Prefabricated rail ensemble for an embedded rail system, method for forming an embedded rail system and method for manufacturing a prefabricated rail ensemble

Abstract

A prefabricated rail ensemble, a method for forming an embedded rail system and a method for manufacturing a prefabricated rail ensemble. The prefabricated rail ensemble has a rail and an anchoring sheet delimiting at least a portion of each of opposed longitudinal sides, and a polymer compound between the rail and inner faces of the anchoring sheet. The cured polymer compound bonds to the rail and forms a mechanical interlock with the inner face of the anchoring sheet and provides continuous elastic support to the rail. The outer faces of the anchoring sheet are adapted to establish a mechanical bond via the anchoring formations with a binder.

Description

[0001] PREFABRICATED RAIL ENSEMBLE FOR AN EMBEDDED RAIL SYSTEM, METHOD FOR FORMING AN EMBEDDED RAIL

[0002] SYSTEM AND METHOD FOR MANUFACTURING A PREFABRICATED RAIL ENSEMBLE

[0003] The present invention relates to a prefabricated rail ensemble to be embedded in situ in an elongated open-topped channel of a railway track support structure and fixed by a binder to form an embedded rail system, the prefabricated rail ensemble comprising a rail having rail ends and a curable polymer compound, which, when cured, has bonded to the rail and provides continuous elastic support to the rail.

[0004] Such embedded rail systems (ERS) are generally known in the field of railway tracks for e.g. train, tram, metro, crane and other railbound vehicle applications. Often polyurethane based elastomeric compounds are used to obtain the required resilient behaviour as well as provide a reliable structural connection of the rail to the railway track support structure in the absence of other connection members. The embedded rail system is for instance found in level crossings and (steel) bridges.

[0005] In the prior art approach the installation of such an embedded rail system often (but not necessarily) involved the preparation of the outer surface of the steel rail that were to be bonded to the compound by application of a primer on the steel surface. The purpose of the primer is to establish a chemical bond with the curing compound, based on polymerisation. When done properly a very strong and reliable bond is obtained in this manner.

[0006] In situ installation of such an embedded rail system could however give rise to practical problems, often by the fact that installation has to be done in a short time, e.g. during the night when work is done on an existing track. Problems are e.g. encountered when working in wet, moist and / or dust / dirt-laden conditions. Such conditions are bound to have a detrimental effect on the primer, with the result that no bond or an insufficient bond with the compound is obtained. Protocol may even prohibit that the compound is actually poured under certain conditions thus causing undesirable problems such as the availability of the track for railway services. A delay in pouring the compound may then result in the primer become inactive over time, requiring that a new layer of primer is applied. In practice, conditions such as a (heated) tent are often mandatory.

[0007] In EP2845951 a prefabricated rail jacket for coating a rail is disclosed. The jacket envelops the rail and can be prefabricated and installed on site. The jacket is made of an elastomeric material and has a U- shaped profile. Shoulders are provided on each outer side for retaining the jacket in the concrete support or raft in which the rail is intended to be embedded. This shoulder is intended to fix the jacket and indirectly the rail in its housing. It is therefore possible to avoid fixing the rail by metal fasteners to its support. The jacket can thus fulfil the role of the ballast used in the case of conventional tracks and fixes the rail vertically and transversely on and in its rigid support. DE102007003348 discloses a prefabricated sheath for enclosing a railway rail, in particular a tram rail, for installation in a track body. The sheath is used for enclosing rail chamber fillers and for supporting railway rails in track construction and comprises leg sections having ripples or corrugations on its outer sides for engaging with concrete. The sheathed railway rails are installed in a track body without the need to use tension clamps and screw bolts.

[0008] In the systems disclosed in the above documents the jacket or sheath functions as a protective barrier around the rail, having a form-fitting connection with the binder.

[0009] It is an object of the present invention to overcome or at least alleviate the above-mentioned installation problems and difficulties. The present invention achieves this aim by providing a prefabricated rail ensemble according to claim 1 .

[0010] According to the invention a prefabricated rail ensemble is provided, further comprises an anchoring sheet delimiting at least a portion of each of opposed longitudinal sides of the prefabricated rail ensemble, which anchoring sheet is a double-faced fabric sheet with opposed faces, the fabric forming a multitude of anchoring formations over the entire surface of each fabric sheet face and allowing penetration of the curable polymer compound and the binder, such that the curable polymer compound, when cured over time between the rail and inner faces of the anchoring sheet, has formed a mechanical interlock with the anchoring formations on the inner face of the anchoring sheet; and the anchoring formations on the outer faces of the anchoring sheet are adapted to establish a mechanical bond with the binder.

[0011] Such a prefabricated rail ensemble, preferably a one-piece prefabricated rail ensemble, is advantageously fabricated at a location remote from the railway track, preferably indoors in a controlled environment, e.g. in a tent close to the railway track or a remote specialized factory. A conditioned environment with constant temperature and humidity is advantageous for the properties of the polymer compound.

[0012] In embodiments, the curable polymer compound is be poured or casted around the rail. It is also conceivable that the polymer compound is extruded around the rail. The inventive prefabricated rail ensemble advantageously provides a continuous polymer compound around the rail, minimizing the number of joints, and thereby reducing a risk of electrical leak currents.

