of track components.

[0003] The aforementioned track defects not only increase maintenance workload and costs but also severely restrict the loading efficiency of coal loading lines, limiting the improvement of coal transportation capacity. Currently, coal transportation companies are vigorously developing smart railways and intelligent logistics, achieving basic maintenance-free or low-maintenance effects for transportation equipment. The traditional maintenance operation mode of ballast track on coal loading lines, involving track lifting, screening, and fine-tuning, is incompatible and uncoordinated with the maintenance-free concept of smart construction, becoming a key factor restricting the high-quality development of coal loading line transportation.

[0004] Currently, the widely used cast-in-place long-sleeper embedded monolithic track bed suffers from poor durability. During the retrofitting process, the required period for the cast-in-place concrete to reach its full strength is long, failing to meet the technical requirements for rapid track replacement in coal loading lines. Furthermore, precast slab track used in high-speed rail and urban rail transit cannot meet the requirements for construction in the confined spaces and during track maintenance windows of coal loading lines. Moreover, when traditional precast slabs are laid using a bottom-up method, the accompanying reaction frame combined with fine-tuning claws cannot be installed in the confined spaces of coal loading lines.

[0005] Therefore, it is necessary to propose new measures to overcome the above-mentioned shortcomings. Summary of the Invention

[0006] The purpose of this invention is to provide a fully prefabricated integral track bed structure for silo coal loading lines and its temporary support mechanism to solve the problems of poor track bed durability, inability to quickly replace track, and limited operating space in existing railway dedicated lines.

[0007] To achieve the above objectives, the technical solution adopted by the present invention is as follows:

[0008] A temporary support mechanism is provided for the fully prefabricated integral track bed structure of the silo coal loading line. The temporary support mechanism is vertically set between the prefabricated small unit track slab and the prefabricated base of the fully prefabricated integral track bed structure. It includes prefabricated supports and support limiting structures. The support limiting structure includes support limiting sleeves, connecting steel plates, limiting sleeve anchoring bolts and limiting sleeve anchoring bolts.

[0009] The limiting sleeve anchor bolts are respectively embedded in the bottom surface of the prefabricated small unit track plate and the top surface of the prefabricated base, with the ends exposed.

[0010] The exposed part of the limiting sleeve anchoring screw passes through the round hole provided on the connecting steel plate and is fixed by the limiting sleeve anchoring bolt, so that the two connecting steel plates are respectively fixed to the bottom surface of the prefabricated small unit track plate and the top surface of the prefabricated base.

[0011] The two support limiting sleeves are respectively fixed to the two connecting steel plates, and the top and bottom of the prefabricated support are respectively inserted into the upper and lower support limiting sleeves.

[0012] Furthermore, the temporary support mechanism also includes an elastic support sleeve, which has a base plate and a protective ring;

[0013] The two elastic support sleeves are respectively fitted onto the top and bottom of the precast support and are located inside the support limiting sleeve.

[0014] Furthermore, the elastic support sleeve is prefabricated according to the thickness of the base plate.

[0015] On the other hand, a fully prefabricated integral track bed structure is provided for the silo coal loading line, the fully prefabricated integral track bed structure including prefabricated small unit track slabs, prefabricated bases, and the temporary support mechanism.

[0016] An intermediate adjustment layer is formed between the prefabricated small unit track slab and the prefabricated base by injecting grouting material.

[0017] Furthermore, the prefabricated small unit track slab is prefabricated in sections, with lifting sleeves on the sides and two rows of rail support platforms on the top surface, and the surface of the rail support platforms has pre-embedded fastener nylon sleeves.

[0018] The prefabricated small unit track plate is provided with vertically penetrating grouting holes located between the two rows of track support platforms.

[0019] Furthermore, the prefabricated base is prefabricated in sections, and the surface is provided with limiting grooves.

[0020] Furthermore, after the temporary support mechanism is supported between the prefabricated small unit track plate and the prefabricated base, grouting material is injected downward through the grouting hole until the limiting groove is filled, and the bottom of the formed intermediate adjustment layer has a limiting protrusion that is inserted into the limiting groove.

