CN107059506A - A method for replacing a track plate of a slab ballastless track - Google Patents

Abstract

The present invention relates to a kind of plate-type ballastless track track plates replacing options, the replacing options include Replacement procedure, equipment frock and injecting paste material, fastener before and after track plates to be replaced is specially unclamped into certain length, rail is risen into certain altitude, track plates to be replaced are subjected to jacking, it is set to depart from bottom filling bed mortar, suspender with multiple suspension centres is installed on track plates, by the switching of gantry crane and suspender suspension centre, to being replaced, track plates progress translation is hung out and the translation of new plate is hung in, after new plate is in place, using fast hard injecting paste material injection filling new-track plate and former unsticking lamellar spacing, recover rail and fastener.

Description

A method for replacing a track plate of a slab ballastless track

technical field

The invention belongs to the technical field of maintenance and repair of slab-type ballastless track of high-speed railway, and in particular relates to a method and tooling for replacing a track plate of slab-type ballastless track.

Background technique

Slab ballastless track is the most advanced ballastless track technology in the world today. It is the main track structure type used in the construction of high-speed railways in my country. , Hangzhou-Ningbo, Ning-Hang, He-Fu, Jin-Qin, Shanghai-Kunming, Haqi, Ning'an, Zheng-Xu, Shen-Dan and other high-speed railways all adopt slab ballastless track type. At present, there are mainly three types of slab ballastless track in my country: CRTS Ⅰ, Ⅱ, Ⅲ. Among them, the CRTS I-type slab ballastless track is a prefabricated track slab paved on the cast-in-place reinforced concrete base, adjusted through the mortar filling layer, and limited by the convex stopper, and adapted to the unit slab type of ZPW-2000 track circuit Ballastless track structure type; CRTS II slab ballastless track is a track slab filled with cement asphalt mortar, laid on the concrete support layer (roadbed, tunnel) or reinforced concrete base (bridge) poured on site, and adapted to ZPW-2000 track circuit’s vertically connected slab ballastless track structure; CRTS Ⅲ type slab ballastless track is a prefabricated concrete track slab with reserved connecting steel bars laid on the cast-in-place reinforced concrete base or concrete support layer, and an automatic track slab is set in the middle. The dense concrete filling layer is suitable for the ballastless track structure type of ZPW-2000 track circuit. The slab ballastless track cancels the sleeper and ballast bed of the traditional ballast track, and uses the prefabricated reinforced concrete track slab to directly support the rail, and fills the cement emulsified asphalt mortar or self-compacting concrete filling layer between the track slab and the concrete base, which has a smooth High performance, good stability, long service life, good durability, less maintenance workload and other technical advantages. However, with the extension of service time and complex reasons such as changes in geological conditions, individual track slabs of the slab ballastless track will deteriorate locally. When the deterioration reaches a certain level, individual damaged track slabs need to be replaced to ensure Safety, stability and long-term durability of ballastless tracks.

At present, the method used to replace the track slab is to cut off the rail first, then use the hoisting equipment of the rail car to move out the damaged track slab, move in the new track slab, and then re-weld and lock the rail. Using this method, the rails must be cut before the plate is changed, and the skylight must be temporarily connected to the rails on the same day. After the plate is changed, the rails must be welded, polished, and weld flaw detection. , greater damage to the rail.

In view of the disadvantages of cutting the rails to replace the track slabs, the experimental research on the replacement process tooling of the track slabs within the skylight time has been carried out at home and abroad without cutting the rails, but it is still in the stage of experimental development. Among them, the patent "a slab ballastless track Track slab replacement device and replacement method (201310108682.3)", which provides a track slab replacement device and replacement method for slab-type ballastless track without cutting the rails, and does not involve the bonding restoration of the new track slab and the original filling layer mortar or Close-fitting state control technology, and there are many and heavy on-site installation tools, which are not convenient for construction during skylight time; and the equipment used in the patent "a subway board changing car and a board changing unit including the subway board changing car (201420251605.3)" is large In addition, this patent is not applicable to the replacement and repair of the ballastless track slabs of high-speed railways. Therefore, in order to fundamentally solve the technical problem of rapid replacement and repair of the slab ballastless track slab within the skylight time without cutting the rail, the system formation is applicable to the straight section and curved section of the CRTS Ⅰ, Ⅱ, and Ⅲ slab ballastless track respectively. The track track plate replacement technology is a problem to be solved urgently in this field.