[0013] In situ the prefabricated rail ensemble is embedded and fixed into an elongated open-topped channel of a railway track support structure, to form an embedded rail system.

[0014] In the application a railway track support structure is often used as an example of an elongate opentopped channel, but other open-topped channels such as concrete slots used in level crossings are also envisaged among other things. According to the invention, the anchoring formations on the outer faces of the anchoring sheet are adapted to establish a mechanical bond with the binder.

[0015] Fixation with a binder, e.g. a cement-based binder, is a commonly applied technique during renovation in situ, and advantageous in that the application of a primer in situ is dispensed with, as well as the use of less common materials as polymer compounds.

[0016] According to the invention, the anchoring sheet is a double-faced fabric sheet with opposed faces, the fabric forming a multitude of anchoring formations over the entire surface of each fabric sheet face and allowing penetration of the curable polymer compound and the binder. The double-faced anchoring sheet is configured for absorbing materials, in particular the curable polymer and the binder penetrating the anchoring sheet.

[0017] During fabrication of the prefabricated rail ensemble the polymer compound penetrates into the inner face of the anchoring sheet, i.e. is absorbed by the fabric anchoring sheet. During installation in situ the binder penetrates into the outer face of the anchoring sheet. As a result, in use the anchoring sheet forms a mechanical interface between the polymer compound which has bonded to the rail and the binder which has bonded to the railway track support structure. As a result, as both the polymer compound and the binder form a continuous mechanical bond with the anchoring sheet, a transfer of stresses and forces takes place between the rail and the railway track support structure via the entire anchoring sheet after installation. This enables a transfer of forces in all directions, including in the longitudinal direction of the rail. This is in particular advantageous during heat-related shrinkage and elongation of steel rails.

[0018] A further possible advantage is that less polymer compound is needed to prepare a prefabricated rail ensemble. In particular when compared to in situ installation of such an embedded rail system, wherein due to the tolerances a larger amount of polymer compound is provided in the elongated open-topped channel of a railway track support structure.

[0019] The anchoring sheet preferably has a sufficient thickness such that the polymer compound does not completely saturate throughout the anchoring sheet. This allows for the binder to establish a mechanical bond via the anchoring formations of the outer face of the anchoring sheet. If the anchoring sheet would be completely saturated by the polymer compound, the anchoring formations on both the inner face and outer face of the anchoring sheet would have formed a mechanical interlock with the polymer compound. In such cases, not according to the invention, the binder which is used during installation in situ will not be able to form a strong mechanical bond with the anchoring formations.

[0020] The fabric of the double-faced fabric anchoring sheet forms a multitude of anchoring formations over the entire surface of each fabric sheet face and allows penetration of the curable polymer compound and the binder. A fabric sheet inherently comprises a high density of anchoring formations, such as fibres or filaments, which enable the mechanical interlocking or bonding with the polymer compound and the binder.

[0021] In embodiments, the anchoring sheet is a sheet with looped anchoring formations, e.g. plastic loops and / or hooks, e.g. similar to a hook-and-loop fastener system. A well-known alternative is the hook- and-mushroom fastener system, wherein a sheet is provided with hooks and the other sheet with mushroom members, which may also be applied in the present invention.

[0022] In embodiments, at least one of the opposed longitudinal sides of the anchoring sheet comprises chamfered upper ends, preferably wherein the chamfered upper ends are angled outward. This allows for an improved transfer of stresses and forces compared to completely vertical opposed longitudinal sides when the prefabricated rail ensemble is installed in situ.

[0023] In embodiments, the sides of the prefabricated rail ensemble delimited by the anchoring sheet are nonvertical. For example, the sides are (partially) tapered upwards or (partially) tapered downwards. It is also conceivable that the sheet is provided with one or more curvatures, e.g. following the contour of a rail. Such a shape provides a form-fit in a vertical direction, and attributes to fixation of the embedded rail system in use, and in particular to the improved resistance against forced in a vertical direction.

[0024] According to the invention, the anchoring sheet delimits at least a portion of each of the opposed longitudinal sides of the prefabricated rail ensemble. Preferably, the entire length of the prefabricated rail ensemble is delimited by the anchoring sheet. Advantageously, but not necessarily the entire height of the cured polymer compound part of prefabricated rail ensemble is delimited by the anchoring sheet. In embodiments the anchoring sheet delimits also at least a portion of the bottom of the prefabricated rail ensemble.

[0025] In embodiments, the anchoring sheet is of a one-piece structure defining a trough / channel, delimiting both opposed longitudinal sides and the bottom of the prefabricated rail ensemble.

[0026] The anchoring sheet can be a single layer sheet or a multilayer sheet. In embodiments wherein the anchoring sheet is a multilayer sheet, optionally a central layer is provided that is substantially impenetrable for the polymer compound and / or the binder. For example, the multilayer sheet can have layers comprising different densities, i.e. fibre densities, or a different thickness based on the polymer or binder to be absorbed by the sheet.

[0027] The double-faced fabric anchoring sheet can be woven and / or non-woven, e.g. a needle punched nonwoven fabric, e.g. a geotextile. Advantageously, the anchoring sheet is a plastic sheet (PA, PE, PP, EVA, etc). The anchoring sheet advantageously has a thickness of 1 -5mm, e.g. 3,5mm. Preferably the double-faced fabric anchoring sheet has openings therein allowing penetration of the curable polymer compound and the binder. Possibly, in a multilayer sheet, penetration between layers is allowed thus attributing to the mechanical interlock.

