EP1533421A2 - Method and device for reconditioning and testing used concrete sleepers - Google Patents

Abstract

To process and test used concrete sleepers (1), from a railway permanent way, the quality of the concrete is tested by an acoustic ultrasonic analysis, and its elasticity is tested by bending stresses. The depression is measured where the rails lay, and the strength of the screw bolts (2) and dowels (3) anchored in the concrete is assessed by pulling (6) at a clamp (4) on them while the surrounding zones (5) are secured. The concrete sleeper is also inspected visually for any cracks, or other faults.

Description

The invention relates to a method and a device for processing and Checking used concrete sleepers of a superstructure of railways.

Components of a superstructure of railways are rails and sleepers, connected by means of iron to track grates, switches and crossings are. Small bars in this case include in particular sleeper screws, spring washers, Clamp plates and ribbed plates. With the help of these ironmonger be Rails and sleepers bolted to a track grid. As attenuation of Vibrations and to increase driving comfort is an intermediate layer Plastic or wood inserted between rail and the support surface.

The superstructure itself lies in a ballast bed, which in turn on a substructure rests. All the forces that are put into the rail will be through the sleepers over the ballast bed and transferred to the substructure.

Railways are essentially made up of three different types Sleepers used: concrete sleepers, wooden sleepers and steel sleepers. by virtue of their universal applicability and their robustness against the weather Above all concrete sleepers are used today. In concrete sleepers However, sleeper screws can only be screwed in with the help of dowels who are placed in the threshold.

Due to dynamic effects of train operation, weather-dependent influences such as frost and corrosion can be the connection between rail and concrete sleeper ease up. This can cause undesirable effects of the train operation lead.

From the generally published DB-Fachbuch "Arbeitsverfahren für die Instandhaltung of the superstructure ", Eisenbahn-Fachverlag 1991, it is known that removed as a measure for repair or processing damaged dowels and be replaced by new dowels.

• Sichten der Betonschwelle und visuelle Inspektion,
• Entfernen der Rippenplatte und vermessen der Tiefe der Fläche der Betonschwelle unterhalb der Rippenplatte,
• wenn die Betonschwellen Holzdübel aufweisen, werden die Holzdübel entfernt und durch haltbarere Kunststoffdübel ersetzt,
• wenn die Betonschwellen Kunststoffdübel aufweisen, werden die Kunststoffdübel auf Beschädigungen überprüft und ggf. ausgetauscht.

As state of the art it is furthermore known that a work-up and examination of used concrete sleepers comprises the following work steps:

• Viewing the concrete sleeper and visual inspection,
• Removing the ribbed plate and measuring the depth of the surface of the concrete sleeper below the ribbed plate,
• if the concrete sleepers have wooden dowels, the wooden dowels are removed and replaced by more durable plastic dowels,
• If the concrete sleepers have plastic anchors, the plastic anchors are checked for damage and replaced if necessary.

Disadvantage of both methods, however, is that they only visual inspections perform and change the mainly stressed dowels. A review the internal structure of the concrete sleeper is not carried out.

It is therefore an object of the invention, a simple method and a simple Device for preparation and inspection of all essential parts of used To provide concrete sleepers.

This object is achieved in conjunction with the preamble of the main claim according to the invention for the method by the in claim 1 and for the device solved by the features specified in claim 5.

The test and work-up according to the invention makes it possible in its sum, to get an idea about the condition of the concrete sleeper, which is in unexpected Way clearly beyond the mere sum of their individual parts and the previous ones State of the art goes out. As you know, quality requirements, which are placed on components of the superstructure, in particular concrete sleepers, disproportionately with the speed range for which it is used should be. Thus, the use of the prior art of Engineering restored concrete sleepers on a low speed range limited to up to 120 km / h. The test according to the invention and reprocessing, however, allows in particular by a review the material properties of the concrete, the concrete sleeper in such a state Restore that use even without any speed limit is possible.

Due to this extended area of application, the scope of application will also increase considerably extended for reconstructed concrete sleepers. Due to the previous restriction to a low speed range of up to 120 km / h could be processed by the state of the art Concrete sleepers can be used only on a few routes. By the extension to a mission without any speed limit can the inventively tested and refurbished concrete sleepers particularly advantageous also on routes of high-speed traffic, especially up to 300 km / h.

