Double block reinforced concrete railway sleepers with steel tube reinforcement.

Abstract

------14 / 01 / 2563------(OCR) The assembled rail sleeper is a double block reinforced concrete steel pipe joint assembly consisting of a first concrete rail sleeper block (1), a second concrete rail sleeper block (2), and a large number of matching reinforced concrete steel pipe joint columns (3). All of the above are independently assembled. These components are separated by welding during transport and warehouse assembly, and after being unloaded at the construction site, the reinforced concrete steel pipe joint columns (3) and the rail sleeper blocks are assembled into one by threading or slurry welding. Not only can the fastening and assembly process be realized quickly with high precision at the construction site, but it can also ensure that the rail sleeper is assembled with good form and positioning ability while significantly reducing the use of connecting pieces. In particular, the rail sleeper has a distinct advantage in reducing the difficulty of entering into the welding process in large quantities, for example, in warehouse assembly, transport and construction, improving process efficiency and reducing costs. ------------ What was provided were double-block reinforced concrete railway sleepers with steel tube components. Consisting of the first (1) concrete railway sleeper block, railway sleeper block The second type of concrete (2), and numerous matching steel pipe reinforced concrete columns (3) in total. As mentioned above, these components are processed independently; they are separated but connected during transport. And connected to the warehouse and, after being transported to the construction site, the columns of reinforced concrete pipes. Steel(3) and railway sleeper blocks are assembled together using thread or slurry of Welding is not just a process of fastening and assembly; it can be realized quickly with high precision. At the construction site, however, it can still be ensured that the railway sleepers are arranged in a good manner. The ability to maintain position while significantly reducing the use of connecting pieces, especially wood. Railway sleepers have a significant advantage in reducing the difficulty of the connection process. Many examples illustrate this in manufacturing, warehousing, transportation, and construction, focusing on improving process efficiency. Cost reduction

Description

A prefabricated steel-concrete double-block sleeper [Technical Field]

[0001] This invention belongs to the technical field of ballastless track, and more specifically, relates to a prefabricated steel-concrete double-block sleeper. [Background Technology]

[0002] In a sleeper-type ballastless track system, the sleeper, as a key component, primarily functions to provide positioning for pre-embedded fasteners and determine the geometric shape of the track during the construction of the ballastless track slab. To effectively control the width and number of cracks between the precast concrete sleepers and the old concrete in the cast-in-place track slab, and to ensure that the main structure of the ballastless track meets the relevant durability requirements for concrete structures, traditional long concrete sleepers have been gradually optimized into concrete sleeper blocks connected and positioned by truss reinforcement.

[0003] Currently, the most widely used and mature concrete sleepers in ballastless track include the French Stdedf sleeper (using angle steel for sleeper connections), the German Radar 2000 (using steel truss for sleeper connections), the German Schupperling double-block sleeper, and the CRTSI type double-block sleeper widely laid in China. The existing double-block ballastless track sleepers mainly consist of two concrete blocks at both ends of the sleeper, and an integral structure connecting the two concrete blocks using steel trusses or angle steel. However, further research shows that the above-mentioned sleeper structures still have the following defects or shortcomings in manufacturing, handling, storage, and construction:

[0004] First, in the manufacturing process, as described in the article "A Brief Discussion on the Prefabrication of Double-Block Ballastless Track Sleepers" ("Architectural Engineering Technology and Design", Wang Chenyan, March 2016), it requires the use of multiple complex devices such as steel models, model conveyor rollers, concrete pouring equipment, vibration tables, curing pools, model transport vehicles, and flipping-demolding machines to prefabricate the aforementioned integrated sleepers. Among them, the processes such as the installation of embedded sleeves and the installation of steel trusses are not only cumbersome to operate, but also require these connecting parts to have sufficient strength and high material requirements, which has a great impact on manufacturing efficiency and overall sleeper manufacturing costs.

