EP0905319B1 - Railway track and its construction method - Google Patents

Abstract

A solid bed rail track has the continuous lay track with brackets (4) attached to the sleepers and supporting the track on support strips (9) laid onto the prepared bed (1). Other brackets (6) are attached to the sleepers and extend under the bottom of the sleepers with the free ends secured to horizontal bars. The sides of the track are bounded by shuttering (11) attached to the track by spacer bars (10). Concrete is poured into the laid track and fills the spaces between the sleepers and between the sleepers and the shuttering.

Description

The invention relates to a method for producing a slab track for rail transport, as well as a slab track produced by this method.

The higher load on railways caused by high-speed trains has led to slab tracks, at least in the case of high-speed lines to move away from the classic track construction with a ballast bed and high entertainment costs.

Of the numerous constructions of slab track, the "Rheda" system dating back to 1972 is the most well-known and best-tried concrete construction using only concrete. In this design, a reinforced concrete trough is concreted in a modern design variant on a hydraulically bound support layer (HGT) within which a track grille is laid and brought with adjusting screws in its desired position. A variant of the Rheda system is known, in which troughs are produced in the trough under the threshold longitudinal ribs on which the track grating is placed without vertical spindle. The track, which is aligned in the desired position, is cast in with cast-in-situ concrete so far that the lower sill part and, through it, openings in the longitudinal direction of the track laid reinforcing bars are embedded in concrete. For the in-situ concrete, the trough serves as a formwork, whereby the height of the trough walls is determined.

The construction Rheda is very complex. The trough is a high cost factor. The alignment of the track with adjusting screws is labor-intensive and costly and at the same time prevents the use of continuously operating track laying equipment. The threading of the longitudinal bars through the sleepers is not only difficult, but also the full potting of the holes across the sleepers under construction site conditions is not ensured.

An effective corrosion protection of the longitudinal iron by rich wrapping with concrete is therefore not always given and can not be tested under any circumstances.

In order to secure the bond between the trough plate and the grouting concrete of the track grating, today concrete steel hoops are drilled vertically into the trough sole and connected with glue or mortar. This technique is not only expensive, but also questionable in terms of its quality on site.

From DE-A-44 30 769 a system RHEDA related solid roadway construction is known, in which on a support layer 8 - for example, a hydraulically bonded gravel layer (HGT) - as a substructure a trough plate 7 made of reinforced concrete is concreted. On the trough plate 7 of the track grating 1 is moved with concrete support body 5 made of concrete height accurate on rail support base 10. The pedestals 10 are then submerged and poured with flowing concrete.

This construction is - as the former construction - very complex because it requires at least two independently and successively performed concreting operations: the concreting of the trough plate 7 and the production of the two composite strips 6. In addition, it seems doubtful whether the intended in this construction narrow Flow concrete strips are sufficient to transfer the forces from traffic load safely from the grate into the trough plate 7.

From DE-U-29703508 a slab track is known, consisting of a support plate made of concrete and mounted on the plate at a distance from the plate surface and anchored to the plate and cast concrete with prestressed concrete sleepers. In order to achieve a good anchorage of the track grid with the support plate, the thresholds have protruding reinforcing elements, which are non-positively connected to corresponding elements that protrude from the support plate, and are cast after adjustment of the track grid on the plate with concrete.

• dass nur ein vor Ort in tragendem konstruktivem Stahlbeton hergestelltes Konstruktionselement für die Feste Fahrbahn erforderlich ist,
• dass alle notwendigen Konstruktionselemente der Festen Fahrbahn voll tragend mitwirken, indem die Konstruktionsregeln des Stahl- und Spannbetonbaus eingehalten werden,
• dass kontinuierlich arbeitende Gleisverlegeeinrichtungen einsetzbar sind, und
• dass aufwändige Handarbeiten - besonders innerhalb des kritischen Weges der Gleisbauarbeiten - weitgehend vermieden werden, und
• dass unter Baustellenbedingungen wenig praktikable Bauverfahren vermieden werden.