An economic success is achieved in particular by the fact that a Restored concrete threshold only about half the price of a new concrete sleeper costs. In addition, by reusing the Concrete sleepers spared important resources. This is the work-up concrete sleepers and reuse in a wider range of applications in the context of the circular economy a not inconsiderable contribution to the active environmental protection. The listed measures will additionally ensure that the recovered concrete sleeper the same physical Features like a new concrete sleeper.

Claims 2 to 4 include advantageous embodiments of the invention Solution of claim 1.

According to claim 1, first a visual inspection of the concrete sleeper carried out, this is according to claim 2 in particular on outbreaks, visible Cracks, sharp edges of the concrete sleepers body, in particular the Underside, contamination by adhering pollutants, damage in the Rail support area and the condition of the iron.

Following this, the concrete sleepers will be replaced by a high-pressure water system cleaned. In particular, smaller deposits will be involved at the concrete threshold of this solved, the concrete threshold of dirt freed and detached loose concrete parts.

In addition, a check of the concrete threshold for possible presence of material damage of the concrete with the help of a structure-borne sound analysis carried out

According to claim 3 is the concrete threshold through the structure-borne sound analysis an ultrasound examination for possible presence of material damage of the concrete. This happens especially in the rail support area as well as in the area of the iron and the ribbed plate. Kicking unexpected Reflections of the ultrasonic waves introduced into the concrete are irregularities present in the concrete, in particular material damage and / or Transverse cracks. In these cases, the concrete sleeper is scrapped.

Furthermore, for the structure-borne noise analysis according to claim 3 a Swinging test performed on the concrete sleeper by the concrete sleeper excited with at least one frequency to a vibration and the Reverberation time of this vibration is determined. At the same time the concrete threshold becomes by a mass impact or a vibration exciter, in particular a Shaker, in the short term excited to swing. From a determined decay behavior, the so-called reverberation time, the vibrations and the determined natural frequencies The concrete sleeper can be directly inferred on possibly in the concrete threshold pull existing longitudinal cracks. Be deviations from one expected Abklinverhalten and expected natural frequencies, the concrete sleeper is taken out of service.

In addition, for the structure-borne sound analysis according to claim 3, a mechanical Impedance of the concrete threshold determined. For this purpose, the concrete threshold with at least a frequency excited to a vibration, a force of excitation and determines an oscillation speed of the concrete sleeper. The relationship from the force of the excitation and the vibration speed results in the mechanical Impedance of the concrete sleeper. Be deviations from an expected Determined course of the mechanical impedance of the concrete threshold, the Concrete threshold retired.

Then the elasticity of the concrete sleeper is determined by a bending test. Here, the concrete sleeper is supported especially at their ends and applied on its upper side in the region of its center with a bending force. The deflection of the concrete sleeper caused by the bending force is measured and compared with a predetermined limit. If the measured deflection exceeds the limit value, the concrete threshold will be exceeded retired.

The sleeper screws are used in particular with a screwdriver removed and possibly dowels turned off.

A lowering of the rail support area is measured and with the one brand new concrete sleeper compared. This must be the same measured value as in the brand new concrete threshold.

The iron is changed with a screwdriver and possibly dowels turn on again. The sleeper screws are put on, tightened and clamped with a factory-new concrete threshold corresponding torque.

With a pull - out of the previously strained sleeper screw is the Quality of anchoring the sleeper screw or anchor in the concrete sleeper checked. Here, the concrete threshold is firmly clamped, so that she can not be raised. A clamp surrounds the sleeper screw and pull her with a certain force opposite to hers Screw direction. During the Ausziehversuches must be the sleeper screw in the dowel and the dowels remain firmly anchored to the concrete body.

Finally, the concrete sleepers for verification and documentation the quality checked. This is on the concrete threshold in particular a test seal and a permanent barcode attached.

The above sequence of operations of the invention Method or the device according to the invention is not mandatory. Of course - with the exception of the final documentation - any other order according to organizational and / or company specifications are selected. This will be the largest possible Adaptability and variability of the method or the device ensures.

