Mold for manufacturing a support in fixing material for the direct installation of rails on a concrete structure

Abstract

A rigid mold (100) for applying a fixing material around a metal saddle and fixing elements for fixing the metal saddle supporting the rail of a railway track in the fixing material when directly laying the railway track on a concrete structure, the mold (100) comprising: a first L-shaped structural part (101) and a second L-shaped structural part (102) intended to be assembled together to form a frame by surrounding the metal saddle (2) and the fixing elements so as to delimit an area (20) intended to receive the fixing material; an assembly system (104) configured to assemble the two structural parts together; a fixing system (103) configured to fix the mold (100) removably against a surface of the rail. Abstract Figure: Figure 3

Description

Title of the invention: Mold for manufacturing a support made of fixing material for the direct installation of rails on a concrete structure Technical field

[0001] The present invention relates to the field of construction and maintenance of railways where the rails are fixed by direct installation on a concrete structure by means of a metal saddle. In particular, the present invention relates to a mold for manufacturing a resin or concrete support around fixing elements allowing the fixing of saddles supporting the rails of the railway. The invention also relates to a method of laying rails on a concrete structure using such a mold. Prior art

[0002] It is known to proceed with the direct laying of a railway track on a concrete structure. The rails are pre-fixed on plate plates by fixing elements. The rails are then fixed at the place where the track is to be laid. The plate plates on which the rails rest support fixing elements consisting of threaded rods which pass through the plate plates and have a lower part intended to be received in the concrete structure. A resin or concrete support is then poured under the rails up to the height of the plate plates, thus embedding the lower part of the fixing elements in the resin support. Once the resin has solidified, the plate plates are permanently immobilized in the resin support by tightening nuts on the threaded rods, these nuts bearing on the upper face of the plate plates. The metal plate plates supporting the rail are thus anchored to the concrete structure by the fixing elements and the support.

[0003] The current method of manufacturing the support around the metal saddle fasteners involves using foam to create a recess into which the fastener material is poured. The foam allows a mold to be created on site around the desired area. Once the foam has solidified, resin or concrete is poured inside the space defined by the foam. The resin solidifies and takes the shape of the foam mold, creating a structure into which the saddle and fasteners are anchored.

[0004] Such a method of constructing a railway track using foam formwork, however, has many technical drawbacks. The foam formwork technique is often imprecise in the dimension and shape of the supports, which results in poor formation of the support. Thus, when tightening the nuts on the threaded rods to immobilize and anchor the tie plates, the support does not provide a good bearing surface for the tie plates. It is then necessary to dismantle the tie plate and manually rework the poor construction of the support to provide good support for the tie plate. Such rework is time-consuming and costly and significantly slows down the laying of the railway track. In addition, the use of a foam mold results in wasted material and high amounts of waste and non-recyclable materials.

[0005] Also, an object of the present invention is to provide a mold for the direct laying of a railway track which ensures a defect-free, uniform and precise formation of a support on which the saddle supporting the rails rests.

[0006] Another object of the present invention is to provide a mold which is simple and economical to produce while being resistant to wear and corrosion.

[0007] Another object of the present invention is to provide a reusable mold which thus makes it possible to reduce material waste.

[0008] Finally, another object of the present invention is to provide a mold designed to be easily installed and adjusted in terms of size, allowing customization of the mold according to the needs of the railway. Summary

[0009] The present disclosure improves the situation.

[0010] A rigid mold is provided for applying a fixing material around a metal saddle and fixing elements allowing the fixing of the metal saddle supporting the rail of a railway track in the fixing material during the direct laying of the railway track on a concrete structure, the mold comprising: a. a first L-shaped structural part and a second L-shaped structural part intended to be assembled together to form a frame by surrounding the metal saddle and the fixing elements so as to delimit an area intended to receive the fixing material; b. an assembly system configured to assemble the two structural parts together; c. a fastening system configured to removably secure the mold against a surface of the rail.

[0011] The features set out in the following paragraphs may, optionally, be implemented, independently of one another or in combination with one another:

[0012] The two structural parts are identical, each of the parts comprising a transverse side wall and a longitudinal side wall which form a right angle between them.

[0013] Each structural part comprises a horizontal wing which extends from a lower edge of the side walls and oriented towards the outside of the frame when the two parts are assembled together, said horizontal wing forming a bearing surface to place the structural part on the concrete structure.

[0014] The assembly system comprises a movable locking element mounted on one end of one of the two structural parts and a locking plate provided with a groove mounted on one end of the other structural part, said movable locking element comprising a threaded rod having one end welded to a rotation shaft and an opposite end intended to be received in said groove, and a clamping nut mounted on said threaded rod adapted to be tightened against the plate to lock the threaded rod in the groove.