[0005] Secondly, in the handling and storage stages, the former, as disclosed in CN101245578A and CN202785279, requires manual labor or special loading tools or lifting equipment to handle double-block sleepers. It mainly relies on the rigidity of the connecting parts to avoid geometric deformation during transportation. The lifting equipment includes a crossbeam, a left hook, a right hook, and a synchronous linkage mechanism, thereby performing the handling operation of a stack of 25 sleepers, such as 5*5. In the storage stage, as disclosed in CN203246881, it uses an automatic double-block sleeper stacking machine, which includes a fixed bracket, a main traveling car set along the toothed track, and lifting arm traveling cars installed on both sides of the main traveling car. The lifting arm and the robotic arm are used to perform the positioning and stacking lifting operations of the sleepers. It is obvious that existing technologies have significant limitations in both handling and storage solutions. For example, a set of prefabricated double-block sleepers weighs about 270 kg, making it time-consuming and laborious to transport to the construction site. Double-block sleepers connected by angle steel or steel trusses have a limited number of stacking layers in the factory, which not only increases storage costs but also creates a lot of unusable space when stacked in transport vehicles during transportation, resulting in high transportation costs.

[0006] Finally, in the on-site construction phase, as disclosed in CN101289828A and CN102268851A, the construction process of double-block ballastless track generally requires modular track frames, self-propelled paving machines, multi-functional electrically controlled lifting equipment, and mobile mechanical assembly platforms. These large supporting units have disadvantages such as a wide variety of types, complex construction techniques, and the need for dedicated logistics channels, thus posing significant challenges to construction difficulty and efficiency. Accordingly, the field urgently needs to provide more comprehensive solutions to address the aforementioned technical problems in order to better meet the growing demand for high-quality engineering.

[0007] [Summary of the Invention]

[0008] To address the shortcomings or improvement needs of existing technologies, this invention provides a prefabricated steel-concrete composite double-block sleeper. By comprehensively considering the actual needs of manufacturing, handling, storage, and construction, the overall structure and installation method of the double-block ballastless track sleeper have been re-studied and redesigned. Targeted improvements have been made to the specific structures of key components and the requirements of handling, storage, and on-site assembly. Compared with existing technologies, this invention not only enables rapid and high-precision fixing and assembly on-site, but also ensures good shape and position retention of the sleeper while significantly reducing the use of connecting parts. In particular, it has significant advantages in reducing the technological difficulty, improving process efficiency, and reducing costs in manufacturing, storage, handling, and construction, making it especially suitable for ballastless track engineering applications with high construction cycle requirements and limited construction conditions.

[0009] To achieve the above objectives, according to one aspect of the present invention, a prefabricated steel-concrete composite double-block sleeper is provided, characterized in that the sleeper comprises multiple components processed independently of each other, namely, a first concrete sleeper block and a second concrete sleeper block arranged in pairs, and a plurality of matching steel-concrete composite columns, wherein:

[0010] The first concrete sleeper block and the second concrete sleeper block each have a pre-embedded bolt sleeve on the top surface, and each end has a threaded positioning hole extending inward along the length of the sleeper block itself; the steel pipe concrete column is formed by pouring self-compacting concrete into a hollow steel pipe and curing it, and its two ends are processed into a threaded structure.

[0011] In addition, the first concrete sleeper block, the second concrete sleeper block, and the multiple steel-concrete composite columns are kept separate during the handling and storage processes. After being transported to the construction site together, the distance and geometric position between the two concrete sleeper blocks are first adjusted and fixed. Then, the two ends of the multiple steel-concrete composite columns are screwed into the threaded positioning holes of the first concrete sleeper block and the second concrete sleeper block respectively, and finally locked.

[0012] According to another aspect of the present invention, a different type of prefabricated steel-concrete composite double-block sleeper is provided, characterized in that the sleeper comprises multiple components processed independently of each other, namely, a first concrete sleeper block and a second concrete sleeper block arranged in pairs, and a plurality of matching steel-concrete composite columns, wherein:

[0013] The first concrete sleeper block and the second concrete sleeper block each have pre-embedded bolt sleeves on their top surfaces, and each has a hole extending inward along the length of the sleeper block at its end; the steel-concrete composite column is formed by pouring self-compacting concrete into a hollow steel pipe and curing it, and the outer diameter of its end basically matches the inner diameter of the hole.