[0021] Furthermore, the surface of the prefabricated base is provided with an isolation layer, and the isolation layer is provided with openings corresponding to the positions of the limiting grooves.

[0022] Furthermore, when the prefabricated base is laid longitudinally, there is an expansion joint between adjacent prefabricated bases and the joint is filled with caulking material;

[0023] When the prefabricated small unit track slabs are laid longitudinally, there are expansion joints between adjacent prefabricated small unit track slabs, and the intermediate adjustment layer is filled with caulking material after it is formed.

[0024] Furthermore, the side of the prefabricated base is provided with a limiting bolt sleeve. After two adjacent prefabricated bases are laid in place, an elongated hole limiting clip is covered on the outside of the limiting bolt sleeve of the two prefabricated bases. The T-shaped anchor bolt is inserted into the elongated hole and then into the limiting bolt sleeve to limit and connect the two prefabricated bases to each other.

[0025] Compared with the prior art, the beneficial effects of the present invention are as follows:

[0026] This invention provides a fully prefabricated integral track bed structure for silo coal loading lines and its temporary support mechanism. It meets the requirements of construction in the confined space and during maintenance windows of silo coal loading lines, avoids the construction delays caused by the strong cycle of cast-in-place structures, and the temporary support mechanism meets the functions of track slab fine adjustment and temporary support. It ensures the feasibility of the prefabricated ballastless track structure within maintenance windows, reduces the daily maintenance workload of coal loading lines, improves loading turnover efficiency, and meets the requirements of high-quality transportation development of coal loading lines. Attached Figure Description

[0027] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other embodiments can be obtained from these drawings without creative effort.

[0028] Figure 1 This is a three-dimensional view of the fully assembled integral track bed structure provided in an embodiment of the present invention.

[0029] Figure 2 This is an elevation view of the fully assembled integral track bed structure provided in an embodiment of the present invention.

[0030] Figure 3 This is a side view of the fully assembled integral track bed structure provided in an embodiment of the present invention.

[0031] Figure 4 This is a structural diagram of a prefabricated small unit track slab provided in an embodiment of the present invention.

[0032] Figure 5 This is a structural diagram of the prefabricated base provided in an embodiment of the present invention.

[0033] Figure 6 This is a structural diagram of the intermediate adjustment layer provided in an embodiment of the present invention.

[0034] Figure 7 This is a schematic diagram showing the assembly relationship between the prefabricated support, the support limiting structure, and the support sheath provided in the embodiments of the present invention.

[0035] Figure 8 This is a schematic diagram showing the assembly relationship between the support limiting sleeve and the limiting sleeve anchor bolt provided in an embodiment of the present invention.

[0036] Figure 9 This is a schematic diagram of the base limiting connector provided in an embodiment of the present invention.

[0037] The diagram is labeled as follows:

[0038] 1-Fully prefabricated integral track bed structure for silo coal loading line with temporary support mechanism; 2-Prefabricated small unit track slab; 3-Prefabricated base; 4-Prefabricated support; 5-Support limiting structure; 6-Elastic support sleeve; 7-Intermediate adjustment layer; 8-Isolation layer; 9-Base limiting connector; 10-Rail support platform; 11-Embedded fastener nylon sleeve; 12-Grouting hole; 13-Lifting sleeve; 14-Limiting groove; 15-Support limiting sleeve; 16-Connecting steel plate; 17-Limiting sleeve anchor bolt; 18-Oblong hole limiting clip; 19-T-type anchor bolt; 20-Limiting bolt sleeve; 21-Limiting sleeve anchor bolt. Detailed Implementation

[0039] To facilitate understanding of the present invention, a more complete description will be given below with reference to the accompanying drawings. Preferred embodiments of the invention are shown in the drawings. However, the invention can be implemented in many different forms and is not limited to the embodiments described herein. Rather, these embodiments are provided to provide a thorough and complete understanding of the disclosure of the invention.