[0028] The rail of the prefabricated rail ensemble is preferably part of a railway track. Commonly, the rail is a steel rail. In embodiments, the rail has a rail head, a vertical web, and a foot broader than the vertical web. Other rail designs are well known in the art.

[0029] In embodiments, the length of the rail Lr exceeds the length Lp of the polymer compound and anchoring sheets of the prefabricated rail ensemble, e.g. 50 cm at each end. The prefabricated rail ensembles thus have two rail ends exceeding the length Lp of the polymer compound and anchoring sheets of the prefabricated rail ensemble at both ends. This enables welding of the rail ends together, in particular after positioning of the prefabricated rail ensemble in situ.

[0030] The rail can have a length in the order of 700 -2000mm. Also rails having a length in the order of 15-25 meter are common, and even rails having a length of 150-200 meter, in particular 180m. Fortramway rails a length in the order of 10-30 meter is common, in particular a length of 18 meter. For railways a length of 90 - 300 meter is common, in particular a length of 180 meter.

[0031] In embodiments, the rail of the prefabricated rail ensemble can be a curved rail. This enables the use of prefabricated rail ensembles during installation of curved railway sections.

[0032] In embodiments, a primer has been applied to the outer surface of the rail that were to be bonded to the polymer compound. The purpose of the primer is to establish a chemical bond with the polymer compound, based on polymerisation. When done properly a very strong and reliable bond is obtained in this manner.

[0033] In embodiments, the prefabricated rail ensemble further comprises one or more filler blocks or filling elements provided on opposed sides of the rail, e.g. on opposed sides of the web of the rail. Optionally, tubes are provided in the filler blocks, to allow the passage of cables therethrough.

[0034] In embodiments, the head and the foot of the rail are broader than the web, and filler blocks are clamped between the head and the foot. Possibly, filler blocks are made of concrete or a foam material, preferably a rigid foam material, preferably polyurethane rigid foam or EPP. Possibly a primer is applied to the filler blocks prior to providing the polymer compound. In the prefabricated rail ensemble, advantageously the cured polymer compound has bonded to the filer blocks.

[0035] In embodiments, the prefabricated rail ensemble further comprises wedges to position the filler blocks, which wedges are e.g. made of polymer or cork. In embodiments, the prefabricated rail ensemble further comprises an elastic resilient (padded) mat or strip, placed under the rail to provide damping. The mat is advantageously made of a micro cellular elastomer. A preferred material for such a mat is commercially known as Trackelast®. An advantage of the provision of such an elastic resilient mat is increased damping, providing elasticity. With such elastic resilient mats, the elasticity of a prefabricated rail ensembles can be tuned in that mats having distinct elasticity can be provided, or no mat at all.

[0036] It is both conceivable that the elastic resilient mat is provided directly against the rail, and a configuration wherein there was an open space between the rail and the mat prior to the provision of the polymer compound, which is then filled with the polymer compound. Possibly, but not necessarily, shims such as polymer shims are provided between the mat and the rail.

[0037] In embodiments, an anchoring sheet is provided at the bottom of the mat. In embodiments, primer is applied to the mat.

[0038] Optionally, the mat has lateral flanges clamped on the sides of the (foot of the) rail.

[0039] In embodiments, the mat is made of elements, e.g. having dimensions in the order of 1100x165x7mm. Advantageously, in a prefabricated rail ensemble comprising elastic resilient mats, the cured polymer compound has bonded with the mat.

[0040] In embodiments, the prefabricated rail ensemble further comprises one or more void forming members such as tubes. Advantageously, such void forming members allow the passage of an (electric) cable therethrough. The void forming members may be provided in filler blocks but can also be provided a distance spaced from the rail prior to providing the polymer compound. Possibly, primer is applied to the void forming members.

[0041] Advantageously, in a prefabricated rail ensemble comprising void forming members, the cured polymer compound has bonded with the void forming members.

[0042] In embodiments, the prefabricated rail ensemble further comprises a (steel or polymer) reinforcement profile, e.g. provided at an upper corner of the prefabricated rail ensemble. Advantageously, the reinforcement profile is bonded to an upper end of an outer face of the anchoring sheet. Alternatively, the reinforcement profile is provided above an upper end of (an outer face of) the anchoring sheet. Possibly a primer is applied to the reinforcement profile prior to providing the polymer compound.

[0043] Advantageously, in a prefabricated rail ensemble comprising a reinforcement profile, the cured polymer compound has bonded to the reinforcement profile.

[0044] In embodiments, the railway track support structure comprises one or two parallel open-topped channels. Commonly such a channel has a height between 100 - 500 mm, in particular in the order of 100-250 mm, more particular in the order of 300 mm, and a width in the order of 100 - 650 mm, more particular in the order of 100-300 mm. The dimensioning of the channel depends on the type of rail used and the rail dimensions. For example, for a tramway rails a height and width of 200mm by 200mm is commonly found.

[0045] The inventive prefabricated rail ensemble is suitable for new embedded rail systems. The prefabricated rail ensemble is then first positioned at the desired location, e.g. using an installation portal. Then, the ensemble is embedded in a channel of the railway track support structure by casting a binder, e.g. made of concrete. For example, in such embodiments, the railway track support structure is a concrete support structure, also referred to as a slab, that is cast using a suitable formwork. In embodiments, the slab is a level crossing slab, preferably a monolithic level crossing slab.