[0015] The fixing system comprises a threaded rod screwed into a nut secured to a vertical plate and an L-shaped angle iron, said vertical plate being secured to an outwardly facing surface of the frame of one of the two structural parts of the mold, said threaded rod being capable of causing a surface of the L-shaped angle iron to be pressed against a lower surface of the rail to stabilize the mold against the rail.

[0016] Preferably, each of the two structural parts of the mold is provided with a fixing system.

[0017] Preferably, the two structural parts are made of a corrosion-resistant material.

[0018] According to one embodiment, the internal surfaces of the frame intended to be brought into contact with the material are coated with a layer of release oil before the material is poured into the area.

[0019] According to another aspect, there is provided a method of constructing a support for fixing material around a metal saddle and fixing elements during the direct laying of a rail on a concrete structure allowing the fixing of the metal saddle supporting the rail of a railway in the fixing material during the direct laying of the railway on a concrete structure, said method comprising the following steps: a. providing a mold as described above, b. position the two parts of the mold structures around the saddle metal and fixing elements by placing the ends of the two parts opposite each other, forming a frame so as to delimit an area intended to receive the fixing material; c. assemble the ends of the two parts using the assembly system; d. fix each part against a surface of the rail by means of the fixing system; e. coating the inner face of the side walls of the mold intended to be in contact with the fixing material with an oil; f. pour the fixing material up to the height of a lower surface of the metal saddle in the area delimited by the frame; g. unlock the fixing system so that the mold is not held fixed to the rail after a drying time of the fixing material; h. disassemble the assembly system to separate the two structural parts; i. remove the two structural parts from the mold one after the other.

[0020] Preferably, the fixing material is concrete or resin. Brief description of the drawings

[0021] Other characteristics, details and advantages will appear on reading the detailed description below, and on analyzing the attached drawings, in which: Fig.l

[0022] [Fig.l] [Fig.l] shows a schematic top view of a rail fixed to a concrete structure by direct installation via a metal saddle and fixing elements immobilized in a support made of fixing material applied by a mold according to one embodiment; Fig. 2

[0023] [Fig.2] [Fig.2] shows a sectional view along axis II of [Fig.l]; Fig. 3

[0024] [Fig.3] [Fig.3] shows a perspective view of the application mold according to an embodiment of the invention of [Fig.l]; Fig. 4

[0025] [Fig.4] [Fig.4] shows a perspective view representing only one of the two structural parts of the mold of [Fig.l] equipped with an assembly system for assembling the two parts of the mold and a fixing system for removably fixing the mold to a rail of the railway; Fig. 5

[0026] [Fig.5] [Fig.5] shows an enlarged view of the assembly system according to an embodiment which makes it possible to assemble the two parts of the mold together; Fig. 6

[0027] [Fig.6] [Fig.6] is an enlarged view of the fastening system according to an embodiment which makes it possible to fasten the mold to the rail; Fig. 7

[0028] [Fig.7] [Fig.7] shows an image of a rail placed on a metal saddle fixed in a support made of fixing material applied by the mold according to one embodiment. Description of the embodiments

[0029] To facilitate reading of the drawings, only the elements necessary for understanding the invention have been shown. The same elements bear the same references from one figure to another.

[0030] With reference to figures 1 and 2, a rail 1 laid on a concrete structure 10 in a direct laying manner is illustrated.

[0031] The rail 1 is fixed in a known manner by direct installation on the concrete structure 10 by means of a metal saddle 2, the fixing elements 6.1, 6.2, 6.3, 6.4 and a support made of fixing material 3. In other words, the rail 1 is laid on discontinuous supports formed by metal saddles along the railway track. Such installation is generally intended to consolidate tracks during maintenance operations or to equip existing tracks.

[0032] The metal saddle 2 is generally a metal plate having a substantially rectangular shape. It has four openings adapted to receive known fixing elements 6.1, 6.2, 6.3, 6.4. Each fixing element is composed for example of a guide sleeve, a threaded fixing rod and a locking nut. The sleeve has an outside diameter adjusted to the diameter of the opening and an inside bore adapted to receive the threaded rod. The metal saddle is fixed to the rail 1 via two fasteners 5.1, 5.2 and two fixing elements 6.1, 6.4 arranged on either side of the rail when the saddle is fixed on the rail. The metal saddle 2 is fixed to the concrete structure 10 via the other two fixing elements 6.2, 6.3. As shown in [Fig.2], the rods 7.2, 7.3 of the corresponding fixing elements 6.2, 6.3 are each received in an opening made in the concrete structure.The parts of the rods which protrude from the metal saddle are embedded and immobilized in the support 2. .

