GB2379701A

GB2379701A - Rail installation

Info

Publication number: GB2379701A
Application number: GB0122362A
Authority: GB
Inventors: Barnaby Temple; Charles Penny; Mike Robertshaw
Original assignee: Balfour Beatty PLC
Current assignee: Balfour Beatty PLC
Priority date: 2001-09-17
Filing date: 2001-09-17
Publication date: 2003-03-19
Also published as: WO2003025286A1; GB0122362D0

Abstract

A system for aligning rails includes a alignment system 100 having a lateral bar 108 supporting rails 4 by clamps 112 having a ratchet. Support members 102 are fixed to the track bed 90 and adjustable supports 110 are mounted on the support members on rollers to allow the supports 110 to slide laterally. Screws are provided to adjust the position of the lateral bar 108 and hence the rails 4. The ratchet and roller combination allow easy raising of the rails and alignment of the rails even by a single operator. A complete rail installation kit and method is also described.

Description

RAIL INSTALLATION The invention relates to a method of rail installation and apparatus for rail installation, especially a rail installation method and apparatus suitable for slab track systems.

Conventional rail laying apparatus and methods present a number of difficulties in the construction of all kinds of track, including embedded rail track forms, and consequently there is a need for new methods and handling procedures and corresponding equipment to overcome these difficulties and to improve the speed and accuracy of installation.

In particular, the alignment of rails may be critical. For example, there may be a requirement to super-elevate the outer rail to assist high speed trains traverse curves.

Further, rails need to be aligned to have the correct gauge and height and inclination along the length of the track. Accordingly, there is a need for apparatus to accurately align rails.

A specific example of a rail system is described in W099/63160, which describes a slab track system having a railway or tramway rail and rail fastening system. A rail is mounted in a longitudinal channel formed, for example, in cast concrete. In a system described in W099/63160, a rail having a waist is held in a suitably formed longitudinal channel by means of a resilient filling inside an outer shell. The arrangement is such that pinch points are produced which hold the rail in place. Alignment of rails in this and other slab track systems is a particular difficulty.

Accordingly, there is a need for systems for laying rail for all kinds of system, and in particular but not exclusively in embedded rail systems.

According to the invention, there is provided a rail alignment support for aligning rails with respect to a track bed comprising: a plurality of laterally spaced clamps for gripping a corresponding plurality of longitudinal rails from above; and adjustable supports for supporting the clamps and adjusting the position of the clamps with respect to the track bed to align the rails. The clamps are preferably inverted Ushape.

By holding the rail from above and providing adjustment units it becomes possible to lift, align and incline rails, to hold them at the desired gauge width, and

providing a means of adjustment both for vertical and lateral position of the rails in conjunction with the desired gauge and inclination.

Preferably, the rail support includes a lateral support beam carrying a pair of adjustable supports and the plurality of clamps are fixed to the support beam between the adjustable supports. The support system may further comprise support members for fixing with respect to the track bed for carrying and supporting the rail alignment supports. Preferably, each adjustable support can be adjusted vertically and laterally with respect to the support members.

In order that the system is suitable for use with a slab track system, each clamp may further comprise a fastening for supporting a shell extending under the rail from one side of the rail to the other.

As well as the above system for aligning rails, the system of the invention

includes, in another aspect, a rail laying trailer unit comprising : a frale ; at least rwo . UV"'L & . u. \J,. 1. U J. J. Vf.. U'-'. 1 a P\"I\"I", Çt.. 1al1. 1Q. J 1. 1. 1 Ua. 1. 1'-"i IL,. Ul.. lL \.. IVi. l !} J. !.. !. 1. 1. 1. a . lau. l"",, al Iva L LV'V laterally spaced wheels on the underside of the frame for supporting the frame and allowing the frame to be wheeled longitudinally; and rail supports fixed to the frame above the laterally spaced wheels, each rail support including a pair of laterally opposed guides and a roller between the guides with its axis aligned laterally for supporting a rail whilst allowing longitudinal movement.

A plurality of rail laying trailer units can be fixed together to provide a rail laying train. This system has a number of advantages. Each of the units can readily be manhandled, yet the combination provides a stable articulated rolling bed support to guide rails without twist or sagging. The rail laying train is towable to allow it to be manoeuvred out from under completed, continuously welded, rail lengths. The low resistance to towing afforded by virtue of the roller supports mean that the rail laying train can be operated, even in the case that the train is a long train made up of a large number of units.