[0046] The inventive prefabricated rail ensemble is equally suitable for renovating an existing embedded rail systems. After removal of an old rail or rail ensemble a channel is created and cleaned. Then the inventive prefabricated rail ensemble is placed in the channel and a binder is used to fix the prefabricated renovation rail ensemble in situ.

[0047] In embodiments, an additional anchoring sheet, such as a fabric sheet, is attached to the elongated open-topped channel or trough of a railway track support structure, e.g. using an epoxy adhesive.

[0048] In embodiments, the dimensions of the prefabricated rail ensemble are a width of 100-400, e.g. 200 mm, and a height of 100-300, e.g. 150 mm.

[0049] In embodiments, the curable polymer compound is a polymer resilient binding compound, e.g. a polyurethane based compound, e.g. the compound commercially known as Corkelast®. Other suitable polymers are silyl-modified polymers (SMP; also known as silane-modified polymers, modified-silane polymers, MS polymers, silane-terminated polymers, etc.), which are polymers terminating with a silyl group. In embodiments of the prefabricated rail ensemble, the polymer compound is also provided below the rail. The polymer compound provides a continuous elastic support, e.g. a vertical and / or horizontal support.

[0050] Additional advantages of a curable polymer compound around the rail, in particular a steel rail, are that it provides both electrical insulation an prevents the ingress of water.

[0051] In embodiments, the binder is a cement-based binder, such as a fixation grout, which has the advantage of being relatively cheap. Alternatively, a polymer-based binder is also conceivable, e.g. an epoxy-based binder. In particular in new embedded rail systems, a cement-based railway track support structure in the form of concrete is used. In particular in renovated embedded rail systems, a cementbased binder comprising mortar is used. The invention also relates to a prefabricated rail ensemble to be embedded and fixed in situ in an elongated open-topped channel of a railway track support structure to form an embedded rail system, the prefabricated rail ensemble comprising: a rail having two rail ends, an anchoring sheet delimiting at least a portion of each of the opposed longitudinal sides of the prefabricated rail ensemble, which anchoring sheet is double-faced in that opposed faces thereof are each provided with a multitude of anchoring formations, a polymer compound which is cured between the rail and inner faces of the anchoring sheet so that the cured polymer compound o has bonded to the rail and o has formed a mechanical interlock with the inner face of the anchoring sheet and o provides continuous elastic support to the rail, the outer faces of the anchoring sheet being adapted to establish a mechanical bond via the anchoring formations with the railway track support structure, e.g. via a binder.

[0052] This prefabricated rail ensemble can be combined with any of the embodiments and features as described above. Unless explicitly stated otherwise, the embodiments disclosed herein are not mutually exclusive and may be combined in any technically meaningful manner. The invention is not limited to the specific examples provided, and modifications or variations falling within the scope of the prefabricated rail ensemble are likewise envisaged.

[0053] The present invention further relates to an embedded rail system comprising a railway track support structure with multiple prefabricated rail ensembles according to the invention positioned in line, wherein rail ends have been welded together, and preferably primer has been applied to the welded together rail ends, wherein a trough-shaped anchoring sheet has been provided below the welded together rail ends, wherein a polymer compound has been provided in a void between the anchoring sheet and welded rail ends, surrounding the welded rail ends, the multiple prefabricated rail ensembles being embedded and fixed by a binder in situ.

[0054] The present invention further relates to a method for forming an embedded rail system comprising the steps of: providing multiple prefabricated rail ensembles, each prefabricated rail ensemble comprising o a rail, o an anchoring sheet delimiting at least a portion of each of the opposed longitudinal sides of the prefabricated rail ensemble, which anchoring sheet is double-faced in that opposed faces thereof are provided with a multitude of anchoring formations, o a polymer compound which cures over time between the rail and inner faces of the anchoring sheet so that the cured polymer compound has bonded to the rail and ■ has formed a mechanical interlock with the inner face of the anchoring sheet and

[0055] ■ provides continuous elastic support to the rail, o the outer faces of the anchoring sheet being adapted to establish a mechanical bond via the anchoring formations with the railway track support structure, e.g. via a binder, positioning multiple prefabricated rail ensembles in line with each other in situ, e.g. in an elongated open-topped channel of a railway track support structure, welding the rail ends together, preferably applying primer to the welded together rail ends, providing a trough-shaped open-topped anchoring sheet below the welded together rail ends, providing a polymer compound in the trough between the anchoring sheet and welded rail ends, surrounding the welded rail ends, embedding the prefabricated rail ensembles, either by casting the railway track support structure or by providing a binder into the elongated open-topped channels with the prefabricated rail ensembles.