The object of the invention is to develop the system Rheda so

• that only a structural element made on site in load-bearing structural reinforced concrete is required for the slab track,
• that all necessary structural elements of the slab track are fully supporting by adhering to the design rules of steel and prestressed concrete construction,
• that continuous track laying equipment can be used, and
• that elaborate manual work - especially within the critical path of track construction work - largely avoided, and
• that under construction site conditions less practicable construction methods are avoided.

The object is achieved by a method for producing a slab track according to claim 1, as well as by a slab track produced according to this method according to claim 11.

The HGT support layer is a lean concrete layer of low strength, which - as also results from DE-A-44 30 769 - anyway in track construction is required as a substructure for a slab track. It forms the worktop for the construction of the actual reinforced concrete structure of the slab track. So it only has to be so strong that it can handle the supply traffic of the construction site through standard construction vehicles. As a rule, heavy laying vehicles can already run on the rails which they themselves put in front of their heads and load the HGT layer only indirectly, distributed over the large number of column feet of the track grid. Likewise, the HGT layer corresponds to the base course of asphalt, gravel, gravel, mineral concrete or solidified soil used as substructure.

By directly laying the load-bearing in-situ concrete slab of the slab track on the HGT layer on the substructure of the track body, the reinforced concrete slab required in the known slab track constructions is saved.

The production of the elaborate trough before the track construction can be omitted. The concrete slab on the HGT, which incorporates the threshold grid, serves as the actual slab of the slab track. The required side formwork can be kept cost-saving on the threaded heads of the tension wires in the threshold or special anchor sleeves on the end faces of the thresholds.

The support feet can be installed in the sleeper factory so precisely calibrated that the manufacturing tolerances of the thresholds at least halve. In order to ensure the immediate accessibility of the unscreened track grille under construction conditions, compensation layers are installed between the support legs and the HGT to avoid stress peaks. These leveling layers (eg made of plastic, rubber, bitumen board or geotextile) can be applied to the alignment feet in the factory on the support feet or on the construction site.

The already provided at the thresholds at the thresholds ironing, anchor trays and support legs save assembly work on the site. Also, the longitudinal reinforcement in the Ortbetontragplatte can already be pre-assembled in Jochmontagen before receiving a Gleisrostabschnitts by the track laying device to save time in track installation.

The invention gives various possibilities for the height adjustment of the tracks. According to claim 2, the height adjustment is effected by lift, which are used under the rails between the sleepers on the support layer.

According to claim 5, the slab track is adjusted by inserted in the threshold axes of the track grid spindles of height.

After moving the track grate and adjusting it to its height, the track grate must be temporarily held in its horizontal orientation until its final horizontal stabilization by the hardened in-situ concrete slab. Serve this purpose devices as described in claims 19 and 20.

Further expedient embodiments of the invention describe the method claims 3 to 10 and the device claims 11 to 20.

Fig. 1 bis 5

Schnitte durch eine Feste Fahrbahn nach den Ansprüchen 1 und 2,

Fig. 1

einen Querschnitt im Bauzustand nach dem Versetzen des Gleisrostes,

Fig. 2

einen Längsschnitt in Gleisachse mit eingebauten Hebern zur temporären Stützung,

Fig. 3

einen Längsschnitt in Gleisachse mit dem mittels der Heber nach Lage und Höhe fixierten Gleises,

Fig. 4

einen Längsschnitt in Gleisachse im Bauzustand nach dem Richten des Gleises nach Lage und Höhe und dem Vergießen des Spaltes zwischen Stützfuß und hydraulisch gebundener Tragschicht (HGT),

Fig. 5

einen Längsschnitt wie in Fig. 4, jedoch nach dem Einbringen des Ortbetons für die tragende Platte,

Fig. 6 bis 9

Schnitte durch eine erfindungsgemäße Feste Fahrbahn nach den Ansprüchen 5 und 12, Fig. 8 und 10 in Schwellenlängsachse und Fig. 7 und 9 und senkrecht zur Schwellenlängsachse mit einer Vorrichtung zum Höhenjustieren nach den Ansprüchen 8 und 15, Fig. 8 und 9 nach den Ansprüchen 8 und 16,

Fig. 10 und 11

Schnitte in Schwellenachse mit einer Vorrichtung nach Anspruch 18; Fig. 10 als Widerlager gegen Seitenverschiebung, Fig. 11 gegen Längsverschiebung,

Fig. 12

Schnitte in Schwellenachse mit Vorrichtungen nach Anspruch 19.