[0014] In addition, the first concrete sleeper block, the second concrete sleeper block, and the multiple steel-concrete composite columns are kept separate during the handling and storage processes. After being transported to the construction site together, the distance and geometric position between the two concrete sleeper blocks are first adjusted and fixed. Then, the two ends of the multiple steel-concrete composite columns are respectively inserted into the holes of the first concrete sleeper block and the second concrete sleeper block on site. Finally, adhesive grout is injected into the holes for curing.

[0015] As a further preferred embodiment, both the first concrete sleeper block and the second concrete sleeper block are integrally cast from concrete, and preferably, they are also provided with steel mesh or stirrups inside.

[0016] As a further preferred embodiment, both the first concrete sleeper block and the second concrete sleeper block have an inclination angle of 11:1 to 7:1 on their sides, and their upper corners are chamfered.

[0017] As a further preferred embodiment, the number of the plurality of steel-concrete composite columns is preferably 2 or 3. When designed to be 3, the line connecting the center of the ends of the three steel-concrete composite columns forms an inverted triangle when viewed from the sleeper cross-section.

[0018] As a further preferred embodiment, the depth of the threaded positioning hole or cavity is preferably 708 mm, and the inner diameter is preferably 45 mm.

[0019] As a further preferred embodiment, the number of threaded positioning holes or openings is preferably two or three, and the spacing between them is set to 150mm to 180mm.

[0020] As a further preferred embodiment, the aforementioned steel-concrete composite double-block sleeper does not have a steel truss or angle steel.

[0021] In summary, compared with the prior art, the above-described technical solutions conceived by this invention mainly possess the following technical advantages:

[0022] 1. By comprehensively considering the actual needs of multiple stages such as manufacturing, handling, warehousing and construction, the overall double-block sleeper structure is decomposed into multiple independent components for processing and manufacturing, and then transported together to the construction site for on-site installation. Correspondingly, the integral molding of steel pipe concrete columns and concrete sleeper blocks effectively increases the sleeper's ability to maintain spatial geometry, and better meets the bending and torsional resistance requirements of double-block sleepers. In addition, through targeted design of the specific structure and setting of each component, the construction site no longer requires too many large supporting units and dedicated logistics channels, and construction efficiency is significantly improved.

[0023] 2. In particular, the present invention effectively overcomes the inherent shortcomings of traditional double-block sleepers, which must rely on the rigidity of the connecting parts to maintain the geometric position of the sleepers during stacking, storage, hoisting and transportation. It also greatly improves the efficiency of factory manufacturing, stacking and storage and transportation to various construction sites, and is no longer limited by the number of stacking layers, which is conducive to saving storage space.

[0024] 3. The prefabricated steel-concrete double-block sleeper of the present invention can effectively overcome various technical problems faced by the prior art in multiple stages such as factory manufacturing, multi-point transportation, centralized storage and on-site construction. It also has a good combination effect with the track bed slab, strong spatial positioning ability and good track stability. In addition, it has the advantages of simple manufacturing process, low cost, reliable quality, flexible specifications and easy maintenance, thus possessing high economic and social value. [Image Description]

[0025] Figure 1 is a schematic diagram of the composition structure of a concrete sleeper block constructed according to the first preferred embodiment of the present invention;

[0026] Figure 2 is a structural schematic diagram of a steel-concrete composite column constructed according to a preferred embodiment of the present invention;

[0027] Figure 3 shows a construction diagram of placing the first and second concrete sleeper blocks face to face after they have been transported separately to the construction site.

[0028] Figure 4 shows a construction schematic diagram of the continued integrated assembly of multiple steel-concrete composite columns with the first and second concrete sleeper blocks;

[0029] In all the accompanying drawings, the same reference numerals are used to denote the same elements or structures, wherein:

[0030] 1-First concrete sleeper block; 2-Second concrete sleeper block; 3-Steel-concrete composite column; 11-Embedded bolt sleeve; 21-Embedded bolt sleeve; 12-Threaded positioning hole; 22-Threaded positioning hole [Detailed Implementation]

[0031] To make the objectives, technical solutions, and advantages of this invention clearer, the invention will be described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative and not intended to limit the invention. Furthermore, the technical features involved in the various embodiments of this invention described below can be combined with each other as long as they do not conflict with each other.