[0056] The invention further relates to a method for forming an embedded rail system comprising the steps of: providing multiple prefabricated rail ensembles, each prefabricated rail ensemble comprising a rail having rail ends and a curable polymer compound, which, when cured, has bonded to the rail and provides continuous elastic support to the rail; and further comprises an anchoring sheet delimiting at least a portion of each of opposed longitudinal sides of the prefabricated rail ensemble, which anchoring sheet is a double-faced fabric sheet with opposed faces, the fabric forming a multitude of anchoring formations over the entire surface of each fabric sheet face and allowing penetration of the curable polymer compound and the binder, wherein the cured polymer compound has formed a mechanical interlock with the anchoring formations on the inner face of the anchoring sheet; and positioning multiple prefabricated rail ensembles in line with each other in situ in an elongated open-topped channel of a railway track support structure, welding the rail ends together, preferably applying primer to the welded together rail ends, providing a trough-shaped open-topped anchoring sheet defining a trough below the welded together rail ends, providing a polymer compound in the trough between the anchoring sheet and welded rail ends, surrounding the welded rail ends, embedding the prefabricated rail ensembles by providing a binder into the elongated opentopped channel with the prefabricated rail ensembles, whereby the anchoring formations on the outer faces of the anchoring sheet establish a mechanical bond with the binder.

[0057] In embodiments, for the positioning of the prefabricated rail ensembles use is made of support and alignment portals from which the rails are kept suspended. For example, during bottom-up positioning of the prefabricated rail ensemble used is made of shims or wedges, while in top-down positioning of the prefabricated rail ensemble use is made of alignment portals. The present invention further relates to a method for manufacturing a prefabricated rail ensemble to be embedded and fixed in situ in an elongated open-topped channel of a railway track support structure to form an embedded rail system, comprising the steps of: providing a mould defining a trough having opposed longitudinal sides providing an anchoring sheet which anchoring sheet is double-faced in that opposed faces thereof are provided with a multitude of anchoring formations, the anchoring sheet(s) delimiting at least a portion of each of the opposed longitudinal sides, the outer faces of the anchoring sheet being adapted to establish a mechanical bond via the anchoring formations with the railway track support structure, e.g. via a binder; providing a rail in the trough providing a polymer compound which cures overtime in the mould, at least between the steel rail and inner faces of the anchoring sheet so that the cured polymer compound o bonds to the rail and o forms a mechanical interlock with the inner side of the anchoring sheet and o provides continuous elastic support to the rail.

[0058] The present invention further relates to a method for manufacturing a prefabricated rail ensemble to be embedded and fixed in situ in an elongated open-topped channel of a railway track support structure to form an embedded rail system, comprising the steps of: providing an anchoring sheet shaped as a trough having opposed longitudinal side, which anchoring sheet is double-faced in that opposed faces thereof are provided with a multitude of anchoring formations, the anchoring sheet(s) delimiting at least a portion of each of the opposed longitudinal sides, the outer faces of the anchoring sheet being adapted to establish a mechanical bond via the anchoring formations with the railway track support structure, e.g. via a binder; providing a rail in the trough; providing a polymer compound which cures over time in the trough, at least between the steel rail and inner faces of the anchoring sheet so that the cured polymer compound o bonds to the rail and o forms a mechanical interlock with the anchoring sheet and o provides continuous elastic support to the rail.

[0059] The invention further relates to a method for manufacturing a prefabricated rail ensemble to be embedded in situ in an elongated open-topped channel of a railway track support structure and fixed by a binder to form an embedded rail system, comprising the steps of: providing a mould defining a trough having opposed longitudinal sides; providing an anchoring sheet which anchoring sheet is a double-faced fabric sheet with opposed faces, the fabric forming a multitude of anchoring formations over the entire surface of each fabric sheet face and allowing penetration of a curable polymer compound and the binder, the anchoring sheet(s) delimiting at least a portion of each of opposed longitudinal sides, the anchoring formations on the outer faces of the anchoring sheet being adapted to establish a mechanical bond with the binder; providing a rail having rail ends in the trough; providing a curable polymer compound which cures over time in the mould, at least between the rail and inner faces of the anchoring sheet so that the cured polymer compound o bonds to the rail and o forms a mechanical interlock with the anchoring formations on the inner face of the anchoring sheet and provides continuous elastic support to the rail.

[0060] The trough in which the rail is provided is either defined by a mould or by the anchoring sheet. Either method for manufacturing a prefabricated rail ensemble can be carried out in an upright orientation, in which the trough is oriented with the bottom down, and the rail oriented upright. The polymer compound is provided in the trough, surrounding the rail, while leaving the head of the rail uncovered.

[0061] Alternatively, in case the trough is defined by a mould, it is possible to provide the rail oriented upside down. Optionally, an elastic resilient mat is provided on top of the rail during manufacturing. Filler components are provided to leave the head of the rail uncovered. The polymer compound is provided in the trough, surrounding the rail. After curing of the polymer compound, the ensemble is turned upside down and the mould and filler components are removed, resulting in the prefabricated rail ensemble according to the present invention, wherein the head of the rail is uncovered.