[0040] In the description of this invention, it should be understood that the terms "upper", "lower", "vertical", "horizontal", "top", "bottom", "inner", "outer", etc., indicate the orientation or positional relationship based on the orientation or positional relationship shown in the accompanying drawings. They are only for the convenience of describing this invention and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, or be constructed and operated in a specific orientation. Therefore, they should not be construed as limitations on this invention.

[0041] In the description of this invention, it should be noted that, unless otherwise explicitly specified and limited, the terms "installation," "connection," "setting," etc., should be interpreted broadly. For example, they can refer to a fixed connection or setting, a detachable connection or setting, or an integral connection or setting. Those skilled in the art can understand the specific meaning of the above terms in this invention according to the specific circumstances.

[0042] It should also be noted that although the order of steps is mentioned in the method description, in some cases, steps may be performed in a different order than that described here, and this should not be interpreted as a restriction on the order of steps.

[0043] In a specific implementation, the direction of the track line is defined as longitudinal, and the direction perpendicular to it is defined as transverse.

[0044] The existing cast-in-place long-sleeper embedded ballastless track used in silo coal loading lines has poor durability, is prone to cracking, and has a long concrete strength-enhancing period, which does not meet the conditions for construction and modification during track maintenance windows. Addressing the characteristics of confined working space and short track maintenance windows in silo coal loading lines, this invention designs a fully prefabricated integral track bed structure for silo coal loading lines. This structure includes a track slab and a base slab, both of which are prefabricated components transported to the site and assembled. Grouting material is poured between the two slabs to form an intermediate adjustment layer, creating a three-layer composite structure from top to bottom. Crucially, this invention incorporates a temporary support mechanism to provide support between the track slab and base slab before the intermediate adjustment layer is poured or when its strength is insufficient. This mechanism serves as a temporary support and limiting mechanism during the track laying construction and temporary loading operation phases.

[0045] Specifically, the temporary support mechanism is vertically installed between the prefabricated small unit track slab 2 and the prefabricated base 3 of the fully assembled integral track bed structure. Figure 1-3 In one embodiment, the temporary support mechanism is arranged in two longitudinal rows, with equal spacing between them. For example... Figure 7 and Figure 8The temporary support mechanism includes prefabricated supports 4 and supports limiting structures 5. The supports limiting structure 5 includes supports limiting sleeves 15, connecting steel plates 16, limiting sleeve anchoring bolts 17, and limiting sleeve anchoring bolts 21. The limiting sleeve anchoring bolts 17 are pre-embedded in the bottom surface of the prefabricated small unit track slab 2 and the top surface of the prefabricated base 3, with their ends exposed. During on-site installation, the exposed parts of the limiting sleeve anchoring bolts 17 pass through the circular holes provided on the connecting steel plates 16 and are fixed by the limiting sleeve anchoring bolts 21, thus fixing the two connecting steel plates 16 to the bottom surface of the prefabricated small unit track slab 2 and the top surface of the prefabricated base 3, respectively. Then, the two supports limiting sleeves 15 are fixed to the two connecting steel plates 16, and the top and bottom of the prefabricated supports 4 are inserted into the upper and lower supports limiting sleeves 15, respectively. The prefabricated supports 4 are cylindrical or cuboid, and the shape of the supports limiting sleeves 15 matches them. The support limiting sleeve 15 and the connecting steel plate 16 can be welded or cast as a whole.

[0046] In addition, the temporary support mechanism also includes elastic support sleeves 6, which have a base plate and a retaining ring, and can be hot-cast from elastic buffer materials such as rubber or polyester elastomer. Two elastic support sleeves 6 are respectively fitted onto the top and bottom of the precast support 4 and located within the support limiting sleeve 15, coordinating their limiting function. The elastic support sleeves 6 are elastic buffer layered structures, improving the tightness of the connection between the precast support 4 and the support limiting structure 5, alleviating stress concentration problems, reducing the impact and localized damage from locomotives and rolling stock, and playing a role in buffering and strengthening the connection. The elastic support sleeves 6 can be prefabricated in different models according to the thickness of the base plate. Elastic support sleeves 6 with different base plate thicknesses can meet different elevation adjustment requirements during laying. For example, they can be prefabricated as standard parts and adjustment parts. During construction, the standard parts are installed first, and then the adjustment parts are added for rough elevation adjustment.