[0032] As specifically analyzed in the "Background Art" section above, the existing double-block ballastless track sleepers face several practical technical limitations in multiple stages, including factory manufacturing, transportation, warehousing, and on-site construction. These limitations result in significant manpower and material costs, low efficiency, and high costs. Accordingly, this invention has specifically re-studied and redesigned the overall structure and configuration of the double-block ballastless track sleepers, while also improving the specific structure of each key component and the requirements for handling, warehousing, and on-site assembly.

[0033] Technical Solution 1

[0034] According to a first preferred embodiment of the present invention, a prefabricated steel-concrete composite double-block sleeper is provided, characterized in that the sleeper includes multiple components that are processed independently of each other, namely a first concrete sleeper block 1 and a second concrete sleeper block 2 configured in pairs, and a plurality of steel-concrete composite columns 3, and these components remain separate in all handling, storage or other stages, and before arriving at the construction site.

[0035] More specifically, the first concrete sleeper block 1 and the second concrete sleeper block 2 each have pre-embedded bolt sleeves 11 and 21 on their top surfaces, and threaded positioning holes 12 and 22 extending inward along the length of the sleeper block itself are respectively reserved at their ends. As illustrated in Figure 1, the number of pre-embedded bolt sleeves 11 is preferably two, which are symmetrically arranged on the top surface of the first concrete sleeper block 1 and extend downward, thereby being used to install fasteners and other components; the number of threaded positioning holes 22 is preferably two and distributed on the left and right sides of the threaded positioning holes, more preferably three, and from the longitudinal section of the sleeper, the center line connecting the three threaded positioning holes forms an inverted triangle.

[0036] Please refer to Figure 2. The steel-concrete composite column 3 is preferably formed by pouring self-compacting concrete into a hollow steel tube and curing it, with both ends machined into a threaded structure. In this way, the first concrete sleeper block 1, the second concrete sleeper block 2, and the multiple steel-concrete composite columns 3 are not only kept separate during transportation and storage, but also integrated for installation only after being transported together to the construction site, minimizing the inconveniences that may arise from on-site processing and manufacturing. More specifically, during on-site processing, the distance and geometry between the two concrete sleeper blocks are first adjusted and fixed. Then, the two ends of the multiple steel-concrete composite columns 3 are screwed into the threaded positioning holes 12 and 22 of the first concrete sleeper block 1 and the second concrete sleeper block 2, respectively, and finally locked, thereby obtaining the required steel-concrete composite double-block sleeper.

[0037] Various practical tests have shown that double-block sleepers manufactured, transported, stored, and installed on-site according to the above scheme can effectively increase the ability to maintain the spatial geometry of the sleepers during construction, thus better meeting the bending and torsional resistance requirements of double-block sleepers. Furthermore, in stacking, storage, hoisting, and transportation, it is no longer necessary to rely on the rigidity of the connecting parts to maintain the sleeper's geometry, which greatly improves the operational convenience and work efficiency of factory manufacturing, stacking, storage, and transportation to various construction sites, and is no longer limited by the number of stacking layers, thus saving storage space. Finally, by using a threaded engagement method for positioning and adjusting the sleeper blocks and the steel-concrete composite columns, construction efficiency and convenience are further improved, and subsequent maintenance and inspection are facilitated.

[0038] Technical Solution Two

[0039] According to a second preferred embodiment of the present invention, another type of prefabricated steel-concrete composite double-block sleeper is provided, characterized in that the sleeper includes multiple components that are processed independently of each other, namely a first concrete sleeper block 1 and a second concrete sleeper block 2 configured in pairs, and a plurality of steel-concrete composite columns 3, and these components remain separate in all handling, storage or other stages, and before arriving at the construction site.

[0040] More specifically, the first concrete sleeper block 1 and the second concrete sleeper block 2 each have pre-embedded bolt sleeves 11 and 21 on their top surfaces, and each has a hole (not shown in the figure) extending inward along the length of the sleeper block itself at its end, which replaces the threaded positioning hole in the previous scheme.