The modular nature of the rail laying train, made up of a plurality of units, allows a variable number of trailer units to be used depending on the length of rail to be handled.

In embodiments of the invention, there may be provided a special end unit having a frame, a pair of laterally spaced rail support units for supporting a rail, each rail support unit including at least one wheel on the underside of the rail support and a plurality of longitudinally spaced rollers having a laterally aligned roll axis for

supporting the rail as it is extended longitudinally from the end train unit. This unit may support the curved cantilevered section of rail as the support systems are attached and the rail is lowered into a desired position on the track, for example a channel for an embedded rail slab track system.

In a yet further aspect, there is provided a rail laying train assembly comprising: a train of rail laying trailer units fixed together longitudinally; a plurality of wheels under the train assembly to support the assembly and allow wheeled motion; a plurality of rollers for supporting at least one length of rail at a plurality of points spaced along its length allowing the rail to be rolled longitudinally on the rollers; and a plurality of guides for laterally locating the at least one length of rail.

The invention also relates, in another aspect, to a rail lifting beam comprising: a longitudinal beam made up of a plurality of modular sections; a plurality of lifting points longitudinally spaced on the upper side of the beam for lifting the beam; and a plurality of rail carrying units spaced longitudinally along the beam, each rail carrying unit comprising a pair of lateral members extending downwardly from the beam and defining a pair of laterally opposed holes, and a rail support pin passing through the laterally opposed holes to support a rail from below.

The rail lifting beam supports the rail under the rail foot avoiding any damage to the head or web of the rail. It can pick up rail from either side of a stack, and uses removable locking bearing pins to support the rail by its base. By virtue of the shape of the frame at the bearing points it holds the rail stable.

A key aspect of this design is the modular nature of the beam sections which enable both convenient transportation and storage, and mean that different lengths can be assembled, according to particular need. The joint sections are each preferably permanently fixed onto one beam section and releasably fastened to an adjoining beam section. The releasable fastening may be a nut and bolt arrangement.

In another aspect, there is provided a rail support system for supporting a stack of rails comprising: a base unit having cross beam with a base surface and an upper surface and a plurality of pins spaced along the cross beam extending from the upper surface; and a plurality of intermediate units having a cross beam with a lower surface and an upper surface and a plurality of pins spaced along the cross beam extending from the upper and lower surfaces; wherein the shape and spacing of the pins is

arranged to hold and support rails between adjacent pins at a suitable spacing for lifting.

This enables, in particular, the lifting beam (above) to pick up rails from a stack in a convenient and efficient manner. Accordingly, the invention also relates to a system including a lifting beam and the support system.

The invention also relates to a method of aligning track using a rail alignment support having a plurality of laterally spaced clamps for gripping a corresponding plurality of longitudinal rails from above and adjustable supports for supporting the rail alignment supports, the method comprising: fixing the rail alignment support to a plurality of laterally spaced rails from above using the plurality of inverted clamps; adjusting the adjustable supports to align the rails, and fixing the rails in place in their aligned position.

By holding the track from above using a rail alignment support and then fixing the rails in place the rails can be correctly aligned, inclined and positioned before fixing.

Preferably, a plurality of rail alignment supports are fixed to the rails longitudinally spaced from one another to align a length of track.

The method has particular application for aligning rails within channels of a slab track system, by supporting a shell extending under the rail within the channel, wherein the step of fixing the rails in place includes filling the gap between the shell and the inner side of the channel with fixing material.

By using the alignment system according to the invention, it becomes possible to lay slab track having rails accurately aligned without requiring similar alignment of the track bed. Using more conventional methods, the rails simply follow the channels of the track bed.

In another aspect the invention relates to a method of laying track, including: mounting a rail section on rollers on a wheeled rail laying train on a track bed; and moving the wheeled rail laying train longitudinally with respect to the rail laying train to remove the wheeled rail laying train from under the rail section to lay the rail section on the track bed. Preferably, the rails remain substantially in place as the wheeled rail laying train is removed from under the rails.

In particular, the method may include mounting a further rail section on the wheeled train in alignment with the original rail section when part only of the original

rail section is still on the wheeled train and welding the further rail section to the original section.

