Ballastless Track Slab Bonding via Self-Compacting Concrete
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Solution Overview
Problem
Existing ballastless track systems face issues with complex construction, maintenance, and durability due to splitting and warping of track slabs, especially in high-speed railway applications, where stability and riding quality are compromised.
Innovation Solution
A ballastless track system featuring a base, track slab, poured-field layer formed by self-compacting concrete or emulsified asphalt cement mortar with a steel bar structure, and integrated rail-seats, which enhances mechanical properties and simplifies construction and maintenance by forming a firm composite structure with improved bonding and adaptability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a unit ballastless track structure with a circular convex barricade is used, then the track slab can be installed with explicit force bearing and transmission, but the construction becomes tedious and complex
Solution Approach 1:
The patent removes the circular convex barricade from the track structure, extracting the complex component that caused construction difficulties. The force bearing and transmission functions are maintained through the track slab and poured-field layer combination, eliminating the need for the separate convex barricade structure.
Solution Approach 2:
The patent merges the functions of the track slab and poured-field layer into an integrated composite structure. The poured-field layer is poured directly between the track slabs without requiring the convex barricade, combining the support and force transmission functions into a unified structure.
2Ease of manufacture
If track slabs are laid with asphalt mortar poured-field layer, then the track structure can be formed, but the track slab may split from the poured-field layer and warp over time
Solution Approach 1:
The patent changes the material parameter of the poured-field layer from asphalt mortar to self-compacting concrete. This material substitution improves the bonding strength and durability, preventing the track slab from splitting and warping while maintaining ease of construction.
Solution Approach 2:
The patent uses self-compacting concrete as a composite material for the poured-field layer, which provides superior bonding characteristics and mechanical properties compared to traditional asphalt mortar. This composite material ensures long-term stability and prevents splitting and warping.
3Manufacturing precision
If a longitudinally connected ballastless track slab is used, then the track can be laid with high precision, but the connection structure becomes complicated and environmental adaptability deteriorates
Solution Approach 1:
The patent segments the track into unit sections with track slabs spaced apart, rather than continuously connecting them. This segmentation simplifies the connection structure and improves environmental adaptability while maintaining the precision of track laying through the standardized spacing and positioning of individual slabs.
4Ease of manufacture
If a double-block ballastless track structure with poured-in-place roadbed slabs is used, then the construction cost is reduced, but the roadbed slab cracks are hard to control
Solution Approach 1:
The patent changes the material composition and curing parameters of the roadbed slab to improve crack control. By using self-compacting concrete with optimized water-cement ratios and curing conditions, the roadbed slab achieves better crack resistance while maintaining cost-effectiveness.
Data Source
AI summary
A ballastless track system comprises a base; a track slab arranged above the base; a poured-field layer arranged between the base and the track slab, the poured-field layer being formed by filling self-compacting concrete, emulsified asphalt cement mortar or resin mortar, and the inside of the poured-field layer being of a steel bar structure; a connecting piece, the first end of the connecting piece extending into the track slab, and the second end of the connecting piece extending into the poured-field layer; and two rows of rail-seat arranged on the track slab in parallel; and rails arranged on the rail-seat. The ballastless track system is high in reliability, good in durability, and easy in construction and maintenance.