Electric flat car track and equipment foundation insulation method

Abstract

The invention relates to the technical field of track insulation construction, in particular to an electric flat car track and equipment foundation insulation method. According to the technical scheme, insulating material parameters are matched according to construction environment humidity; and then a multi-layer insulation system is constructed through the four steps that insulation grouting materials are poured into the embedded bolt holes, the top face of the foundation is coated with insulation paint, an insulation cushion leather plate is laid, a rail is installed and fixed through a rubber rail pressing device, and secondary insulation grouting is conducted on the upper portion of the rail. Insulation detection nodes are respectively arranged after track installation and secondary grouting, qualified detection is used as a process conversion condition, and an insulation performance file is synchronously established. Through combination of environment adaptation, multi-layer insulation, process detection and data filing, the problem of low success rate of one-time construction in the prior art is solved, and a systematic, verifiable and full-period controllable insulation construction quality control system is formed.

Description

Technical Field

[0001] This invention relates to the field of track insulation construction technology, and in particular to a method for insulating electric flatcar tracks and equipment foundations. Background Technology

[0002] In the field of industrial logistics and production transfer, electric flatcars, as a common heavy-duty handling equipment, widely adopt rail-based power supply to achieve power transmission and continuous operation. The rails not only provide mechanical guidance and load-bearing functions but are also the key conductors for power transmission. This power supply method requires reliable electrical isolation between the rail system and the ground. Any unexpected current leakage will directly endanger personnel safety and equipment stability, especially in humid and dusty industrial environments where the risk of insulation failure is even more pronounced. Therefore, insulation treatment between the rails and the foundation has become an indispensable core aspect of this technical field.

[0003] Currently, commonly used insulation technologies primarily achieve this by introducing a physical insulating medium between the track and the concrete foundation. Common methods include laying insulating pads made of rubber or polymer materials, coating the foundation surface with insulating coatings such as epoxy resin, and installing insulating sleeves or washers at fastening points. These methods essentially fall under the category of "contact isolation," relying on the volume resistivity of the insulating material to block the direct electrical connection between the metal track and the conductive foundation. The construction process typically employs a segmented work model, with each insulating component installed separately according to its designed location. Finally, the effectiveness of the insulation system is verified through overall electrical testing.

[0004] However, while existing methods can achieve basic insulation functions to a certain extent, their quality control heavily relies on the final overall test, lacking phased verification and real-time control of insulation quality at each critical stage during construction. Since the integrity of an insulation system is composed of multiple independent construction stages, defects in any stage (such as localized damage to the pad, uneven coating thickness, or inadequate sealing at fasteners) can lead to overall insulation failure. These problems are often only discovered during final testing, resulting in large-scale rework and severely impacting the one-time success rate and economic efficiency of complex insulation projects. Summary of the Invention

[0005] The purpose of this invention is to address the problems existing in the background art by proposing a method for insulating the track of an electric flatcar from the equipment foundation.

[0006] This application provides a method for insulating the track of an electric flatcar from the equipment foundation, including the following steps: S1. First insulation protection: After installing the pre-embedded bolts in the reserved bolt holes of the equipment foundation, grouting is carried out using insulating grout. The insulating grout contains, by weight, 100 parts cement, 120-150 parts graded aggregate, 5-15 parts insulating mineral admixture, 0.8-1.5 parts water-reducing agent and 0.3-1.0 parts water-repellent agent. S2. Secondary insulation protection: Apply insulating coating to the top surface of the equipment foundation, and then lay insulating mats along the entire length; S3. Third insulation protection and first insulation test: Install the steel rail on the insulation pad according to the position of the center line of the steel rail and the center line of the electric flatcar track, fix the rail to the pre-embedded bolts with rubber rail clamps, and then perform the first insulation test. S4. Fourth insulation protection and second insulation test: After the first insulation test is qualified, the upper part of the track is subjected to secondary insulation grouting. After the grouting layer is cured and dried, the second insulation test is carried out.

[0007] By adopting the above technical solution, a complete insulation construction process was defined in four steps, with each step corresponding to a specific insulation protection or inspection. A systematic construction framework was constructed by breaking down the insulation treatment into multiple orderly and clearly defined sub-steps. The four insulation protections target different potential leakage paths, such as bolt connections, track bottom surfaces, installation fixing points, and external encapsulation, while the two insulation inspections are precisely set at key process nodes, thus achieving quality control and timely feedback during construction. This structured approach ensures clear construction logic and well-defined responsibilities at each stage, laying the foundation for successful construction on the first attempt.

[0008] Optionally, the insulating grout further comprises reinforcing fibers, wherein the amount of reinforcing fibers added is 0.5-1.0 parts by weight.