[0062] The invention is further elucidated in relation to the drawings, in which:

[0063] Fig. 1 is a perspective view of a prefabricated rail ensemble according to the invention;

[0064] Fig. 2 is a cross section of the prefabricated rail ensemble of fig. 1 ;

[0065] Fig. 3 is a perspective view of a railway track support structure with the prefabricated rail ensemble of fig. 1 ,

[0066] Fig. 4 is a cross section of the embedded rail system of fig. 3;

[0067] Fig. 5 is a perspective view of an alternative prefabricated rail ensemble according to the invention; Fig. 6 is a perspective view of an alternative railway track support structure with a prefabricated rail ensemble,

[0068] Fig. 7 is a cross section of the embedded rail system of fig. 6;

[0069] Fig. 8 is a cross section of an alternative embedded rail system with a prefabricated rail ensemble; Fig. 9 is a cross section of an alternative embedded rail system with a prefabricated rail ensemble; Fig. 10 is a cross section of an alternative embedded rail system with a prefabricated rail ensemble;

[0070] Fig. 11 is a cross section of an alternative embedded rail system with a prefabricated rail ensemble;

[0071] Fig. 12 is a cross section of an alternative embedded rail system with a prefabricated rail ensemble;

[0072] Fig. 13 is a cross section of an alternative embedded rail system with a prefabricated rail ensemble;

[0073] Fig. 14 is a cross section of an alternative embedded rail system with a prefabricated rail ensemble. Figs. 1-4 show a prefabricated rail ensemble 10, which in figs. 3 and 4 is embedded and fixed in situ in an elongated open-topped channel 21 of a railway track support structure to form an embedded rail system 20.

[0074] The prefabricated rail ensemble 10 comprises a rail 1 , which is preferably part of a railway track. Commonly, the rail is a steel rail. In the shown embodiment, the rail 1 has a rail head 1a, a vertical web 1 b, and a foot 1 c broader than the vertical web 1 b. Other rail designs are well known in the art.

[0075] Here, as preferred, the length of the rail Lr exceeds the length Lp of the polymer compound and anchoring sheets of the prefabricated rail ensemble 10 at each end. The prefabricated rail ensemble 10 thus has two rail ends T. 1” exceeding the length Lp of the polymer compound and anchoring sheets of the prefabricated rail ensemble at both ends. This enables welding of the rail ends together, in particular after positioning of the prefabricated rail ensemble in situ.

[0076] The prefabricated rail ensemble 10 comprises an anchoring sheet 2. As visible in fig. 1 , the length of the prefabricated rail ensemble 10 is delimited by the anchoring sheet 2.

[0077] As visible in fig. 2, here the anchoring sheet is a one-piece sheet defining a trough, comprising sides 2a, 2b delimiting each of the opposed longitudinal sides of the prefabricated rail ensemble, and a bottom 2c delimiting the bottom of the prefabricated rail ensemble. The anchoring sheet 2 is doublefaced in that opposed inner face 2i and outer face 2u thereof are provided with a multitude of anchoring formations.

[0078] In the shown embodiment, the prefabricated rail ensemble further comprises filler blocks 5a, 5b, here provided on opposed sides of the web 1 b of the rail. Optionally, tubes are provided in the filler blocks, to allow the passage of cables therethrough. This is e.g. visible in fig. 10.

[0079] In this embodiment wherein the head 1a and the foot 1c of the rail are broader than the web 1 b, filler blocks 5a, 5b are clamped between the head and the foot.

[0080] In the shown embodiment, the prefabricated rail ensemble 10 further comprises an elastic resilient mat 6, placed under the rail to provide damping. The mat is advantageously made of a micro cellular elastomer. In the shown configuration an open space is present between the rail 1 and the mat 6, prior to the provision of a polymer compound, which has been filled with the polymer compound.

[0081] The prefabricated rail ensemble further comprises a curable polymer compound 3 which has cured over time between the rail 1 and inner faces 2i of the anchoring sheet so that the cured polymer compound o has bonded to the rail 1 and o has bonded to the filler blocks 5a, 5b, and o has bonded to the elastic resilient mat 6, and o has formed a mechanical interlock with the inner face 2i of the anchoring sheet and o provides continuous elastic support to the rail 1 .

[0082] The outer faces 2u of the anchoring sheet 2 are adapted to establish a mechanical bond via the anchoring formations with the binder 22.

[0083] In figs. 3 and 4 an embedded rail system 20 comprising a railway track support structure with a prefabricated rail ensemble 10 according to the invention is shown. This is a new embedded rail system, to be installed as a new system.

[0084] In fig.5 a perspective view of an alternative prefabricated rail ensemble according to the invention is shown. The protruding rail end 1 ’ of rail 1 is visible. Furthermore the configuration of anchoring sheet 2, polymer compound 3 and mat 6 is similar. Filler blocks are not present in this embodiment.

[0085] In figs.6 and 7 a perspective view and a cross-sectional view of an alternative prefabricated rail ensemble 10 according to the invention is shown. Here, first the prefabricated rail ensemble 10 is made. The anchoring sheet 2 is shaped such that it follows the contour of the rail 1 . Between the anchoring sheet 2 and the rail 1 a polymer compound 3 is provided. Subsequently, the railway track support structure is provided around the prefabricated rail ensemble, leaving the upper end of the rail 1 uncovered.

[0086] In the alternative embedded rail system 20 shown in cross section in figure 8, the prefabricated rail ensemble 10 does not comprise filler blocks but is provided with tubes 8, here two at opposed sides of the rail, to allow the passage of cables and the like. The rail 101 shown in this embodiment has an alternative design. Furthermore, in the embodiment of fig. 8 it is visible that one of the longitudinal sides 2a of the prefabricated rail ensemble 10 is higher than the opposed longitudinal side 2b. In this embodiment, also a mat 6 is provided. Additionally, in this figure chamfered edges 23 are shown. Here the chamfered edges are outward chamfered edges. This way the embedded rail system 20 provides resistance to both horizontal and vertical forces.