[0047] The fully prefabricated integral track bed structure for silo coal loading lines provided by this invention includes prefabricated small unit track slabs 2, prefabricated bases 3, and the aforementioned temporary support mechanism. An intermediate adjustment layer 7 is formed between the prefabricated small unit track slabs 2 and the prefabricated bases 3 by injecting grouting material.

[0048] like Figure 4 The prefabricated small-unit track slabs 2 are prefabricated in sections and are the main load-bearing components of the fully assembled integral track bed structure. The sides of the prefabricated small-unit track slabs 2 have lifting sleeves 13 for convenient hoisting during prefabrication, construction, and maintenance. Two rows of rail support platforms 10 of a certain height are provided on the top surface. The surface of the rail support platforms 10 has pre-embedded fastener nylon sleeves 11 to meet the interface requirements for rail and fastener installation. A certain number of vertically penetrating grouting holes 12 are provided on the prefabricated small-unit track slabs 2 at the center line between the two rows of rail support platforms 10 for grouting and observing the grouting quality of the self-compacting concrete.

[0049] like Figure 5The prefabricated base 3 is prefabricated in sections and serves as the lower foundation for the fully assembled integral track bed structure. Limiting grooves 14 are provided on the surface of the prefabricated base 3. After the temporary support mechanism is supported between the prefabricated small unit track slab 2 and the prefabricated base 3, grouting material is poured downwards through the grouting holes 12 until the limiting grooves 14 are filled. The bottom of the resulting intermediate adjustment layer 7 has limiting protrusions that insert into the limiting grooves 14, such as... Figure 6 The intermediate adjustment layer 7 connects the precast small unit track slab 2 and the precast base 3, ensuring the support and continuity of the precast base 3, and also adjusting the geometric deviations of the precast small unit track slab 2 during laying, satisfying the integrity of the structure, ensuring the continuity and stability of the upper load transfer during and after the laying of the ballastless track structure, and effectively connecting the lower roadbed foundation.

[0050] The grouting material is an inorganic material that is easy to flow and does not require vibration, such as self-compacting concrete, mortar, fine stone concrete and other inorganic non-metallic materials, which meets the functions of connecting and supporting the precast small unit track slab 2 and the precast base 3 and transmitting loads. The intermediate adjustment layer 7 only plays its role after the strength reaches the set requirements.

[0051] In addition, an isolation layer 8 is provided on the surface of the prefabricated base 3, and openings are provided in the isolation layer 8 corresponding to the positions of the limiting grooves 14. The isolation layer 8 is an isolation layer structure made of organic polymer material to prevent the intermediate adjustment layer 7 from solidifying into a whole with the prefabricated base 3, which facilitates the removal and maintenance of the panel during operation and maintenance. It should also have a certain degree of water resistance to prevent the intermediate adjustment layer from seeping down.

[0052] The side of the precast base 3 is also equipped with a limiting bolt sleeve 20. After two adjacent precast bases 3 are laid in place, an elongated hole limiting clip 18 is covered on the outside of the limiting bolt sleeve 20 of the two precast bases 3. The T-shaped anchor bolt 19 is inserted into the elongated hole and into the limiting bolt sleeve 20 to generate torque, pressing the elongated hole limiting clip 18, thus longitudinally limiting and connecting the two precast bases 3 to each other, forming a whole, and working together to participate in the transmission and distribution of the upper load, ensuring reliable longitudinal force transmission of the structure. The limiting bolt sleeve 20 also serves as a hoisting sleeve during the precasting, construction, and maintenance stages.

[0053] When laying the precast base 3 longitudinally, there are expansion joints between adjacent precast base 3, which are filled with caulking material. Similarly, when laying the precast small unit track slabs 2 longitudinally, there are expansion joints between adjacent precast small unit track slabs 2, and the intermediate adjustment layer 7 is filled with caulking material after it is formed. The caulking material is an elastic cushioning material, and waterproof sealing must be done at the same time.