[0009] By adopting the above technical solution and adding a specific proportion of reinforcing fibers to the insulating grout, the crack resistance and overall toughness of the grout are effectively improved. The network structure formed by the fibers in the grout can inhibit the generation and development of microcracks during plastic shrinkage and drying, reducing the formation of through-hole water seepage or leakage channels due to cracking. This helps maintain the structural integrity and insulation continuity of the grout layer under long-term loads and environmental effects, thereby enhancing the long-term reliability of the first and fourth insulation barriers.

[0010] Optionally, the reinforcing fiber is polypropylene fiber.

[0011] By adopting the above technical solution and selecting polypropylene fiber as the reinforcing material, the overall performance of the grouting material was further optimized. Polypropylene fiber has excellent dispersibility, chemical inertness, and good compatibility with cementitious substrates. Its addition not only exerts the aforementioned crack resistance and toughening effects, but also improves the workability of the grouting material to a certain extent, and has no negative impact on the subsequent insulation performance, providing a suitable material selection for achieving the design strength and insulation performance.

[0012] Optionally, a construction environment survey step may be included before the pre-embedded bolt insulation grouting step; Determine the humidity level of the construction environment, and based on this level, determine the dosage of the water-repellent agent, the type of the insulating coating, and the material of the insulating mat.

[0013] By adopting the above technical solution, environmental surveys and material matching steps are introduced before formal construction, giving the insulation solution preliminary environmental adaptability. By identifying the ambient humidity level and dynamically adjusting the formulation and selection of key materials accordingly, the adverse effects of specific environmental factors (such as moisture) on the insulation system can be mitigated or reduced in advance. The feedforward control mechanism optimizes material configuration from the source, improving the adaptability of the insulation system under different operating conditions and its long-term service stability.

[0014] Optionally, in the second insulation protection, the dry film thickness of the insulating coating is 150-250 micrometers; and the thickness of the insulating pad is 5-10 millimeters.

[0015] By adopting the above technical solutions, clear construction parameters are provided for the dry film thickness of the insulating coating and the thickness of the insulating pad, thus enabling secondary insulation protection. A suitable coating thickness ensures that the insulating coating forms a continuous, defect-free insulating film with sufficient dielectric strength; the pad thickness within the specified range ensures reliable electrical isolation while also considering construction operability and the impact on the flatness of the track installation, allowing the composite insulation layer on the top surface of the foundation to stably perform its design function.

[0016] Optionally, the passing result of the first insulation test is a necessary prerequisite for performing the second grouting and final testing steps.

[0017] By adopting the above technical solution, a strict process control logic is established by setting the passing of the first insulation test as a necessary prerequisite for subsequent secondary grouting. This mandates that the insulation status of the installed portion must be verified before implementing the encapsulation process (secondary grouting) that might mask previous defects. This effectively prevents unqualified intermediate products from being brought into the final process, providing a crucial institutional guarantee against large-scale rework.

[0018] Optionally, both the first insulation test and the second insulation test include measuring the insulation resistance between the steel rail and the equipment foundation using a megohmmeter. The passing standard for the first insulation test is an insulation resistance value of not less than 10 MΩ, and the passing standard for the second insulation test is an insulation resistance value of not less than 20 MΩ.

[0019] By adopting the above technical solution, it was determined that both insulation tests would use a megohmmeter to measure insulation resistance and set progressively higher acceptable thresholds, providing an objective and quantitative evaluation standard for quality control. The phased and standard-based testing method systematically verified the quality of the construction process and the performance of the final product.

[0020] Optionally, the insulation method also includes recording the insulation resistance value and location information of each test point during each insulation test to form an insulation performance file.

[0021] By adopting the above technical solution, resistance values ​​and location information are recorded and archived at each test, upgrading the testing process from simple pass / fail judgment to data-driven information collection. This not only provides a basis for process flow but, more importantly, establishes a traceable baseline for insulation performance. It provides valuable data support for subsequent status comparison, performance trend analysis, and fault location in operation and maintenance, achieving full-cycle information management for insulation projects.

[0022] Optionally, the thickness of the secondary insulating grout layer in S4 is 30-60 mm.

[0023] By adopting the above technical solution, the thickness of the secondary insulating grout layer is limited, ensuring that the encapsulation layer can effectively cover and protect critical parts such as the track edges and rail clamp bolts. An appropriate thickness provides sufficient electrical isolation and mechanical protection while avoiding problems such as increased shrinkage stress, increased cracking risk, or material waste caused by excessive grout thickness, thus achieving a balance between effectiveness and economy in the fourth layer of insulation protection.