Contents of the invention

Aiming at the disadvantage of replacing the track slab when the rail is cut, the invention invents a method and tooling for replacing the damaged track slab without cutting the rail, which is suitable for implementation within the skylight time. The invention is fast in construction, practical and reliable, and economical in cost, and provides a fast, convenient, practical, and economical new method for replacing and repairing damaged track slabs within the skylight time.

The present invention adopts the following technical solutions to achieve the above object:

The invention relates to a method for replacing a track slab of a slab-type ballastless track. The replacement method includes a replacement process, equipment tooling and grouting materials, specifically, loosening the front and rear fasteners of the track slab to be replaced by a certain length, and raising the top of the rail to a certain height , lift the track plate to be replaced to separate it from the mortar of the lower filling layer, install a spreader with multiple lifting points on the track plate, and move the track plate to be replaced through the switching of the track crane and the lifting points of the spreader Hoisting out and lifting in of the new slab, after the new slab is in place, use fast-hardening grouting material to fill the gap between the new track slab and the original debonded layer, and restore the rails and fasteners.

A method for replacing a track slab of a slab-type ballastless track. The track slab replacement process includes the following steps: (1) positioning and marking the position of the slab to be replaced; (2) removing the fastener system; (3) testing the rail temperature; (4) Vertical rail lifting; (5) Lifting of the track slab to be replaced; (6) Moving out of the old slab and moving in the new slab; (7) Rough laying and fine adjustment of the track slab, restoration of rails and fasteners; (8) Glue injection at the bottom of the slab ; (9) Line fine-tuning.

A method for replacing a track slab of a slab ballastless track. The sling is fixed on the track slab through the hoisting hole of the track slab or across the bottom of the slab. Reduce the lifting point to facilitate the lifting of the track slab.

A method for replacing a track slab of a slab-type ballastless track. The track crane is composed of a locomotive, a flatbed truck, hoisting equipment and hydraulic outriggers, and must meet the conditions for safe departure of the railway. It can transport and hoist a new track slab to a replacement site , Lift and transport the old track slab to the designated place.

A method for replacing a track slab of a slab-type ballastless track. The track crane has more than two sets of hoisting equipment. When one set of hoisting equipment fails, the other set is immediately activated to ensure reliable operation of the skylight without affecting the punctual opening of the line.

A method for replacing a track plate of a slab ballastless track, the pressure adjustment range of the grouting equipment is 0.1MPa~50MPa, the grouting flow rate adjustment range is 0L/min~200L/min, and the temperature control range for the grouting material is 10 ℃~100℃.

A method for replacing the track slab of a slab ballastless track, the grouting material is an expansive or non-expandable quick-setting rapid-hardening material, the working time is 5s~800s, and the 1h compressive strength reaches 50% of the design strength Above; the quick-setting quick-setting material is one of the organic quick-setting quick-setting materials polyurethane, polyurea, epoxy resin, vinyl resin or unsaturated polyester, or the inorganic quick-setting quick-setting material water glass— One of cement system, sulfoaluminate system, aluminate and phosphate system; the grouting material has the characteristics of quick setting and fast hardening, so as to realize the positioning of the newly replaced track slab to meet the load and traffic requirements feature request.

Compared with the existing ballastless track track slab replacement technology, the present invention has the following advantages:

(1) No rail cutting, less disturbance to the line and less damage to the rail;

(2) The tooling equipment used is light, with low failure rate and high safety, ensuring that it will not affect the next day's driving;

(3) The process is simple, which is convenient for the organization and construction of skylights;

(4) The grouting materials used can be more inorganic cement-based materials, which have better durability, environmental performance, and higher economy, and can save more than 60% of the cost of repair materials;

(5) High applicability, not only suitable for the replacement of track slabs of CRTS Ⅰ, Ⅱ, Ⅲ ballastless track in straight section, but also suitable for the track slab replacement of CRTS Ⅰ, Ⅱ, Ⅲ ballastless track in curved section.

To sum up, the present invention is obviously different from the existing track slabs. Under the condition of not cutting the rails, the damaged track slabs are replaced by using the skylight time, and the joint grouting between the newly replaced track slabs and the debonding layer is completed. For tasks such as repairing, track fine-tuning, and line restoration, the present invention has many advantages such as fast construction, low cost, durability and environmental protection, practicality and reliability, and high applicability, and the technical economy is remarkable.