[0033] According to [Fig.2], the guide sleeves and the fixing rods of the fixing elements intended to be inserted into a fixing hole previously made in the concrete structure have a lower part which protrudes beyond the lower part of the saddle. The metal saddle and the fixing elements are intended to be embedded and immobilized in a support made of fixing material.

[0034] Prior to casting the fixing material, a mold 100 for applying this support according to one embodiment is positioned around the metal saddle and the fixing elements. The mold thus forms a frame around the saddle as illustrated in [Fig.l]. This mold, which will be described in more detail below with reference to FIGS. 3 to 6, has the function of delimiting an area into which the fixing material is poured to form the support 3. Thus, the shape and size of the support 3 are defined by the shape and size of the mold 100. Prior to casting the fixing material, the inner face of the mold intended to be brought into contact with the fixing material is coated with a release oil to facilitate the removal of the parts from the mold.

[0035] The fixing material is then poured by gravity to the lower surface of the metal saddle, embedding the lower part of the threaded rods projecting under the saddle. After a drying time of the fixing material, the fixing elements and the metal saddle are anchored in the support 3.

[0036] As illustrated in [Fig.2], a sole 9 made of resilient material can be interposed between a lower face of the rail 1 and an upper surface of the metal saddle 2. This sole has the function of attenuating vibrations.

[0037] The saddle 2 is then immobilized in a conventional manner using nuts screwed onto the threaded rods, the latter bearing on an upper face of the saddle by means of a nut.

[0038] [Fig.7] is an image showing the rail 1 fixed to the concrete structure 10 with the saddle metal 2 and the fixing elements 6.1, 6.2, 6.3, 6.4 anchored in the support 3 after removing the mold 100.

[0039] Reference is now made to Figures 3 to 6 which represent a rigid mold 100 for applying a fixing material support according to one embodiment.

[0040] The rigid mold 100 comprises a first structural part 101 and a second structural part 102. The two parts are identical and have an L shape. The two parts are each formed of a longitudinal side wall 101.1, 102.2 and a transverse side wall 101.2, 102.1. The side walls 101.1, 101.2, 102.1, 102.2 are intended to be erected vertically to form a frame for positioning by surrounding the fixing elements and the metal saddle. The side walls delimit a zone 20 in which the fixing material is poured. The dimension of the zone 20 or of the support is thus defined by the rigid mold. The fixing material can be resin or concrete or a mixture of the two materials.

[0041] The transverse wall and the longitudinal wall of each structural part form a right angle. The two side walls are welded together to form one of the two structural parts of the mold having an L shape.

[0042] According to one embodiment, each of the two parts further comprises a peripheral horizontal wing 101.3, 102.3 oriented towards the outside of the frame forming a horizontal surface intended to bear on the surface of the concrete structure; the part is positioned around the fixing elements to form the mold.

[0043] The two parts are assembled together by means of an assembly system 104 to form a frame having a substantially rectangular shape. Each of the two parts is provided with a fixing system 103 configured to fix the mold against the rail.

[0044] [Fig.4] shows only the second part 102 of the mold 100 of [Fig.3]. It is composed of a lateral transverse wall 102.1 and a longitudinal wall 102.2 which form a right angle between them. The lower periphery of the second part 102 is provided with a peripheral horizontal wing 102.3 to allow the second part to rest on the ground of the concrete structure. The first part 101 of the mold 100 is identical to the second part 102 and will not be described.

[0045] The mold 100 comprises an assembly system 104 for assembling the two parts together. The assembly system comprises a movable locking element 104.1 mounted on one end of one of the structural parts of the mold and a locking plate 104.2 mounted on one end of the other structural part of the mold. The locking element 104.1 and the locking plate 104.2 cooperate to assemble the two ends together. The movable locking element 104.1 comprises a threaded rod 105 having one end 109 welded to a rotation shaft 106, and a butterfly nut type clamping nut 110 mounted on the threaded rod. The locking plate 104.2 is provided with a groove 108 which is adapted to receive one end of the movable locking element 104.1.The rod 105 is rotatable about the rotation shaft 106 between a position in which its other end 111 is free and a position in which its end 111 is received in the groove 108 of the locking plate 104.2. When the opposite end 111 of the rod 105 is received in the groove 108, the clamping nut is moved along the rod to be tightened against the plate 104.2, thus locking the threaded rod 105 in the groove 108. The two ends of each structural part are provided with a locking element and a locking plate of the assembly system. The two ends of the first part are thus assembled with the two ends of the second part by means of the locking element and the locking plate.