[0024] Optionally, in S1 and S4, wet curing for no less than 7 days is required after the grouting is completed.

[0025] By adopting the above technical solution, wet curing for no less than 7 days is required after each grouting operation to ensure the normal development of the cement-based grout's performance. Sufficient wet curing promotes full hydration of the cement, ensures that the grout reaches its design strength, and reduces shrinkage cracks caused by early water loss, thereby ensuring the long-term structural stability and durable insulation performance of the first and fourth insulation layers composed of the grout.

[0026] In summary, this application includes at least one of the following beneficial technical effects: This invention, through a systematic process of four layers of insulation protection and two process inspections, embeds quality control nodes into the construction process, enabling real-time verification and timely correction of the insulation construction process, and significantly improving the one-time success rate and reliability of complex insulation projects.

[0027] Further establish matching rules between construction environment humidity and material parameters, and form a traceable insulation performance file to make the insulation system environmentally adaptable and provide a data-driven, full-cycle management foundation for later operation and maintenance.

[0028] Finally, a progressive multi-layer insulation structure from the bolt root to the top of the track was adopted, combined with process monitoring, to systematically block all possible leakage paths, fundamentally improving the overall safety and operational stability of the track power supply system. Attached Figure Description

[0029] Figure 1 A schematic diagram of the overall structure of the electric flatcar track and equipment foundation insulation method of the present invention is provided. Figure 2 This is a flowchart of a method for insulating the track and equipment foundation of an electric flatcar.

[0030] Attached reference numerals: 1. Rail centerline; 2. Electric flatcar track centerline. Detailed Implementation

[0031] The technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0032] like Figure 1 and Figure 2 As shown, the present invention proposes a method for insulating the track of an electric flatcar from the equipment foundation, comprising the following steps: S1. First insulation protection: After installing the pre-embedded bolts in the reserved bolt holes of the equipment foundation, grouting is carried out using insulating grout. The insulating grout contains, by weight, 100 parts cement, 120-150 parts graded aggregate, 5-15 parts insulating mineral admixture, 0.8-1.5 parts water-reducing agent and 0.3-1.0 parts water-repellent agent. S2. Secondary insulation protection: Apply insulating coating to the top surface of the equipment foundation, and then lay insulating mats along the entire length; S3. Third insulation protection and first insulation test: Install the steel rail on the insulation pad according to the position of the center line 1 of the steel rail and the center line 2 of the electric flatcar track. Use rubber rail clamps to fix the rail to the pre-embedded bolts, and then perform the first insulation test. S4. Fourth insulation protection and second insulation test: After the first insulation test is passed, a second insulation grouting is performed on the upper part of the track. After the grouting layer has cured and dried, a second insulation test is performed. The insulation method is described in detail below: In this embodiment, the first step is to provide insulation protection for the pre-embedded bolts. After installing the pre-embedded bolts in the reserved bolt holes in the equipment foundation, a specific insulating grout is used for grouting. This insulating grout is based on cement and graded aggregates, and includes insulating mineral admixtures, water-reducing agents, and water-repellent agents. Through this step, a first insulating barrier is formed between the bolts and the concrete foundation body, blocking the leakage current path that may be conducted to the foundation through the bolt metal members.

[0033] Secondly, composite insulation protection is applied to the top surface of the foundation. An insulating coating is applied to the top surface of the equipment foundation to form a continuous, dense thin-film isolation layer, followed by the continuous laying of an insulating pad. This step constitutes the second insulation layer between the bottom surface of the track and the top surface of the foundation. The insulating coating fills the micropores in the concrete surface, while the insulating pad provides primary physical isolation and pressure cushioning; the combination of the two enhances the reliability of the insulation.

[0034] Next, the track is installed and secured, and a third layer of insulation is applied, followed by the first insulation test. The steel rails are installed on the insulating pad according to the centerline 1 of the steel rail and the centerline 2 of the electric flatcar track, and rubber rail clamps are used to secure the rails to the pre-embedded bolts. The rubber rail clamps themselves constitute the third layer of insulation between the rails and the fixing bolts. Immediately after installation and fixation, a comprehensive first insulation resistance test is conducted between the track system and the equipment foundation. This test aims to verify the immediate effectiveness of the first three layers of insulation protection; a passing result is a necessary prerequisite for proceeding to the subsequent irreversible process (i.e., secondary grouting).