The invention will be explained by means of examples in FIGS. 1 to 12. Show it:

Fig. 1 to 5

Cuts through a slab track according to claims 1 and 2,

Fig. 1

a cross section in the state of construction after the displacement of the track grate,

Fig. 2

a longitudinal section in the track axis with built-in lifters for temporary support,

Fig. 3

a longitudinal section in the track axis with the fixed by means of the lift for position and height track,

Fig. 4

a longitudinal section in the track axis in the state of construction after straightening the track according to position and height and the casting of the gap between the support leg and hydraulically bound support layer (HGT),

Fig. 5

a longitudinal section as in Fig. 4, but after the introduction of the in-situ concrete for the supporting plate,

Fig. 6 to 9

Section through a slab according to the invention according to claims 5 and 12, Fig. 8 and 10 in the threshold longitudinal axis and Fig. 7 and 9 and perpendicular to the threshold longitudinal axis with a device for height adjustment according to claims 8 and 15, Fig. 8 and 9 according to the claims 8 and 16,

10 and 11

Sections in the threshold axis with a device according to claim 18; 10 as an abutment against lateral displacement, Fig. 11 against longitudinal displacement,

Fig. 12

Sections in the threshold axis with devices according to claim 19.

To produce the slab tracks according to the invention is on a support layer 1, which may be, for example, a hydraulically bonded support layer HGT, a track grid 2 of sleepers 3 and mounted thereon with rail fasteners 4 rails 5 is placed. The sleepers are already provided in the production with ironing 6, in which the anchor bolts 7 are expediently pre-assembled before moving the grate. The track grid 2 is deposited on support legs 8 on the support layer 1 horizontally in a scheduled position and then brought to a planned height.

A longitudinal reinforcement 13 can be installed after aligning the track grid or pre-assembled in the track grid.

A formwork 11 for in-situ concrete 14 above the HGT 1 is - built up on the surface of the HGT - useful in large elements, which are largely mechanically feasible - and anchored in corresponding devices which are installed in the end faces of the thresholds 3. Threaded bodies 12 of tendons may serve for this purpose in thresholds produced in the late-shell method. When manufactured with instant formwork sleepers threaded sleeves are expediently installed in the end faces of the thresholds. By pouring the trough between the formwork 11 on the HGT 1 to a certain height by the statics over the Sohlebene the thresholds with in-situ concrete 14, the actual load-bearing slab of the slab track. On the embedment of the threshold in the in-situ concrete of the support plate, the threshold surface to achieve an optimal bond between sleepers 3 and support plate, z. B. by inserting a knobbed foil into the threshold formwork, be profiled.

With reference to FIGS. 2 and 3, elevators 16 are displaced under the rails 5 and the rails 5 with the track grid 2 are spindled to a planned height and thus temporarily fixed in their desired position. Also, the displacement of the lift 16 and the spindle to height could be done by machine. After the height-wise fixation of the track grate 2 joints 17 between the top of the base layer 1 and the lower edge of the pre-assembled support feet 8 switch and potted with fast-hardening mortar. After hardening of the mortar, the track is finally fixed in its position and the lifters 16 can be unwound again, expanded and reused. When the installation of a reinforcement 13 shown in Fig. 5 is completed and the lateral formwork 11 is set, finally, the bearing plate is concreted by introduced in the formwork 11 in-situ concrete 14, which then forms the fixed track with the track grid 2.

Referring to Figures 6 and 7, the sleepers 3 have spindles 18 preassembled in or adjacent the support legs 8. The support legs 8 are optimally arranged for the stress of the threshold 3 expediently in the rail axes. The thresholds can then be dimensioned most economically. However, there may also be reasons - eg. B. if you want to lead spindles in the support legs - to place the support feet 8 near the rail axes. The support legs 8 may have on its underside a load-distributing intermediate layer 15 made of resilient material to the high vertical forces, the track over the track grating installation - immediately after the track grid 2 is attached to the support legs 8 directly on the surface of the support layer 1 - arise, harmless for to distribute the support legs 8 in the support layer 1 and initiate.