As well as the wheeled train providing an alignment support for welding, and other further operations, such as weld testing, grinding, including side and base grinding, may be carried out on the rail on the trailer frame.

After laying, the rails may be aligned as described above.

The track laying method is particularly suitable for laying rail into a channel, whereby the wheels of the wheeled rail laying train may be guided in such channels For a better understanding of the invention, the same will now be described, purely by way of example, with reference to the accompanying drawings, in which: Figure 1 shows a rail stack using a rail stillage system according to an aspect of the invention; Figure 2 shows a rail lifting beam according to the invention; Figure 3 shows a rail train unit according to the invention; Figure 4 shows an alternative rail train unit according to the invention for supporting a single rail; Figure 5 shows a rail train unit incorporating a tow hook according to the invention; Figure 6 shows a rail end train unit according to the invention; Figure 7 illustrates a complete assembled rail train assembly; Figure 8 illustrates the mounting of a rail on the rail train of Figure 7; Figure 9 illustrates positioning for welding; Figure 10 illustrates welding; Figure 11 illustrates extending the rail from the rail train unit; Figure 12 illustrates laying the rail in the track bed; Figure 13 illustrates aligning the rail; Figure 14 shows support units mounted on the track bed; Figure 15 is a longitudinal view illustrating aligning the rails; and Figure 16 is a detailed view of part of Figure 15.

Like components given like reference numerals in the various figures.

Referring to Figure 1, there is shown a stack 2 of longitudinal rails 4 supported on a rail support system 6 including a base unit 8 and a plurality of intermediate units

10. The base unit 8 has a crossbeam 12 with opposed lower 14 and upper 16 surfaces and a plurality of pins 18 extending from the upper surface. The intermediate unit 10 again has upper and lower surfaces 14,16 and a plurality of pins 18 extending from both upper and lower surfaces. As will be seen, the pins are spaced along the crossbeam.

In use, a plurality of base units 8 are placed longitudinally spaced along a horizontal support, for example, as illustrated, the track bed 90. A plurality of rails are then placed between the pins to form a first layer 22 of rails. Then, a corresponding plurality of intermediate units is placed, one above each of the base units, held in place by the pins 18 extending from the lower surface 14, and a first layer 22 is placed on the intermediate unit. This is repeated until all the rails required to be stored are included in the stack.

The pins are spaced to provide both lateral stability of the stack and to ensure correct spacing for the lifting beam described below.

Referring to Figure 2, lifting beam 24 is a longitudinal lifting beam made up from a plurality of sections 26. The sections 26 are joined together to form the lifting beam by joint or support sections 28. Each support section 28 includes a pair of lateral plates 30 on either side of the lifting beam defining a pair of downwardly extending side members 32 which define a corresponding pair of through holes 34 through which a lifting pin 36 can pass. The support sections 28 are each welded onto one of the sections 26 and are fixed by means of nuts 38 and bolts 40 to the adjacent section to make the longitudinal beam 24. Some of the support sections 28 also include lifting points 42, including a pair of opposed holes 34 and a lifting bolt 36. These lifting points are used to support lifting ropes 44 or other lifting gear.

In use, the lifting beam is lowered onto a rail 4, for example in a stack 2 as shown in Figure 1. The side members 32 extend downwardly around the rail, and lifting bolts 36 are introduced under the rail to support the rail at a plurality of locations along the length. The rail 4 can then be lifted into place where required.

It will be noted that the rail support system illustrated in Figure 1 holds the rails off the ground in order that they can be lifted.

The sections 26 of the lifting beam are suitable for site assembly using the nuts and bolts 38,40. The units support the rail under the rail foot (the underside of the rail) thereby avoiding any damage to the head (top) or the web (intermediate portion) of the

rail. The units can pick up a rail from either side of a stack. The shape of the frame at the support sections 28 and in particular the side members 32 laterally around the rail hold the rail stable whilst the rail is being lifted.

Referring to Figure 3, an individual rail train unit will now be described. The rail train unit 72 has a frame 50 made up from a plurality of braces 52 and joints 54.

The unit has a pair of laterally opposed wheels 56 fixed to the frame under corresponding rail supports 58. Each rail support includes a roller 60 mounted with its axis laterally so that it can roll longitudinally, and a pair of opposed guides 62. The frame includes a longitudinally extending member with a joint component 94 which is for cooperating with another joint component 96 on the other end of another rail train unit 72 to form an articulating joint (98, Figure 7), here a pin joint, to enable two rail train units 72 to be connected together.