Fig. 1

schematisch eine Betonschwelle mit Dübeln und Schwellenschrauben, bei der an einer Schwellenschraube ein Ausziehversuch durchgeführt wird,

Fig. 2

schematisch eine Betonschwelle deren Elastizität durch einen Biegeversuch überprüft wird,

Fig. 3

schematisch eine Betonschwelle deren Absenkung des Schienenauflagerbereiches gemessen wird.

The inventive method and the device according to the invention will be explained in more detail with reference to an advantageous embodiment and a drawing with three figures. The drawing shows in

Fig. 1

schematically a concrete sleeper with dowels and sleeper screws, in which a pull-out test is performed on a sleeper screw,

Fig. 2

schematically a concrete sleeper whose elasticity is checked by a bending test,

Fig. 3

schematically a concrete threshold whose lowering of the rail support area is measured.

In the particularly advantageous embodiment, a visual inspection of the concrete sleeper 1 of FIG. 1 is carried out first, paying particular attention to outbreaks, visible cracks, sharp edges of the concrete sleepers body, in particular the underside, contamination by adhering pollutants, damage in Schienenauflagerbereich and the state of the iron becomes.

Following this, the concrete sleeper 1 is in particular with a high-pressure water system cleaned. In particular, smaller deposits will be involved solved at the concrete threshold, the concrete threshold 1 of dirt freed and detached loose concrete parts.

In addition, the concrete sleeper 1 by a structure-borne noise investigation on possible presence of material damage to the concrete.

This is done in particular by an ultrasound examination in a rail support area 11 from FIG. 3 as well as in the area of the iron and the ribbed plate. If unexpected reflections of the ultrasonic waves introduced into the concrete occur, there are irregularities in the concrete, in particular material damage and / or transverse cracks. In these cases, the concrete sleeper 1 is retired.

Furthermore, for the structure - borne sound analysis, a swing - out test on the Concrete sleeper 1 performed by the concrete sleeper 1 with at least one Frequency excited to a vibration and the reverberation time of this vibration is determined. In this case, the concrete sleeper 1 by a mass impact or a vibration generator, in particular a shaker, in the short term too Swinging excited. From a determined decay behavior, the so-called reverberation time, the vibrations as well as the determined natural frequencies of the concrete sleeper 1 can be direct conclusions on possibly in the concrete sleeper 1 existing Pull longitudinal cracks. Be deviations from an expected Abklinverhalten as well as expected natural frequencies is determined, the concrete threshold 1 retired.

In addition, for the structure - borne sound analysis, a mechanical impedance of the Concrete threshold 1 determined. For this purpose, the concrete sleeper 1 with at least one Frequency excited to a vibration, a force of stimulation and a Swing speed of concrete sleeper 1 determined. The relationship from the Power of the excitation and the vibration velocity results in the mechanical Impedance of Concrete Threshold 1. Be deviations from an expected Determined course of the mechanical impedance of the concrete sleeper 1, the Concrete threshold retired.

Then, as shown in Fig. 2 , determined by a bending test, the elasticity of the concrete sleeper 1. Here, the concrete sleeper 1 is set in particular in the region of their ends on support 7 and acted on its upper side in the region of its center with a bending force 8. The caused by the bending force 8 bending line 10 with the deflection 9 of the concrete sleeper 1 is measured and compared with a predetermined limit. If the deflection 9 exceeds the limit value, the concrete sleeper 1 is scrapped.

The sleeper screws 2 are in particular with a screwdriver removed and possibly all dowels 3 unscrewed.

A depth 12 of the rail support portion 11, as shown in Fig. 3 , measured and compared with the corresponding depth of a brand new concrete sleeper. Here the same measured value must result as with a brand new concrete sleeper. If the measurement shows that the rail support area 11 is lowered or unduly deformed due to the previous loads on the concrete sleeper 1 by rail traffic, the concrete sleeper 1 is taken out of service.

All iron is changed with the screwdriver and possibly the Dowel 3 screwed in again. The sleeper screws 2 are put on, tightened and a torque corresponding to a brand new concrete sleeper braced.