After the laid section of the track grate 2 is run over by the track leveling machine, this section is raised by means of the spindles 18 at the desired height and thereby resulting between lower edge support leg 8 and top edge of the base layer 1 joint 17 closed with fast-curing high-strength mortar. Thus, the track grille 2 is fixed vertically and horizontally in this position.

The spindle 18 is preassembled in the threshold 3. If the support leg 8 is arranged next to the rail axis, a spindle screw 19 can be guided through it in a recess 21, as shown in FIG. 9. The screw 19 of the spindle 18 is expedient tapered conically at its lower end 32 to produce on the surface of the support layer 1, a greater resistance to lateral displacement.

Until the pouring of the track grate 2 on the base layer 1 with in-situ concrete 14, the orientation of the track must be secured not only the amount but also against lateral displacements. This can be achieved in the same way with devices, which are shown in Figs. 10-12 in all production variants of the slab track.

As shown in Fig. 10, the horizontal displacement of the not yet poured aligned on the support layer 1 track 2 with glued blocks 22 is prevented. The blocks 22 are suitably prefabricated concrete. 10 arranged in the threshold axis in front of a surface of the support leg 8, they form abutment against lateral movements of the track grate 2, analogously arranged in the track axis of FIG. 11 abutment against movements in the track axis. Lateral movements of the track grate 2 should also prevent a device 23 according to FIG. 12. The device 23 is firmly anchored with a seal 24 in a bore 25 in the support layer 1. At an appropriate height above the base layer surface, the flute 24 has a horizontal bore 26. Provided with thread, this hole 26 can already serve as a guide for a screw screw 27, which, against an outer surface 29 of the track 2 -. B. on the front side of the threshold 3 - pressed, can prevent lateral movement of the track 2. The screw 27 may also be guided in a threaded element 28, which is held with a bore 30 in a roll 31. The Dollen 31 should expediently have a correspondingly larger cross-section. It can also be a square profile.

Claims (20)

1. Method of manufacturing a fixed carriageway for rail-bound traffic, consisting of a substructure, on which a track grid (2) consisting of rails (5) preassembled on the track- or points-sleepers (3) is laid with height- and position precision relative to the specified track axis, and is cast with in situ concrete (14),
   characterised in that

   a) the support layer (1) - e.g. a hydraulic support layer (HGT) - fixing the substructure is used as an assembly support layer,

   b) that the sleepers (3) are equipped at manufacture with shackles (6) and anchor irons (7) in the sleeper axis and with support feet (8) of about 600 cm² cross-section, on which the track grid (2) is deposited temporarily on the support layer (1) during assembly,

   c) that the track grid (2) consisting of rails (5) and sleepers (3) is laid complete and selectively with longitudinal reinforcements under the sleepers, with conventional track-laying apparatus on the HGT,

   d) that the track grid (2) is aligned precisely in position vertically and laterally relative to the specified track axis and is immediately temporarily fixed in the reference position,

   e) that the joint (17) between the support plates (1) and the support feet (8) is cast immediately after height adjustment with quick-setting, high-strength mortar,

   f) that the aligned track grid (2) is fixed with support bodies on the HGT (1) horizontally non-displaceably until it is concreted in,

   g) in front of the sleeper end faces lateral casings (11) are mounted and anchored to the HGT (1), and