[0087] In the embodiments of figs. 9 and 10 the prefabricated rail ensemble is embedded in an existing renovated railway track support structure, in which an elongated open-topped channel 221 has been created. In the channel 221 in fig. 10 reinforcements 223 are positioned in the channel. The reinforcements shown in the figure are steel bulb profiles. These form a part of the railway track support structure and provide additional support which is desired for crossings, e.g. level crossings, and help with transferring forces during the passing of road traffic.

[0088] The prefabricated rail ensemble 210 in fig. 9 comprises a rail 211 , anchoring sheets 212 and a cured polymer compound 213. The anchoring sheets are provided tapering in an upward direction. In this embodiment, the anchoring sheets delimit only portions of the opposed longitudinal sides of the prefabricated rail ensemble. To position the prefabricated rail ensemble 210 in the channel 221 , wedges 218 are provided. Once positioned, a binder 219, e.g. a cement-based binder is poured into the channels 221 to fix the prefabricated rail ensemble 210 in the channel 221.

[0089] The prefabricated rail ensemble 250 in fig. 10 comprises a rail 251 , an anchoring sheet 252 and a cured polymer compound 253. The anchoring sheet 252 delimits the entire prefabricated rail ensemble 250. The prefabricated rail ensemble 250 further comprises tube spacers 255a, 255b, provided at opposite sides of the rail 251 . The tube spacers 255a, 255b are positioned by wedges 256a, 256b, prior to providing the polymer compound 253. Inside the tube spacers 255a, 255b are provided tubes 258a, 258b for cables or the like. To position the prefabricated rail ensemble 250 in the channel 221 , positioning elements 240a, 240b, 240c are provided. Once positioned, a binder 219, e.g. a cementbased binder is poured into the channels 221 to fix the prefabricated rail ensemble 250 in the channel 221 . In fig. 10 furthermore the binder 245a, 245b, for example mortar or concrete, is visible, sealing the upper ends of the channel between the prefabricated rail ensemble 250 and the reinforcements 223.

[0090] Fig. 11 is a cross section of yet an alternative embedded rail system with a prefabricated rail ensemble 300, comprising a rail 301 , anchoring sheets 302a, 302b, filler blocks 305a, 305b and a cured polymer compound 303. The anchoring sheets 302a, 302b delimit portions of the opposed longitudinal sides of the prefabricated rail ensemble 300 and have a tapered configuration. This allows for both a form-fitting anchoring as well as a mechanical bonding by means of the anchoring sheet of the prefabricated rail ensemble 300 in a railway track support structure.

[0091] Figs. 12 and 13 are a cross sections of alternative embedded rail systems 310, 320 are shown. Similar to the embodiment of fig. 10, the prefabricated rail ensembles 310, 320 are embedded in a newly constructed railway track support structure in which an elongated open-topped channel has been created (not shown), using a binder 340.

[0092] The prefabricated rail ensemble 310 comprises a rail 311 and opposed anchoring sheets 312a, 312b, filler blocks 315a, 315b and a polymer compound 313. The anchoring sheets 302a, 302b delimit portions of the opposed longitudinal sides of the prefabricated rail ensemble 300 and have a tapered configuration. This allows for both a form-fitting anchoring as well as a mechanical bonding by means of the anchoring sheet of the prefabricated rail ensemble 310 in a railway track support structure.

[0093] The prefabricated rail ensemble 320 comprises a rail 321 and anchoring sheet 322, filler blocks 325a, 325b and a cured polymer compound 323. The anchoring sheet 322 delimits the opposed longitudinal sides and bottom of the prefabricated rail ensemble 320.

[0094] In the embodiments of figs. 12 and 13, the prefabricated rail ensembles 310, 320 further comprise a (steel or polymer) reinforcement profile 318a, 318b and 328a, 328b respectively, provided at an upper corner of the prefabricated rail ensemble, in particular adhesively bonded to an upper end of an outer face of the anchoring sheets. The embodiment of fig. 14 shows another alternative embodiment of a prefabricated rail ensemble 330 comprising a rail 331 , an anchoring sheet 332, and, filler blocks 333a, 333b. On the outer side of the anchoring sheet 332 a reinforcement profile 334 comprising a hook 335 is installed. Which reinforcement profile is configured for providing additional anchoring and resistance to displacement during operation of the prefabricated rail ensemble during operation, for example during crossing of road traffic over the prefabricated rail ensemble once embedded in a rail system. Preferably the reinforcement profile 334 is a steel reinforcement profile. The profile can be adhesively bonded to the anchoring sheet 332.

Claims

CLAIMS1. Prefabricated rail ensemble (10) to be embedded in situ in an elongated open-topped channel (21) of a railway track support structure and fixed by a binder (22) to form an embedded rail system (20), the prefabricated rail ensemble comprising a rail (1) having rail ends and a curable polymer compound (3), which, when cured, has bonded to the rail and provides continuous elastic support to the rail; characterised in that the prefabricated rail ensemble further comprises an anchoring sheet (2) delimiting at least a portion of each of opposed longitudinal sides of the prefabricated rail ensemble, which anchoring sheet is a double-faced fabric sheet with opposed faces (2i, 2u), the fabric forming a multitude of anchoring formations over the entire surface of each fabric sheet face and allowing penetration of the curable polymer compound and the binder, such that the curable polymer compound (3), when cured overtime between the rail and inner faces (2i) of the anchoring sheet, has formed a mechanical interlock with the anchoring formations on the inner face of the anchoring sheet; and the anchoring formations on the outer faces (2u) of the anchoring sheet are adapted to establish a mechanical bond with the binder (22).