Referring to Figure 4, an alternative unit for a single rail includes a longitudinal frame 60 longitudinally spaced wheels 56 and rail supports 58, and guide wheels 66 laterally spaced from the longitudinal frame 60 to guide the train. The guide wheels 66 are arranged to be guided by an upstand 106 at the edge of the design of the concrete slab track bed, illustrated in section in Figure 15. As will be appreciated, the arrangement of the guide wheels 66 may be varied to suit the shape of the track bed.

Figure 5 shows a rail train unit 74 having a tow point 64, here in the form of a tow ring, to allow a rail train to be towed.

Figure 6 shows an end unit which differs from the other units in that it is designed to support a rail extending in a cantilever fashion from the end unit. Again, a frame 50 is provided, but in this case the frame separates a pair of laterally spaced rail support units 70. Each rail support unit 70 includes, in the example, a pair of longitudinally spaced wheels 56 and a plurality of longitudinally spaced rail support units 58, each including a roller 60 and a pair of guides 62 as above. Note that the vertical position of the rollers 60 is adjustable.

Figure 7 illustrates a complete rail train assembly 78 formed from a train of units 72 as shown in Figure 3 fixed to one another longitudinally by articulating joints 98 formed from joint components 94,96 on individual units 72. The articulated construction of the joints 98 of the assembly 78 permits greater flexibility and manoeuvrability and allows the assembly to be used for curved track beds.

The wheels 56 of the assembly are located under the rollers 60 to support a rail mounted on the rollers 60 without requiring the frame 50 to support the load of the rail 4.

At the front end of the train 78 of units 72, a unit 74 having a tow point 64 is provided. At the other end of the chain, an end unit 76 as illustrated in Figure 6 is provided.

A rail laying train may also be formed from single rail carrying units, for example units as shown in Figure 4.

In use, referring to Figure 8, the assembly 78 is placed on the track bed. Where the track bed includes the channels of a slab rail system, the wheels 56 of the assembly may conveniently be guided within the channels. A rail 4 is lifted into position on the assembly 78 using rail lifting beam 24. It will be noted that an existing rail 4 is already

present on the assembly. Referring to Figure 9, the new rail 4 is mounted with a 26mm F.-L & 11 vi ill t I I Lil I I i gap to the existing rail already present on the assembly. Other spacings can be used if required.

A welding frame 80 (Figure 10), incorporating a welding jig 82 and crucible 84 are then mounted on the pair of rails and the crucible heated to join the existing rail to the new rail.

This is then repeated on the other side of the assembly for the other rail.

Referring to Figure 11, the now welded rail is then lowered onto the track. This may in particular be done by dragging the train 78 forwards.

A shell and pad assembly 86 is introduced under the rail 4 as the rail is taken from the end unit 76 of the rail train assembly 78. As will be appreciated, in embodiments where, as in the example, the rail train assembly 78 carries a plurality of rails 4, each of these rails will extend from the end unit 76; the drawing only shows one rail, for clarity. The shell and pad assembly 86 includes an outer shell 142 and a pad between shell 142 and rail 4 (see insert to Figure 11).

Referring to Figure 12, the rail 4 and outer shell and pad assembly 86 are then lowered into channel 88 in concrete track beds 90. The rail is now in place in the channel, and ready for alignment. This will now be described in more detail.

Referring to Figure 13 a plurality of alignment supports 100 are fixed in place, in the example at a longitudinal spacing of 1.5 metres although this spacing may be varied if required. The alignment supports 100 are fixed in place by first (referring to

Figure 14) fixing a plurality of support members 102 to the track beds with screws 104.

The support members include a vertical end clip 122, a substantially vertical plate 124 having an internal screw thread engaging screw 104, and a lateral joining plate 126.

Each alignment support 100 is fixed on a laterally opposed pair of support members 102, as can be seen on Figure 15.

Figure 15 also illustrates the form of the track bed with the channels 88 and shaped region 106 to which the adjustable support 102 can be mounted. It will further be noted that Figure 15 shows three rails being aligned. The invention is not limited to two rail systems, as discussed above, but can also be due to systems having a vast different number of rails, for example three as shown.