   h) the space within the casings (11) above the surface of the support layer (1) is cast according to the art with in situ concrete (14) up to a specified measure above the sleeper base.
2. Method according to claim 1, characterised in that for the temporary fixing after alignment of the track grid (2), lifters (16) are placed under the rails (5).
3. Method according to claim 2, characterised in that after hardening of the mortar, the lifters (16) are dismantled and are ready for re-incorporation during continued construction of the fixed carriageway.
4. Method according to claim 2 or 3, characterised in that the lifters (16) are adjusted mechanically to the reference height by the straightening machine.
5. Method according to claim 1, characterised in that the track grid (2) is deposited on the HGT on the support feet (8) and is then adjusted in height by means of spindles (18) disposed advantageously close to the track axis, and is then temporarily fixed.
6. Method according to one of claims 1 to 5, characterised in that the support feet (8) are adhered to the sleeper undersides with quick-setting synthetic resin mortar in a sleeper workshop and in this case the sleeper (3) and support foot (8) are calibrated in height to a degree of accuracy of within ± 1 mm.
7. Method according to one of claims 1 to 6, characterised in that the sleepers (3) are profiled laterally provided that they are bonding in the in situ concrete (14).
8. Method according to one of claims 1 to 7, characterised in that the casings (11) are so assembled vertically in front of the end faces of the sleepers (3) using sleepers (3) manufactured using exposed threaded heads of a clamping reinforcement in the late-casing-removal method, that they extend upwards at least as far as the upper edge of the in situ concrete (14) and end at the bottom flush with the surface of the support layer (1).
9. Method according to one of claims 1 to 8, characterised in that for the casings (11) large-area elements are used in front of the sleeper heads, which after hardening of the in situ concrete (14) may be transported with rail-bound transport trucks for re-use.
10. Method according to one of claims 1 to 9, characterised in that the track grid (2) is fixed against horizontal displacement in the track axis and/or perpendicular to the track axis in addition to the formation of suitable counter-abutment devices (22, 23).
11. Fixed carriageway, manufactured by a method according to one of claims 1 to 10, with a track grid (2) consisting of rails (5) and sleepers (3) and a casting of in situ concrete over the support layer (1) up to a specified height above the base of the sleeper (3), characterised in that the track grid (2) consisting of rails (5), sleepers (3) and reinforcement is deposited on support feet (8) and is aligned horizontally and vertically directly on the support layer (1) and is concreted into a solid ferroconcrete panel.
12. Fixed carriageway according to claim 11, characterised in that it has sleepers (3) manufactured according to the late-casing-removal method with threaded ends (12) of clamping rods (10) projecting from the end faces of the sleepers, into which casing supports may be screwed.
13. Fixed carriageway according to claim 11, characterised in that it has sleepers (3) manufactured according to the immediate-casing-removal method, in whose end faces threaded sleeves are incorporated in which lateral casings (11) may be anchored.
14. Fixed carriageway according to one of claims 11 to 13, characterised in that the sleepers (3) used have on their base face shackles (6) incorporated during manufacture and preassembled anchoring irons (7) in the sleeper longitudinal direction.
15. Fixed carriageway according to one of claims 11 to 14, characterised in that at least individual sleepers (3) have spindles (18) close to the axis of the rail (5) or of the support (8), which may be pressed through a corresponding recess in the sleeper (3) against the surface of the support plate (1) and with which the track grid (2) is adjustable in height.
16. Fixed carriageway according to claim 15, characterised in that the support foot (8) is disposed laterally with respect to the rail axis and the spindle (18) is guided through vertical recesses, which penetrate both the sleeper (3) and the support feet (8).
17. Fixed carriageway according to claim 15, characterised in that the spindle (19) is guided below the sleeper base roughly to over the surface of the support layer (1) in a reinforcing tube (21) adjacent to a support foot (8).
18. Fixed carriageway according to one of claims 11 to 16, characterised in that prefabricated blocks (22) are adhered to the support layer (1) against the side faces of support feet (8).
19. Fixed carriageway according to one of claims 11 to 16, characterised in that a bracket (24, 30) is let into a bore (25) in the support plate (1) and has a horizontal bore (26, 31), which has either a female thread or a corresponding threaded element (28) in which a spindle screw (27) may be screwed against a part of the track grid (2) - e.g. the end face (29) of the sleeper (3) - and may be so pressed thereon that it prevents movement of the grid (2) against the spindle (23).
20. Fixed carriageway according to claim 19, characterised in that the spindles (18 and 23 respectively) or at least the spindle screws (19 and 27 respectively) may be recovered.

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