Ballastless Track Slab Assembly for Fast Altimetric Adjustment

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Solution Overview

Problem

Existing ballastless permanent way systems face limitations in altimetric adjustments, high construction costs, and time requirements due to the use of traditional prefabricated slabs, which are not adaptable to varying layouts and often require extensive on-site modifications, leading to construction non-compliance and increased costs.

Innovation Solution

A modular system for laying tracks using prefabricated slabs with adjustable fastening elements and a specialized concrete mixture for on-site casting, allowing for rapid installation and adaptation to different infrastructure conditions, including tunnels, stations, and viaducts, with a focus on minimizing on-site adjustments and ensuring high-quality geometric parameters.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Reliability

If traditional prefabricated slabs are used for ballastless permanent way systems, then structural stability and safety are improved, but altimetric adjustment capability deteriorates and construction time increases

Engineering Contradiction:

Improvestructural stabilityVSAvoidconstruction time

Core Design Contradiction:

ReliabilityVSLoss of time

Solution Approach 1:

The patent applies preliminary action by pre-assembling complete track sections with rails, sleepers, and fastening elements on standardized platforms before transport to the site. This allows the majority of construction work to be completed in advance, reducing on-site assembly time while maintaining structural stability through factory-controlled manufacturing processes.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent segments the track system into modular sections that can be independently manufactured, transported, and assembled. Each section includes integrated platforms, sleepers, and fastening elements as discrete units, enabling parallel construction activities and reducing overall construction time without compromising the structural integrity of the complete track system.

Inventive Principle:

Principle #1Segmentation

2Productivity

If traditional prefabricated slabs with fixed dimensions are used, then manufacturing efficiency is improved, but adaptability to varying layouts deteriorates

Engineering Contradiction:

Improvemanufacturing efficiencyVSAvoidlayout adaptability

Core Design Contradiction:

ProductivityVSAdaptability or versatility

Solution Approach 1:

The patent implements dynamics by designing modular platforms with adjustable components that can be reconfigured to accommodate different track geometries, curves, and alignments. The standardized platforms serve as a base that can be dynamically adjusted through interchangeable fastening elements and adjustable sleepers, maintaining manufacturing efficiency while enabling adaptability to varying infrastructure layouts.

Inventive Principle:

Principle #15Dynamics

Solution Approach 2:

The patent applies universality by creating standardized platforms that can serve multiple functions and accommodate different track configurations. These universal platforms can be used in straight sections, curves, and various gradient conditions, reducing the need for custom-manufactured components while maintaining high manufacturing efficiency and enabling widespread adaptability.

Inventive Principle:

Principle #6Universality (Multi-functionality)

3Manufacturing precision

If on-site adjustments are performed with mortars or resins, then altimetric adjustment capability is improved, but construction costs and material usage increase

Engineering Contradiction:

Improvealtimetric adjustment capabilityVSAvoidmaterial usage

Core Design Contradiction:

Manufacturing precisionVSQuantity of substance

Solution Approach 1:

The patent applies preliminary action by pre-adjusting the altitude and geometric parameters of track sections during factory assembly before transport to the site. This eliminates the need for extensive on-site adjustments using mortars or resins, reducing material usage while maintaining manufacturing precision through controlled manufacturing processes and standardized adjustment mechanisms.

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

The patent employs disposable adjustable fastening elements and modular components that can be easily replaced or repositioned on-site without requiring permanent chemical bonding. These temporary adjustment elements provide necessary altimetric adjustments while avoiding the need for large volumes of expensive mortars or resins, reducing both material costs and construction time.

Inventive Principle:

Principle #27Cheap short-living objects (Disposable)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

The system enables rapid installation with high-quality geometric parameters, adaptable to various layouts, reduces construction time, and lowers costs by utilizing prefabricated slabs with adjustable fastening elements and a quick-setting concrete mixture, suitable for both renovation and new line construction.

Implementation Method 1

a quick-setting concrete mixture

Methodology Applied

Scientific EffectHydration: Chemical Bonding

Data Source

PatentEP4301927B1Process for laying tracks for underground, railway and tramway lines

Publication Date: 2026.01.28 OVERAIL SRL

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AI summary

The present invention relates to a process and to a system for laying tracks for ballastless railway and tramway lines, both in tunnel and in surface.