Description of drawings

Fig. 1 is a typical track slab replacement construction process flow chart provided by the present invention.

Figure 2 is a schematic diagram of a typical track slab vertically hoisted.

Figure 3 is a schematic diagram of a typical track plate falling after translation.

Figure 4 is a schematic diagram of a typical track slab replacement hoisting point.

Figure 5 is a schematic diagram of a typical track slab that continues to translate between lines after replacing the hoisting point.

Figure 6 is a typical schematic diagram of removing the detachable section of the spreader and replacing the lifting points so that the track plate has a vertical lifting space.

Figure 7 is a typical schematic diagram of fixing the spreader to the bottom of the track slab.

Explanation of reference signs:

1—the center line of the left line; 2-1—the left rail of the left line; 2-2—the right rail of the left line; 3—the track plate to be replaced; 4—the concrete boss block; 5—the concrete base plate; 6—the track Plate hoisting hole; 7—sling; 7-1—hanging point one; 7-2—hanging point two; 7-3—hanging point three; 7-4—hanging point four; 7-5—hanging point five; 7 -6—Removable parts of spreader; 8—Cement asphalt mortar filling layer; 9—Center line of right line; 10-1—Cushion block; 10-2—Cushion block.

detailed description

The implementation and beneficial effects of the present invention will be described below through specific embodiments, but the present invention is not limited thereto, and the described embodiments are only some of the embodiments of the present invention, not all of them. Based on the embodiments of the present invention, all other embodiments obtained by persons of ordinary skill in the art without making creative efforts belong to the protection scope of the present invention.

Example 1

Embodiment 1 of the present invention provides a method for replacing the track slab of CRTS I type ballastless track in the double-line straight section. The process flow is shown in Figure 1. The method specifically includes the following contents:

(1) According to the ESC order, carry out catenary power outages, power inspections, ground wires, and take relevant protective measures; use ink lines, rulers, steel rulers, strings, etc. to check the plane and elevation positions of the original track slabs Measure and mark, and make data records, mainly the relative position between the original track slab and adjacent track slabs, including horizontal position, distance between plates, height difference between plates, boss clearance, parameters for positioning track slab status, and marking The track plate moves out and enters the line and is clearly marked;

(2) Remove all spare parts on the track plate that need to be replaced, remove the bolts and gauge blocks within the range of the rail that need to be lifted, and chisel off the boss resin;

(3) The measured rail temperature is 28°C, and compared with the actual locked rail temperature of 30°C, loosen the fasteners at least 15 meters before and after the replacement of the track plate, and raise the rails 2-1 and 2-2 above it by 30cm, as shown in the figure As shown in 2, at the same time, place pads of appropriate height under the rails to completely avoid accidents such as rails falling directly. When the amount of rail lifting reaches 30cm, set up pads of appropriate size at the place adjacent to the starting point and at a certain distance to support and stabilize the lifted rail;

(4) Lift the old track plate synchronously and evenly through four jacks, check and confirm the debonding of the track plate and the filling layer mortar;

(5) As shown in Figure 2, install and fix the spreader 7 with multiple lifting points on the track plate 3 through the lifting hole 6 of the track plate, and the rail crane group parked on the line 9 passes through the hanger 7 located on the inner and outer sides of the rail. Points 7-3 and 7-4 lift the track slab by more than 20cm and less than 30cm, that is, higher than the surface of the concrete boss block 4, lower than the bottom surface of the rail 2-1, 2-2, and leave a safety distance of more than 2cm , and then operate the crane to translate the track plate 3 to the line. When the left hanging rope is close to the inner side of the rail 2-2, place the pads 10-1, 10-2, and then slowly put the track plate 3 on the pad 10- 1, 10-2, as shown in Figure 3, replace the hoisting points of the spreader to 7-1, 7-5, as shown in Figure 4, continue to translate the track 3 until the left hanging rope is close to the inside of the rail 2-2, move Put the pads 10-1, 10-2 to the appropriate position, put the track plate on the pads 10-1, 10-2, as shown in Figure 5, then replace the left lifting point with the lifting point 7-2, and place the The detachable section 7-6 of spreader 7 is pulled down, and as shown in Figure 6, track plate 3 is lifted vertically to the flatbed truck and waits to be transported then;

(6) Check the surface of the cement asphalt mortar filling layer 8 of the debonded layer, and polish and clean the residual scum;