[0035] Finally, a fourth layer of insulation protection and final verification is conducted. After the first insulation test passes, a second layer of insulation grouting is applied to the upper area of ​​the track (including the edges of the track base plate and exposed bolt areas). This grouting layer wraps and seals the previously constructed components, forming a fourth layer of insulation protection and providing auxiliary protection against moisture and dust. After the grouting layer has cured and dried completely, a second insulation test is conducted. This test is the final verification of the integrity of the entire multi-layer insulation system.

[0036] Furthermore, the method may include an environmental survey step before implementation, and the performance parameters of the insulation material may be adjusted according to the humidity level of the construction environment, such as adjusting the amount of water-repellent agent in the grout, and selecting insulation coatings or pad materials with different moisture resistance properties, so that the insulation system has environmental adaptability.

[0037] Furthermore, during each insulation test, the method not only determines whether the insulation is qualified or not, but also records the insulation resistance value of each test point and its corresponding location information, forming a traceable insulation performance file. These files provide a data foundation for subsequent system maintenance and condition assessment.

[0038] like Figure 1 As shown, the insulation method also includes insulation protection; as one embodiment, the insulating grout also includes reinforcing fibers, the amount of which is 0.5-1.0 parts by weight; the reinforcing fibers are polypropylene fibers; before the pre-embedded bolt insulation grouting step, a construction environment survey step is also included; First, determine the humidity level of the construction environment, and then determine the dosage of the water-repellent agent, the type of the insulating coating, and the material of the insulating mat based on this level. In the second insulation protection, the dry film thickness of the insulating coating is 150-250 micrometers; the thickness of the insulating mat is 5-10 millimeters. The insulation protection is described in detail below: In this embodiment, before formal construction, the environmental humidity conditions of the equipment foundation are first surveyed and assessed to determine its humidity level (e.g., dry, moderately humid, or chronically humid). Based on the assessment results, preset material matching rules are invoked to dynamically adjust the selection and proportion of insulation materials. For example, in a humid environment, insulating coatings with stronger water-repellent properties and closed-cell insulating mats are selected, and the amount of water-repellent agent in the insulating grout is increased accordingly. This ensures that the insulation protection system has environmental adaptability, enhancing its long-term stability under specific operating conditions from the source.

[0039] The first layer involves installing pre-embedded bolts in the pre-drilled bolt holes in the equipment foundation, followed by grouting with a specially formulated insulating grout. While meeting structural strength requirements, the grout's formula, containing insulating mineral admixtures and water-repellent components, forms a high-resistance insulating layer between the bolts and the foundation concrete. This layer primarily addresses the fundamental problem of current being directly conducted to the concrete foundation through the metal bolts.

[0040] The second layer: A dense insulating coating is first applied to the top surface of the equipment foundation, forming a continuous, seamless thin film. Subsequently, a physical insulating pad is laid along its entire length on top. This composite structure forms the main insulating barrier between the bottom surface of the track and the top surface of the foundation. The insulating coating fills the micropores in the concrete surface, enhancing surface insulation; the insulating pad provides stable mechanical isolation and cushioning, together preventing the track from forming an electrical connection with the foundation directly or through moisture.

[0041] The third layer: During track installation, rubber rail clamps are used for fixation. The rubber insulators of the rail clamps electrically isolate the track plates, fastening bolts, and track foundation at the mechanical connection points. This protects against bypass leakage that may occur due to direct metal-to-metal contact at the fastening points.

[0042] Fourth layer: After the track is installed and passes preliminary inspection, secondary insulation grouting is performed on the upper part of the track and the area of ​​exposed bolts. This grouting forms a covering layer, sealing off potentially exposed metal parts such as track edges and fasteners, isolating them from external humid air, water accumulation, and contaminants, providing additional outer protection and sealing insulation, and enhancing the overall system's durability.

[0043] like Figure 1 As shown, the insulation method also includes insulation testing; as an implementation, the passing result of the first insulation test is a necessary prerequisite for performing the second grouting and final testing steps; both the first and second insulation tests include measuring the insulation resistance between the steel rail and the equipment foundation using a megohmmeter, the passing standard for the first insulation test is an insulation resistance value of not less than 10MΩ, and the passing standard for the second insulation test is an insulation resistance value of not less than 20MΩ; Furthermore, this insulation method also includes recording the insulation resistance value and location information of each test point during each insulation test to form an insulation performance file; the thickness of the secondary insulation grouting layer in S4 is 30-60mm; in both S1 and S4, wet curing for no less than 7 days is required after the grouting construction is completed. The insulation test is explained in detail below: In this embodiment, the first inspection is conducted after the track machinery is installed and fixed, but before irreversible secondary grouting. This verifies the immediate effectiveness of the first three layers of insulation protection (bolt grout layer, foundation composite layer, and fastening points) after installation. Once the current insulation condition is confirmed to be acceptable, subsequent sealing grouting is performed to avoid covering up defects.