[0046] In [Fig. 4], one end 102.5 of the second part 102 is provided with a locking element 104.1 and the other end 102.6 of the second part 102 is provided with a locking plate 104.2. As described above, the locking element 104.1 is rotatable by means of the rotation shaft 106 between a first position in which the rod 105 is outside the groove 108 and placed parallel against the transverse side wall 102.1 and a second position in which the rod 105 is received in the groove 108 of the locking plate mounted on one end 101.5 of the first structural part 101 during assembly of the two parts. Similarly, the locking plate 104.2 mounted on the end 102.6 of the second part 102 is intended to receive one end of the threaded rod of the locking element mounted on the other end 101.6 of the first part 101.

[0047] With reference to [Fig. 6], the fixing system 103 which makes it possible to fix the mold 100 against the rail 1 is described here. It comprises a threaded rod 112 screwed into a nut 116 secured to a vertical plate 115 and an L-shaped angle iron 113. The vertical plate 115 is itself secured to an outwardly facing surface of the frame of the side wall of one of the two parts of the mold. The threaded rod 112 is capable of causing a bearing surface of the L-shaped angle iron 113 to be pressed against a lower surface of the rail 1 to keep the mold 100 fixed against the rail during the application of the resin. in the reserved area.

[0048] According to an exemplary embodiment, the mold may comprise two fastening systems secured to each of the two structural parts to ensure the stability of the mold during application of the resin. According to another exemplary embodiment, the mold may comprise a single fastening system secured to one of the two structural parts of the mold to ensure the stability of the mold.

[0049] Preferably, the mold structure is made of a material resistant to corrosion and wear, which ensures its durability over time and allows it to be reused. The mold can be made, for example, of galvanized iron, aluminum, wood or plastic.

[0050] The use of the mold 100 previously described in the method of applying a support made of fixing material around the metal saddle and the fixing elements during the direct installation of a rail on a concrete structure will now be described.

[0051] Before applying the support made of fixing material around the saddle and the fixing elements, the rail 1 is pre-fixed in a known manner above the chosen location of the concrete structure. Metal saddles are also pre-fixed on the rail 1 by fasteners 5.1, 5.2 and fixing elements 6.1, 6.4. The metal saddles 2 are then fixed to the concrete structure 10 via the two other fixing elements 6.2, 6.3 inserted into a fixing hole previously made in the concrete structure. The threaded rods thus arranged have a part projecting from the lower face of the metal saddle.

[0052] The metal saddle and the fixing elements can be embedded and immobilized in a support made of fixing material 3. The support can be resin or concrete.

[0053] The method of manufacturing such a support using the mold 100 comprises the following steps.

[0054] In a first step, the two structural parts 101, 102 of the mold 100 are positioned around the metal saddle and the fixing elements by placing the ends 101.5, 101.6 of the first part 101 and the ends 102.5, 102.6 of the second structural part 102 opposite each other. The two parts thus form a frame around the saddle as illustrated in [Fig.l].

[0055] In a second step, the rod 105 of the locking element 104.1 mounted on one end of one of the two parts is turned to engage in the groove 108 of the fixing plate 104.2 mounted on one end of the other part to assemble the two parts of the mold together.

[0056] In a third step, the rod 112 of the fixing system 103 is rotated so as to bring the L-shaped angle iron 113 pressed against a lower surface of the rail to stabilize the mold against the rail.

[0057] In a fourth step and prior to casting the fixing material, the The inner surface of the mold intended to be in contact with the fixing material is coated with a release oil. For example, a layer of petroleum jelly is applied to facilitate demolding.

[0058] In a fifth step, the resin or concrete or any other material is then poured by gravity to the lower surface of the metal saddle, embedding the lower part of the threaded rods projecting under the saddle.

[0059] After a drying time of the resin, the fixing elements and the metal saddle are immobilized in the support.

[0060] In a sixth step, the rod 115 of the fixing system 103 is turned so as to move the L-shaped angle iron 113 so that it is no longer pressed against the lower surface of the rail so that the mold is no longer held fixed to the rail.

[0061] In a seventh step, the rod 105 of the locking element 104.1 mounted on one end of one of the two parts is turned so as to no longer be in the groove 108 of the fixing plate 104.2 mounted on one end of the other part to disassemble the two parts of the mold.

[0062] In an eighth step, the two parts of the mold are removed one after the other.