[0041] Referring also to Figure 2, the steel-concrete composite column 3 is preferably formed by pouring self-compacting concrete into a hollow steel pipe and curing it, with its outer diameter at the end basically matching the inner diameter of the hole, while maintaining a smooth surface. In this way, the first concrete sleeper block 1, the second concrete sleeper block 2, and the multiple steel-concrete composite columns 3 are not only kept separate during transportation and storage, but also integrated for installation only after being transported together to the construction site, minimizing the various inconveniences that may arise from on-site processing and manufacturing. More specifically, as shown in Figures 3 and 4, during on-site processing, the distance and geometric position between the two concrete sleeper blocks are first adjusted and fixed. Then, the two ends of the multiple steel-concrete composite columns 3 are directly inserted into the threaded positioning holes 12 and 22 of the first concrete sleeper block 1 and the second concrete sleeper block 2, respectively. Finally, adhesive grout is injected into these holes for curing, thereby obtaining the required steel-concrete composite double-block sleeper.

[0042] By replacing the threaded engagement method with a bonding grout curing method, the integrity and structural strength of the final double-block sleeper can be ensured. Construction is convenient and quick, requiring no special production equipment and resulting in low project costs. In addition, the cast-in-place concrete sleeper blocks are basically symmetrical to the vertical axis of the rail, with a smaller interface with the cast-in-place track slab. Furthermore, the sides of the concrete sleeper blocks are preferably designed with a certain slope, and the top corners of the concrete sleeper blocks can be chamfered. This facilitates demolding of the concrete sleeper blocks during the manufacturing process and reduces stress concentration in the concrete.

[0043] In summary, the prefabricated steel-concrete composite double-block sleeper of the present invention can effectively overcome various technical problems encountered in the existing technology in multiple stages such as factory manufacturing, multi-point transportation, centralized storage and on-site construction. It also has a good bonding effect with the track bed slab, strong spatial positioning retention capability and good track stability. In addition, it has the advantages of simple manufacturing process, low cost, reliable quality, flexible specifications and easy maintenance. Therefore, it has high economic and social value and is especially suitable for engineering applications with high construction cycle requirements and limited construction conditions.

[0044] Those skilled in the art will readily understand that the above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Any modifications, equivalent substitutions, and improvements made within the spirit and principles of the present invention should be included within the scope of protection of the present invention.

Claims

------14 / 01 / 2020------(OCR)1. Twin block sleepers consisting of a first concrete sleeper block (1) and a second concrete sleeper block (2) which are arranged in pairs, and a concrete-filled steel pipe column (3) in which the first concrete sleeper block (1) and the second concrete sleeper block (2) each have top surfaces provided with at least one embedded bolt sleeve (11,21) and at least one through hole (12,22) connecting both ends of the first / second concrete sleeper block along the length of the first / second concrete sleeper block; the concrete-filled steel pipe column (3) is constructed by pouring self-compacting concrete into hollow steel pipes and concrete curing; and both ends of the concrete-filled steel pipe column are threaded; and the first concrete sleeper block (1), the second concrete sleeper block (2),A large number of concrete-filled steel tubular columns (3) are separated during the transport and storage process and then transported to the construction site; the distances and geometric shapes and positions of the first and second concrete blocks are adjusted and fixed; both ends of the concrete-filled steel tubular columns (3) are screwed separately into the through holes (12,22) of the first concrete sleeper block (1) and the second concrete sleeper block (2) and are tightened.

2. Twin block sleepers which consist of the first concrete sleeper block (1) and the second concrete sleeper block (2) which are arranged in pairs,and a column of steel tubular filled with concrete(3) in which the first concrete sleeper block(1) and the second concrete sleeper block(2) each consist of a top surface provided with at least one embedded bolt sleeve(11) and at least one through hole connecting both ends of the first / second concrete sleeper block along the length of the first / second concrete sleeper block; the column of steel tubular filled with concrete(3) is constructed by pouring self-compacting concrete into hollow steel tubulars and curing the concrete; and the inner diameter of the through hole is matched to the outer diameter of the ends of the steel tubular column; and the first concrete sleeper block(1), the second concrete sleeper block(2),And a large number of concrete-filled steel tubular columns (3) are separated during the transport and storage process and then transported to the construction site; the distances and geometric shapes and positions of the first and second concrete sleepers are adjusted and fixed; both ends of the concrete-filled steel tubular columns (3) are inserted separately into the through holes of the first concrete sleeper (1) and the second concrete sleeper (2) and the through holes are sealed with mortar.