[0054] The structure of this invention is mostly prefabricated, specifically:

[0055] 1. The precast small unit track slab 2 and the precast base 3 can be made of reinforced concrete or prestressed concrete according to the load-bearing capacity and normal use conditions. They are all unit structures produced by factory assembly line.

[0056] The length of the prefabricated small unit track slab 2 units must meet the space requirements for transportation and silo hoisting, and the width must meet the requirements for load-bearing capacity and the arrangement of rails and fasteners. A rail support platform 10 is set on the top surface, a grouting hole 12 is set in the middle, and a pair of lifting sleeves 13 are set on the side near the end of the slab to meet the needs of construction hoisting and maintenance.

[0057] The length of the precast base unit 3 matches the module of the precast small unit track plate 2. The top surface is provided with a limiting groove 14 to form a three-layer interlayer limiting structure with the post-cast intermediate adjustment layer 7. The limiting bolt sleeve 20 on the side serves as an interface for construction hoisting and installation of the base limiting connector 9.

[0058] 2. The support limiting structure 5 consists of a support limiting sleeve 15, a connecting steel plate 16, a limiting sleeve anchoring screw 17, and a limiting sleeve anchoring bolt 21. The support limiting sleeve 15 and the connecting steel plate 16 can be made by cutting steel plates. The two should be welded into a whole before installation. Alternatively, the two can be formed in one piece by integral casting.

[0059] The limiting sleeve anchor bolt 17 can be made of steel bars and is pre-embedded in the prefabricated small unit track slab 2 and the prefabricated base 3. The prefabricated support pier 4 is made of reinforced concrete and is prefabricated in the factory. After the two ends of the support pier sleeve 6 are fitted, the support pier limiting sleeve 15 is inserted to form a temporary support and limiting structure for the prefabricated small unit track slab 2 before the intermediate adjustment layer 7 is poured after the track is laid, which meets the transportation needs of the train in emergency situations.

[0060] 3. The elongated hole limit card 18 can be made by cutting steel plate or by casting in one piece; the T-type anchor bolt 19 is a factory-made product. After passing through the reserved hole of the elongated hole limit card 18, it is screwed into the limit bolt sleeve 20 at the end of the prefabricated base 3 to achieve the limit connection operation.

[0061] 4. Both the lifting sleeve 13 and the limiting bolt sleeve 20 are made of nylon or other functional polymer materials and are integrally formed by hot casting.

[0062] 5. The support limiting sleeve 15 and the connecting steel plate 16 can be made by rolling steel plates and welding them together, or the two can be cast as one piece. The limiting sleeve anchor bolt 17 can be made by bending one end of a steel bar into a hook and machining the other end with a cutting tool to form a thread, and is pre-embedded in the prefabricated small unit track plate 2 and the prefabricated base 3.

[0063] Some structures are also constructed on-site. Specifically, the intermediate adjustment layer 7 can be made of inorganic engineering materials such as self-compacting concrete, mortar, and fine stone concrete, which can meet the technical requirements of self-leveling, fast setting, and early strength.

[0064] Therefore, the main load-bearing components of this invention are all prefabricated or pre-processed in the factory, significantly reducing the workload of on-site construction. The structural design, physical and mechanical properties, and main raw materials, including steel bars, concrete, intermediate adjustment layers, embedded sleeves, limiting structure steel plates, and bolts, should all comply with the requirements of current national and railway industry design specifications and technical conditions. The main structure also adopts a lightweight design to meet the requirements of the coal loading line's hoisting capacity and operating space. The main structure can be prefabricated in the factory, has a high degree of versatility, and reduces the workload of on-site construction. Before the intermediate adjustment layer 7 is poured or when its strength is insufficient, prefabricated supports 4 and support limiting structures 5 can be used to form a temporary support limiting structure to meet the needs of temporary loading operations, reduce the construction period delays caused by the strong period of concrete, and be applicable to the short working limits of the coal loading line construction window, improving the loading turnover efficiency of the coal loading line and increasing the transportation capacity of the coal loading line. The use of an interlayer separation structure can meet the needs of daily maintenance and replacement, and has excellent economic performance throughout its entire life cycle.