[0063] The mold of the present invention can be used to apply any type of material fixing, for example resin or concrete in the context of laying railway tracks, whether in renovation or in consolidation.

[0064] The mold of the present invention allows for precise and uniform application of fixing material.

[0065] Unlike the prior art, the mold of the present invention is reusable, thus reducing material waste and the cost of laying railway tracks.

[0066] The mold is very easy to install and allows for easy size adjustment, allowing the mold to be adapted to the needs of the railway.

[0067] The present disclosure is not limited to the examples described above, but it encompasses all the variants that a person skilled in the art may envisage within the framework of the protection sought.

Claims

Claims

1. A rigid mold (100) for applying a fixing material around a metal saddle (2) and fixing elements (6.1, 6.2, 6.3, 6.4) enabling the fixing of the metal saddle supporting the rail of a railway track (1) in the fixing material when directly laying the railway track on a concrete structure, the mold (100) comprising: a. a first L-shaped structural part (101) and a second L-shaped structural part (102) intended to be assembled together to form a frame by surrounding the metal saddle (2) and the fixing elements so as to delimit an area (20) intended to receive the fixing material; b. an assembly system configured to assemble the two structural parts together; c. a fixing system configured to fix the mold (100) removably against a surface of the rail.

2. A mold according to claim 1, wherein the two structural parts are identical, each of the parts comprising a transverse side wall (101.2, 102.1) and a longitudinal side wall (101.1, 102.2) which form a right angle between them.

3. A mold according to claim 1 or 2, wherein each structural part comprises a horizontal wing (101.3, 102.3) which extends from a lower edge of the side walls and oriented towards the outside of the frame when the two parts are assembled together, said horizontal wing (101.3, 102.3) forming a bearing surface for placing the structural part on the concrete structure (10).

4. Mold according to one of claims 1 to 3, wherein the assembly system (104) comprises a movable locking element (104.1) mounted on one end (102.5) of one of the two structural parts and a locking plate (104.2) provided with a groove (108) mounted on one end (102.6) of the other structural part, said movable locking element comprising a threaded rod (105) having one end (109) welded to a rotation shaft (106) and an opposite end (111) intended to be received in said groove (108), and a tightening nut (110) mounted on said threaded rod (105) adapted to be tightened against the plate (104.2) to lock the threaded rod (105) in the groove (108).

5. Mold according to one of claims 1 to 4, wherein the fixing system (103) comprises a threaded rod (112) screwed into a nut (116) secured to a vertical plate (115) and an L-shaped angle iron (113), said vertical plate (115) being secured to an outwardly facing surface of the frame of one of the two structural parts (101, 102) of the mold, said threaded rod (112) being capable of causing a surface of the L-shaped angle iron (113) to be pressed against a lower surface of the rail (1) to stabilize the mold (100) against the rail (1).

6. Mold according to one of claims 1 to 5, in which each of the two structural parts of the mold is provided with a fixing system (103).

7. Mold according to one of claims 1 to 6, in which the two structural parts (101, 102) are made of a corrosion-resistant material.

8. A mold according to any one of claims 1 to 7, wherein the internal surfaces of the frame intended to be brought into contact with the material are coated with a layer of mold release oil before casting the material into the area.

9. A method of constructing a support for fixing material around a metal saddle (2) and fixing elements (6.1, 6.2, 6.3, 6.4) when directly laying a rail (1) on a concrete structure, enabling the fixing of the metal saddle (2) supporting the rail of a railway track in the fixing material when directly laying the railway track on a concrete structure, said method comprising the following steps: a. providing a mold (100) according to one of claims 1 to 8, b. positioning the two parts (101, 102) of structures of the mold (100) around the metal saddle and the fixing elements by placing the ends (101.5, 102.5, 101.6, 102.6) of the two parts opposite each other, forming a frame so as to delimit an area (20) intended to receive the fixing material; c. assembling the ends (101.5, 102.5, 101.6, 102.6) of the two parts by means of the assembly system (104); d.fixing each part (101, 102) against a surface of the rail by means of the fixing system (103); e. coating the inner face of the side walls (101.2, 101.1, 102.1, 102.2) of the mold intended to be in contact with the fixing material with an oil; f. pouring the fixing material up to the height of a lower surface of the metal saddle in the area (20) delimited by the frame; g. unlock the fixing system so that the mold is not held fixed to the rail after a drying time of the fixing material; h. disassemble the assembly system to separate the two structural parts; i. remove the two structural parts from the mold one after the other.

10. A method according to claim 9, wherein the fixing material is concrete or resin.