[0044] The second inspection: After the secondary grouting layer has been cured and fully dried, a comprehensive verification of the final performance of the entire four-layer insulation protection system is conducted to assess whether it meets the overall insulation level required by the design. This phased inspection method achieves process control, enabling timely detection of problems and pinpointing them to specific construction stages.

[0045] The test was conducted using a megohmmeter. During the test, one electrode of the megohmmeter was connected to the steel rail, which acts as a conductor, and the other electrode was connected to the grounding electrode or structural reinforcement within the equipment foundation. By applying a specified test voltage, the insulation resistance between the rail system and the foundation was measured.

[0046] The pass standard for the first test is set at an insulation resistance not lower than a certain threshold. This standard is mainly to ensure that there are no serious insulation defects after installation.

[0047] The pass / fail standard for the second test is set at a higher threshold, requiring the entire system to have higher insulation reliability after complete encapsulation. Finally, by comparing the measured values ​​with the preset standard, it can be objectively determined whether the insulation construction at this stage is qualified.

[0048] Each test not only determines whether it passes or fails, but also requires systematic data recording. Recorded information includes at least: the specific location of each test point, the measured insulation resistance value, and the test time. The data is then compiled to form an insulation performance file for that section of the project.

[0049] The above specific embodiments are merely several optional embodiments of the present invention. Based on the technical solutions of the present invention and the relevant teachings of the above embodiments, those skilled in the art can make various alternative improvements and combinations to the above specific embodiments.

Claims

1. A method for insulating the track of an electric flatcar from the equipment foundation, characterized in that, Includes the following steps: S1. First insulation protection: After installing the pre-embedded bolts in the reserved bolt holes of the equipment foundation, grouting is carried out using insulating grout. The insulating grout contains, by weight, 100 parts cement, 120-150 parts graded aggregate, 5-15 parts insulating mineral admixture, 0.8-1.5 parts water-reducing agent and 0.3-1.0 parts water-repellent agent. S2. Secondary insulation protection: Apply insulating coating to the top surface of the equipment foundation, and then lay insulating mats along the entire length; S3, Third insulation protection and first insulation test; According to the position of the center line of the steel rail (1) and the center line of the electric flatcar track (2), install the steel rail on the insulation pad, use a rubber rail clamp to fix the rail to the pre-embedded bolt, and then perform the first insulation test; S4. Fourth insulation protection and second insulation test: After the first insulation test is qualified, the upper part of the track is subjected to secondary insulation grouting. After the grouting layer is cured and dried, the second insulation test is carried out.

2. The method for insulating the electric flatcar track and equipment foundation according to claim 1, characterized in that, The insulating grout also contains reinforcing fibers, and the amount of reinforcing fibers added is 0.5-1.0 parts by weight.

3. The method for insulating the electric flatcar track and equipment foundation according to claim 2, characterized in that, The reinforcing fiber is polypropylene fiber.

4. The method for insulating the electric flatcar track and equipment foundation according to claim 1, characterized in that, Before the pre-embedded bolt insulation grouting step, a construction environment survey step is also included; Determine the humidity level of the construction environment, and based on this level, determine the dosage of the water-repellent agent, the type of the insulating coating, and the material of the insulating mat.

5. The method for insulating the electric flatcar track and equipment foundation according to claim 1, characterized in that, In the second insulation protection, the dry film thickness of the insulating coating is 150-250 micrometers; the thickness of the insulating pad is 5-10 millimeters.

6. The method for insulating the electric flatcar track and equipment foundation according to claim 1, characterized in that, The passing result of the first insulation test is a necessary prerequisite for performing the second grouting and final testing steps.

7. The method for insulating the electric flatcar track and equipment foundation according to claim 1, characterized in that, Both the first and second insulation tests include measuring the insulation resistance between the steel rail and the equipment foundation using a megohmmeter. The passing standard for the first insulation test is an insulation resistance value of not less than 10 MΩ, and the passing standard for the second insulation test is an insulation resistance value of not less than 20 MΩ.

8. The method for insulating the electric flatcar track and equipment foundation according to claim 7, characterized in that, The insulation method also includes recording the insulation resistance value and location information of each test point during each insulation test to form an insulation performance file.

9. The method for insulating the electric flatcar track and equipment foundation according to claim 1, characterized in that, The thickness of the secondary insulating grout layer in S4 is 30-60mm.

10. The method for insulating the track and equipment foundation of an electric flatcar according to claim 1, characterized in that, In S1 and S4, wet curing for no less than 7 days is required after the grouting is completed.

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