2. Prefabricated rail ensemble according to the preceding claim, wherein the anchoring sheet is a non-woven fabric sheet, e.g. a needle punched non-woven fabric, e.g. a geotextile.

3. Prefabricated rail ensemble according to any of the preceding claims, wherein at least one of the opposed longitudinal sides has a chamfered upper end, preferably an outward chamfered upper end.

4. Prefabricated rail ensemble according one or more of the preceding claim, wherein the sides of the prefabricated rail ensemble delimited by the anchoring sheet are non-vertical, e.g. are tapered (upwards or downwards) or comprise one or more curvatures, e.g. following the contour of a rail.

5. Prefabricated rail ensemble according to one or more of the preceding claims, wherein the anchoring sheet delimits at least a portion of the bottom (2c) of the prefabricated rail ensemble.

6. Prefabricated rail ensemble according to one or more of the preceding claims, wherein the anchoring sheet is of a one-piece structure defining a trough.

7. Prefabricated rail ensemble according to one or more of the preceding claims, wherein the anchoring sheet is a multilayer sheet, e.g. having multiple layers, e.g. with openings therein allowing penetration of the curable polymer compound and the binder.

8. Prefabricated rail ensemble according to one or more of the preceding claims, wherein the length of the rail Lr exceeds the length Lp of the polymer compound and anchoring sheet of the prefabricated rail ensemble, preferably defining two rail ends (1 ’, 1”) exceeding the length Lp of thepolymer compound and anchoring sheet of the prefabricated rail ensemble at both ends to enable welding of rail ends together.

9. Prefabricated rail ensemble according to one or more of the preceding claims, wherein the prefabricated rail ensemble further comprises an elastic resilient mat (6), e.g. placed under the rail to provide damping.

10. Prefabricated rail ensemble according to the preceding claim, wherein the anchoring sheet is provided at the bottom of the mat (6).11 . Prefabricated rail ensemble according to one or more of the preceding claims, wherein the prefabricated rail ensemble further comprises a reinforcement profile (223, 318a, 318b, 328a, 328b, 334), e.g. provided at an upper corner of the prefabricated rail ensemble.

12. Embedded rail system comprising a railway track support structure with multiple prefabricated rail ensembles according to one or more of the preceding claims positioned in line, wherein rail ends have been welded together, and preferably primer has been applied to the welded together rail ends, wherein a trough-shaped anchoring sheet has been provided below the welded together rail ends, wherein a polymer compound has been provided in a void between the anchoring sheet and welded rail ends, surrounding the welded rail ends, the multiple prefabricated rail ensembles being embedded and fixed by a binder in situ.

13. Method for forming an embedded rail system comprising the steps of: providing multiple prefabricated rail ensembles, each prefabricated rail ensemble comprising a rail (1) having rail ends and a curable polymer compound (3), which, when cured, has bonded to the rail and provides continuous elastic support to the rail; and further comprises an anchoring sheet (2) delimiting at least a portion of each of opposed longitudinal sides of the prefabricated rail ensemble, which anchoring sheet is a double-faced fabric sheet with opposed faces (2i, 2u), the fabric forming a multitude of anchoring formations over the entire surface of each fabric sheet face and allowing penetration of the curable polymer compound and the binder, wherein the cured polymer compound (3) has formed a mechanical interlock with the anchoring formations on the inner face of the anchoring sheet; and positioning multiple prefabricated rail ensembles in line with each other in situ in an elongated open-topped channel of a railway track support structure, welding the rail ends together, preferably applying primer to the welded together rail ends, providing a trough-shaped open-topped anchoring sheet defining a trough below the welded together rail ends, providing a polymer compound in the trough between the anchoring sheet and welded rail ends, surrounding the welded rail ends,embedding the prefabricated rail ensembles by providing a binder into the elongated opentopped channel with the prefabricated rail ensembles, whereby the anchoring formations on the outer faces (2u) of the anchoring sheet establish a mechanical bond with the binder (22).

14. Method according to the preceding claim, wherein for the positioning of the prefabricated rail ensembles use is made of support and alignment portals from which the rails are kept suspended.

15. Method for manufacturing a prefabricated rail ensemble to be embedded in situ in an elongated open-topped channel of a railway track support structure and fixed by a binder (22) to form an embedded rail system, comprising the steps of: providing a mould defining a trough having opposed longitudinal sides; providing an anchoring sheet which anchoring sheet is a double-faced fabric sheet with opposed faces (2i, 2u), the fabric forming a multitude of anchoring formations over the entire surface of each fabric sheet face and allowing penetration of a curable polymer compound and the binder, the anchoring sheet(s) delimiting at least a portion of each of opposed longitudinal sides, the anchoring formations on the outer faces (2u) of the anchoring sheet being adapted to establish a mechanical bond with the binder (22); providing a rail having rail ends in the trough; providing a curable polymer compound which cures over time in the mould, at least between the rail and inner faces of the anchoring sheet so that the cured polymer compound o bonds to the rail and o forms a mechanical interlock with the anchoring formations on the inner face of the anchoring sheet and o provides continuous elastic support to the rail.

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