As shown in FIG. 1 , the quality of the anchoring of the sleeper screw 2 or of the anchor 3 in the concrete sleeper 1 is checked with a pull-out test of the previously tensioned sleeper screw 2. Here, the concrete sleeper 1 is secured in particular at the areas 5 against lifting. A clamp 4 engages around the head of the sleeper screw 2 and pulls it with a certain pull-out force 6 opposite to its screwing. During the Ausziehversuches the sleeper screw 2 must be firmly anchored in the dowel 3 and the dowel 3 with the concrete body of the concrete sleeper 1.

Finally, the concrete sleeper 1 is used for verification and documentation the quality checked. Here, on the concrete sleeper 1 in particular a test seal and a permanent barcode attached.

LIST OF REFERENCE NUMBERS

1

concrete sleeper

2

sleeper screw

3

dowel

4

grab

5

support

6

pullout

7

In stock

8th

bending force

9

deflection

10

elastic line

11

Schienenauflagerbereich

12

Depth of the rail support area 9

Claims (6)

Process for processing and checking used concrete sleepers of a superstructure of railways, characterized in that a visual inspection of the concrete sleeper is carried out the concrete sleepers are cleaned, an examination of the concrete sleeper for possible presence of material damage to the concrete is carried out by means of a structure-borne sound analysis, an elasticity of the concrete sleeper is checked by a bending test, Sleeper screws are removed, a reduction of the rail support area is measured and compared with the measure of a brand-new concrete sleeper Iron and possibly dowels replaced, sleeper screws used, sleeper screws tightened and braced with a torque, an extraction test is performed on the previously tensioned sleeper screw, Finally, the concrete threshold is marked and in the case of irregularities and / or deviations from comparative dimensions of a brand new concrete sleeper, the concrete sleeper is scrapped. A method for processing and checking used concrete sleepers according to claim 1, characterized in that in the visual inspection for outbreaks, visible cracks, sharp edge of the concrete sleepers body at the bottom, contamination by adhering pollutants, the condition of the rail support area and the condition of the iron bar of the concrete threshold is respected , Method for processing and checking used concrete sleepers according to at least one of claims 1 and 2, characterized in that the examination of the concrete sleeper for possible presence of material damage of the concrete by means of the structure-borne sound analysis by an ultrasound examination of the concrete sleeper is carried out and essentially the area of the rail supports and / or the region of the bearing of the rail and the iron and the ribbed plate is examined and / or a swing-out test is performed on the concrete sleeper by the concrete threshold excited with at least one frequency to a vibration and the reverberation time of this vibration is determined and / or a mechanical impedance of the concrete sleeper is determined by the concrete threshold with at least one frequency excited to a vibration, a force of the excitation and a vibration speed of the concrete sleeper is determined. A method for processing and checking used concrete sleepers according to at least one of claims 1 to 3, characterized in that for testing the elasticity of the concrete sleeper by a bending test the concrete sleeper is supported in the area of its ends, a bending force is applied to the top of the concrete sleeper in the area of the middle of the concrete sleeper, Deflection of the concrete threshold is determined, which is caused by the bending force, a statement is made about the elasticity of the concrete sleeper based on a comparison of the determined deflection with a predetermined limit value for the deflection. Process for processing and checking used concrete sleepers according to at least one of claims 1 to 4, characterized in that for the pull-out of the previously strained sleeper screw the concrete sleeper is supported against pulling up, a sleeper screw is clasped with a gripper the sleeper screw is pulled upwards by the gripper with a certain force, the sleeper screw or dowel is checked for firm anchoring in the concrete sleeper. Device for carrying out the method for processing and checking used concrete sleepers of a superstructure of railways according to at least one of claims 1 to 5, characterized in that the device checking the concrete threshold for visually detectable damage, cleaning the concrete sleepers, the concrete sleeper is checked for possible presence of material damage of the concrete by means of a structure-borne sound analysis, checks the elasticity of the concrete sleeper by means of a bending test, Sleeper screws removed, measures a lowering of the rail support area and compares it to the size of a brand new concrete sleepers, Changed iron and dowels if necessary, inserted sleeper screws, tightened sleeper screws and tightened with a torque, performs a pull-out test on the previously tensioned sleeper screw, finally marks the concrete threshold and in the case of irregularities and / or deviations from comparative measures from a brand new concrete sleeper, the concrete sleeper samples.

Images