3. Twin block sleepers of claim 1 or 2 where the first concrete sleeper (1) and the second concrete sleeper (2) are both completely cast in concrete,and reinforcement grids and steel stirrups are provided within the first and second concrete sleeper blocks.

4. Twin block sleeper of claim 3 where both ends of the first concrete sleeper block (1) and the second concrete sleeper block (2) are provided with an angle of inclination of 11:1 to 7:1 and the top corners of the first and second concrete sleeper blocks are chamfered.

5. Twin block sleeper of claim 1 or 2 where the number of steel tubular columns filled with bulk concrete (3) is 2 or 3, when the number of columns is 3, the center of the circle on the ends of the steel tubular columns is 6. Twin block sleepers of claim 5 where the depth of the through hole (12) or through hole is 708 mm and its inner diameter is 45 mm.

7. Twin block sleepers of claim 6 where the number of through holes (12) or through holes is 2 or 3 holes and the distance between them is 150-180 mm. ------------ 1. Twin block sleepers which consist of a first concrete sleeper block (1) and a second concrete sleeper block (2) which are arranged in pairs,and the concrete-filled steel pipe columns (3) in which the first concrete sleeper block (1) and the second concrete sleeper block (2) each have their top surfaces provided with at least one embedded bolt sleeve (11,21) and at least one threading hole (12,22) connecting both ends of the first / second concrete sleeper block along the length of the first / second concrete sleeper block; the concrete-filled steel pipe columns (3) are constructed by pouring self-compacting concrete into hollow steel pipes and curing the concrete; and both ends of the concrete-filled steel pipe columns are threaded; and the first concrete sleeper block (1), the second concrete sleeper block (2), and the concrete-filled steel pipe columns (3) are separated during the transport and storage process and then transported to the construction site; the distance and shape and geographical location of the first and second concrete sleeper blocks are adjusted and fixed; both ends of the concrete-filled steel pipe columns (3) are screwed separately into the threading holes (12,22) of the first concrete sleeper block (1) and the second concrete sleeper block (2) and are fastened together.

2. Twin block sleepers which are assembled together with the first concrete sleeper block (1) and the second concrete sleeper block (2) which are arranged in pairs, and concrete-filled steel pipe columns (3) where the first concrete sleeper block (1) and the second concrete sleeper block (2) each have a top surface provided with at least one embedded bolt sleeve (11) and at least one threading hole connecting both ends of the first / second concrete sleeper block along the length of the first / second concrete sleeper block; concrete-filled steel pipe columns (3) are constructed by pouring self-compacting concrete into hollow steel pipes and curing the concrete; and the inner diameter of the threading hole is matched with the outer diameter of the ends of the steel pipe columns; and the first concrete sleeper block (1), the second concrete sleeper block (2),And a large number of concrete-filled steel tubular columns (3) are separated during the transportation and storage process and then transported to the construction site; the distance and shape and geographical location of the first and second concrete blocks are adjusted and fixed; both ends of the concrete-filled steel tubular columns (3) are screwed separately into the threading holes of the first concrete sleeper (1) and the second concrete sleeper (2) and the threading holes are sealed with mortar.

3. Twin block sleepers of claim 1 or 2 where the first concrete sleeper (1) and the second concrete sleeper (2) are both completely cast in concrete,and reinforcing mesh and steel stirrups are provided within the first and second concrete sleeper blocks.

4. Twin block sleeper of claim 3 where both ends of the first concrete sleeper block (1) and the second concrete sleeper block (2) are provided with an angle of inclination of 11:1 to 7:1 and the top corners of the first and second concrete sleeper blocks are chamfered.

5. Twin block sleeper of claim 1 or 2 where the number of tubular steel columns filled with concrete (3) is 2 or 3, when the number of columns is 3, the centers of the circles on the ends of the tubular steel columns filled with concrete are connected to form an inverted triangle in the cross-section of the sleeper.

6. Twin block sleeper of claim 5 where the depth of the threading hole (12) or through hole is 708 mm and its inner diameter is 45 mm.

7. Twin block sleeper of claim 6 where the number of threading holes (12) or through holes is 2 or 3 holes and the distance between them is 150-180 mm;