[0065] This invention solves the problem of installing traditional reaction frames with fine-tuning claws in small spaces on coal loading lines by quickly installing prefabricated support piers 4 and limiting structures on-site. It saves the equal strength cycle of pouring intermediate adjustment layers, ensures the feasibility of using prefabricated ballastless track on coal loading lines, realizes the goal of rapid replacement of ballastless track on coal loading lines, improves the operation efficiency of coal loading lines, and has the conditions for daily maintenance, repair and replacement. It has excellent durability, is easy to quickly construct and replace, and has excellent economic benefits throughout its life cycle. It provides a brand-new technical solution for the treatment of ballast track defects on silo coal loading lines.

[0066] The specific construction process of this invention is as follows:

[0067] 1. Preparation of related accessories for precast components

[0068] Precast component accessories include: embedded fastener nylon sleeve 11, lifting sleeve 13, limit bolt sleeve 20, limit sleeve anchor bolt 17 and limit sleeve anchor bolt 21, etc.

[0069] The size and shape of the pre-embedded fastener nylon sleeve 11 are determined according to the rail type and axle load, and are consistent with the fastener installation interface. The pre-embedded fastener nylon sleeve 11 should be prepared according to relevant specifications and design documents.

[0070] The strength of the lifting sleeve 13 should meet the requirements for lifting the precast track slab, and a certain safety redundancy should be considered. The lifting sleeve 13 should be prepared according to relevant specifications and design documents.

[0071] The strength of the limit bolt sleeve 20 should meet the hoisting requirements of the prefabricated base, and the interface should meet the installation requirements of the T-type anchor bolt 19.

[0072] The limiting sleeve anchor bolt 17 and the limiting sleeve anchor bolt 21 can be existing general standard products, and should meet the installation interface and bearing capacity requirements of the pier limiting structure 5.

[0073] 2. Precast concrete components

[0074] In this invention, the precast small unit track slab 2 and the precast base 3 can be constructed using ordinary reinforced concrete or prestressed concrete structures. The precast process of the components includes the following main control links: steel formwork processing and assembly, rebar tying (prestressed rebar tensioning), embedded part arrangement (including sleeves and anchor bolts), concrete pouring and vibration compaction, precast component curing, precast component production information labeling, and precast component storage. Among them, the embedded interface components include: embedded fastener nylon sleeve 11, lifting sleeve 13, limiting bolt sleeve 20, limiting sleeve anchor bolt 17, and limiting sleeve anchor bolt 21.

[0075] The precast support pier 4 is made of reinforced concrete and can be precast in the factory or on-site. The precasting process of the component includes: steel formwork processing and assembly, rebar tying, concrete pouring and vibration compaction, curing of precast components, and storage of precast components.

[0076] The design, prefabrication, and storage of precast concrete components should meet the requirements of relevant specifications and technical conditions, and the manufacturing and arrangement of precast concrete components and related parts should meet the engineering interface requirements.

[0077] 3. Preparation of construction and installation materials

[0078] Materials to be prepared before implementation include intermediate adjustment layer 7, which should be an inorganic material that is easy to flow, requires no vibration, and sets quickly. Self-compacting concrete, mortar, fine stone concrete, and other inorganic non-metallic materials can be used.

[0079] Before mass application of intermediate adjustment layer 7, mix proportion tests must be conducted, and its strength and workability indicators should meet the technical requirements of relevant specifications and design documents. Intermediate adjustment layer 7 can be mixed on-site or purchased from a concrete mixing plant.

[0080] 4. Preparation of installation components

[0081] The components to be prepared for installation before implementation include: 5. Support limiting mechanism, 6. Elastic support sleeve, and 9. Base limiting connector.

[0082] The support limiting mechanism 5 is made of steel plate profiles that are processed and welded into a whole, or it can be made of a factory casting.

[0083] The elastic support sleeve 6 is manufactured by factory hot casting and is divided into two categories: standard parts and adjustment parts, depending on the thickness of the top surface.