(7) Use the reverse operation of step (5) to move the new track plate under the rails 2-1 and 2-2;

(8) The new track slab is extensively tested according to the state of the original track slab, and the horizontal and vertical directions of the track slab are positioned according to the state parameter data of the original track slab with fine adjustment claws, and the position of the track slab is rechecked;

(9) Drop the 2-1 and 2-2 rails back to their original positions, and screw in the fasteners that have been loosened before and after plate replacement; when the rails are restored, simultaneously carry out boss resin injection;

(10) According to the state of the track of the new track slab and the state of the gap, determine whether to inject glue at the bottom of the slab. If the gap between the bottom of the new track slab and the original debonded surface is large, use a grouting machine to inject the fast-hardening grouting material into the filling When reaching the gap between the new track slab and the original debonded layer, the grouting material solidifies rapidly, realizing the positioning of the new track slab;

(11) Conduct a comprehensive measurement of the track status before and after the plate replacement section, analyze the line type, and fine-tune the track according to the analysis results to ensure that the smoothness of the line meets the conditions for the opening of the train;

(12) Remove the power supply ground wire, conduct a comprehensive inspection of the track structure and geometric dimensions, clean up the site, remove all tools from the line, and then open the line;

(13) After the line is opened, use wireless transmission to monitor the train operation stability index, the force of the track structure components, the stability index of the track structure, the track stiffness index, the track structure components and the vibration acceleration of the foundation in the plate replacement section in real time. If there is any abnormality, report and deal with it in time.

Example 2

Embodiment 2 of the present invention provides a method for replacing a track slab of a CRTS II ballastless track on a double-line straight section, and the method includes the following contents:

The replacement method of the CRTS Ⅱ ballastless track track slab is basically the same as that of the CRTS Ⅰ ballastless track slab replacement method, only because the CRTS Ⅱ ballastless track track slab has no hoisting holes, and the spreader 7 needs to be fixed on the track slab through the bottom of the slab. As shown in Figure 7.

Claims (5)

1. A method for replacing track slabs of slab-type ballastless track, characterized in that: the replacement method includes replacing process, equipment tooling and grouting materials, specifically loosening the front and rear fasteners of the track slab to be replaced by a certain length, and the top of the rail To a certain height, lift the track slab to be replaced to separate it from the mortar of the lower filling layer, install a spreader with multiple lifting points on the track slab, and use the track crane and the switching of the lifting points of the spreader to replace the track The slab is lifted out in translation and the new slab is hoisted in. After the new slab is in place, fast-hardening grouting material is used to fill the gap between the new track slab and the original debonding layer, and restore the rails and fasteners. 2. The track slab replacement process according to claim 1, characterized in that it comprises the following steps: (1) positioning and marking the position of the slab to be replaced; (2) removing the fastener system; (3) testing the rail temperature; (4) vertically Lifting the rail; (5) Lifting the track plate to be replaced; (6) Moving out the old plate and moving in the new plate; (7) Rough laying and fine adjustment of the track plate, restoration of rails and fasteners; (8) Glue injection at the bottom of the plate; (9) Line fine-tuning. 3. The equipment tooling according to claim 1, characterized in that: the spreader is installed and fixed on the track plate through the lifting hole of the track plate or the bottom of the plate across the installation, it has a plurality of lifting points, and one end of the spreader can be lengthened Or disassemble, in order to increase or decrease the lifting point, and facilitate the lifting of the track plate. 4. The equipment tooling as claimed in claim 1, characterized in that: the pressure adjustment range of the grouting equipment is 0.1MPa~50MPa, the grouting flow adjustment range is 0L/min~200L/min, and the grouting material is heated The temperature control range is 10°C~100°C. 5. The grouting material as claimed in claim 1, characterized in that: the grouting material is an expansive or non-expandable quick-setting rapid-hardening material, the working time is 5s~800s, and the compressive strength is 1h reach more than 50% of the design strength; the quick-setting quick-setting material is one of the organic quick-setting quick-setting materials polyurethane, polyurea, epoxy resin, vinyl resin or unsaturated polyester, or the inorganic quick-setting material Rapid hardening material water glass—one of cement system, sulfoaluminate system, aluminate and phosphate system; the grouting material has the characteristics of rapid setting and rapid hardening, thereby realizing the positioning of the newly replaced track plate, In order to meet the functional requirements of carrying and opening to traffic.