[0084] The elongated hole limit clip in the base limiting connector 9 is made of steel plate profile processed according to design requirements, and the T-type anchor bolt 19 can be made of existing standard parts, which can realize factory-based and standardized manufacturing.

[0085] 5. Project Implementation

[0086] The project implementation includes the following stages:

[0087] (1) Select rails and accessories and fasteners that are compatible with the project standards.

[0088] (2) Foundation excavation and treatment

[0089] Excavate the foundation soil according to the designed track structure height and foundation treatment depth, and carry out foundation treatment according to the design requirements. The compaction and K30 of the treated foundation soil should meet the requirements of the design documents and specifications to ensure that the post-construction settlement after the ballastless track bed is laid meets the track adjustment capacity.

[0090] (3) Precast base laying

[0091] Lay the precast bases according to the design elevation and alignment, and adjust the bases so that their installation position and elevation deviation meet the requirements of relevant specifications and design documents. Set a 2-3cm expansion joint between three adjacent precast bases, and seal the expansion joint with caulking material.

[0092] (4) Install base limiting connector 9

[0093] Align the elongated hole limit clip 18 of the base limiting connector 9 with the limit bolt sleeve 20 on the side of the precast base 3, screw the T-type anchor bolt 19 into the limit bolt sleeve 20, and tighten the T-type anchor bolt 19 to the designed torque using a torque wrench.

[0094] (5) Install the support limiting structure 5 and the precast support 4.

[0095] As per design requirements, the connecting steel plate 16 of the support limiting structure 5 is passed through the limiting sleeve anchor bolt 17 on the upper surface of the base plate.

[0096] On the upper surface of the base and the lower surface of the prefabricated small unit track slab 2, the connecting steel plate 16 of the support limiting structure 5 is passed through the limiting sleeve anchoring bolt 17 embedded in the base and track slab according to the design position, and the support limiting structure 5 is anchored by the limiting sleeve anchoring bolt 21.

[0097] The standard part of the elastic support sleeve 6 is fitted onto the upper and lower surfaces of the precast support, and the precast support 4 is inserted into the support limiting sleeve 15 anchored on the upper surface of the base.

[0098] (6) Laying prefabricated small unit track slabs 2

[0099] Precast small-unit track slabs 2 are hoisted using small machinery, and the support limiting sleeves 15 anchored to the lower surface of the track slabs are fitted onto the support sleeves on the upper surface of the precast support 4. Expansion joints of 2-3cm are provided between adjacent precast small-unit track slabs 2.

[0100] The elevation and planar position of the track slabs were measured using measuring instruments. The elevation of the prefabricated small unit track slabs 2 was coarsely adjusted using the adjusting parts of the elastic support sleeve 6 to ensure that the installation position and elevation deviation meet the requirements of relevant specifications and design documents.

[0101] (7) Pour the intermediate adjustment layer 7

[0102] The intermediate adjustment layer material is injected into the grouting holes 12 of the prefabricated small unit track slab 2 until it is completely filled and compacted. The expansion joints of the track slab are sealed with caulking material.

[0103] (8) Install rails and fasteners

[0104] After installing the rails and fasteners and adjusting the track geometry to meet the laying accuracy deviation requirements of the design specifications and design documents, the line can be opened for operation.

[0105] When the construction period is tight during the use of track maintenance windows, if the intermediate adjustment layer has not reached the design strength or has not yet been poured, the construction procedures of (7) and (8) can be changed. The rails and fasteners can be installed first, and fine-tuning can be carried out to temporarily open the line for operation. After the intermediate adjustment layer is poured at the next track maintenance window or after the intermediate adjustment layer reaches the design strength, the line can be fine-tuned again to meet the conditions for formal opening for operation.

[0106] The above examples illustrate the present invention only to aid in understanding it and are not intended to limit the scope of the invention. Those skilled in the art can make various simple deductions, modifications, or substitutions based on the ideas of this invention.

Claims

1. A fully prefabricated integral track bed structure for silo coal charging lines, characterized by: The fully assembled integral track bed structure includes prefabricated small unit track slabs (2), prefabricated bases (3), and temporary support mechanisms; An intermediate adjustment layer (7) is formed between the prefabricated small unit track slab (2) and the prefabricated base (3) by injecting grouting material. The temporary support mechanism is vertically installed between the prefabricated small unit track slab (2) and the prefabricated base (3) of the fully assembled integral track bed structure, including prefabricated support pier (4) and support pier limiting structure (5). The support pier limiting structure (5) includes support pier limiting sleeve (15), connecting steel plate (16), limiting sleeve anchoring screw (17) and limiting sleeve anchoring bolt (21). The limiting sleeve anchor bolt (17) is pre-embedded in the bottom surface of the prefabricated small unit track plate (2) and the top surface of the prefabricated base (3), with the ends exposed. The exposed part of the limiting sleeve anchor bolt (17) passes through the round hole provided on the connecting steel plate (16) and is fixed by the limiting sleeve anchor bolt (21), so that the two connecting steel plates (16) are respectively fixed to the bottom surface of the prefabricated small unit track plate (2) and the top surface of the prefabricated base (3); The two support limiting sleeves (15) are respectively fixed to the two connecting steel plates (16), and the top and bottom of the prefabricated support (4) are respectively inserted into the upper and lower support limiting sleeves (15).

2. The fully prefabricated integral track bed structure for silo coal charging lines according to claim 1, characterized in that: The temporary support mechanism also includes an elastic support sleeve (6), which has a base plate and a protective ring; The two elastic support sleeves (6) are respectively fitted onto the top and bottom of the precast support (4) and located inside the support limiting sleeve (15).

3. The fully prefabricated integral track bed structure for silo coal loading lines according to claim 2, characterized in that: The elastic support sleeve (6) is prefabricated according to the thickness of the base plate.

4. The fully prefabricated integral track bed structure for silo coal charging lines according to claim 3, characterized in that: The prefabricated small unit track slab (2) is prefabricated in sections, with lifting sleeves (13) on the side and two rows of rail support platforms (10) on the top surface. The surface of the rail support platform (10) has pre-embedded fastener nylon sleeves (11). The prefabricated small unit track slab (2) is provided with vertically penetrating grouting holes (12) located between the two rows of track support platforms (10).

5. The fully prefabricated integral track bed structure for silo coal charging lines according to claim 4, characterized in that: The prefabricated base (3) is prefabricated in sections, and the surface is provided with a limiting groove (14).

6. The fully prefabricated integral track bed structure for silo coal charging lines according to claim 5, characterized in that: After the temporary support mechanism is supported between the prefabricated small unit track plate (2) and the prefabricated base (3), grouting material is injected downward through the grouting hole (12) until the limiting groove (14) is filled. The bottom of the intermediate adjustment layer (7) formed has a limiting protrusion that is inserted into the limiting groove (14).

7. The fully prefabricated integral track bed structure for silo coal charging lines according to claim 6, characterized in that: The surface of the prefabricated base (3) is provided with an isolation layer (8), and the isolation layer (8) is provided with an opening corresponding to the position of the limiting groove (14).

8. The fully prefabricated integral track bed structure for silo coal charging lines according to claim 7, characterized in that: When the prefabricated base (3) is laid longitudinally, there is an expansion joint between adjacent prefabricated bases (3) and the joint is filled with caulking material; When the prefabricated small unit track slabs (2) are laid longitudinally, there are expansion joints between adjacent prefabricated small unit track slabs (2), and the intermediate adjustment layer (7) is filled with caulking material after it is formed.

9. The fully prefabricated integral track bed structure for silo coal charging lines according to claim 8, characterized in that: The side of the prefabricated base (3) is provided with a limiting bolt sleeve (20). After two adjacent prefabricated bases (3) are laid in place, an elongated hole limiting card (18) is covered on the outside of the limiting bolt sleeve (20) of the two prefabricated bases (3). The T-shaped anchor bolt (19) is inserted into the elongated hole and then into the limiting bolt sleeve (20) to limit and connect the two prefabricated bases (3) to each other.

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