The alignment support 100 includes a lateral support bar 108, extending between the pair of alignment supports 102. The support bar 108 is fixed to the support members 102 by adjustable supports 110. As will be seen the detailed view of Figure 16, one of the adjustable supports 110 is a vertical adjustment support 112 for vertically adjusting the position of the beam 108, and the other adjustable support is a lateral support 114 for horizontally adjusting the position of 108. In each case, adjustment screws 116 are used to position the adjustable supports and hence the beam 108 with respect to the support members 102.

Each rail is supported on each alignment support 108 by a clamp 112. The clamps 112 are considered to be inverted U-shaped clamps, although this is not intended to imply an exact U-shape. The clamps 112 also each include support hooks 114, for example, acting as fastenings to hold the rail or its support or a suitable fastening arrangement as appropriate. In the disclosed embodiment, the support hooks are lifted from above on straps threaded through a ratchet mechanism 120. The combination of hooks 114 and ratchet 120 enables the rail and its support system, if appropriate, to be lifted from the trackbed and held securely in the clamp 112, ready for the levelling and aligning process to be performed. The support hooks 114 are also designed to hold the rail or its support system securely in the clamp 112, which is shaped to ensure that the rail will be held at the correct inclination with respect to the alignment support beam 108.

In use, the adjustment screws 116 are used to align, lift and incline the rails, and to provide an easy means of adjustment for both the vertical and the lateral positioning of the rails, for example to adjust the superelevation. Screw 118 adjusts the lateral

positioning of the clamps with respect to one another to adjust the gauge. In this way, it is possible to lay a slab track system to have rails of accurate height and position without needing to lay the track bed to the same accuracy as the rails. Moreover, the invention allows rails to be laid not merely in straight lengths but also in curves.

Once the rails are correctly aligned, cement-based grout is filled into the channels 88, in particular to cement the shell 86 in its now correctly aligned position in the track bed 90. Alternative fixing grouts or materials may be used if required. The rail is now held in place by the pad between the fixed shell and the rail 4.

It will be noted that by providing three clamps the alignment system shown may be used, not merely on two rail systems but also on three rail, dual gauge systems.

There is no need to provide different alignment units depending on the for single and dual gauge systems. The invention may also be used on multi-rail systems having any

nul-I LIL-1 er o-L"rai IS A, by prov-, 4,' ~ ; a'c riui-iiiler C) IP-1---number of rails 4, by providing an appropriate number of clamps.

The system thus provides a track laying system that allows accurate alignment of rails, and is of particular application in slab rail systems.

It should be appreciated that the systems described in the specific embodiment are purely by way of example, and the systems are not exclusively designed for the specific system shown in W099/63160. Some of the components are also suitable for other slab track systems, or conventional rail systems.

Claims

1. A rail alignment support for aligning rails with respect to a track bed comprising : a plurality of laterally spaced clamps for gripping a corresponding plurality of longitudinal rails from above; and adjustable supports for supporting the clamps and adjusting the position of the clamps with respect to the track bed to align the rails.

2. A rail alignment support according to claim 1 further comprising a lateral support beam carrying a pair of the adjustable supports wherein the plurality of clamps are fixed to the support beam between the adjustable supports.

3. A rail alignment support according to claim 1 or 2 further comprising support members for fixing with respect to the track bed and for carrying the rail alignment support.

4. A rail alignment support according to claim 3 wherein each adjustable support engages with a respective support member and can be adjusted vertically and laterally with respect to the support member.

5. A rail alignment support wherein each clamp further comprises a pair of laterally opposed support hooks for supporting a shell extending under the rail from one side of the rail to the other.

6. A rail laying trailer unit comprising: a frame; at least two laterally spaced wheels on the underside of the frame for supporting the frame and allowing the frame to be wheeled longitudinally; and rail supports fixed to the frame above the laterally spaced wheels, each rail support including a pair of laterally opposed guides and a roller between the guides with its axis aligned laterally for supporting a rail whilst allowing longitudinal movement.

7. A rail laying trailer unit according to claim 6 further comprising a tow pin fixed z to the frame for towing a set of linked rail laying trailer units as a rail laying train.

8. An end rail laying trailer unit comprising: a frame ; a pair of laterally spaced rail support units for supporting a rail, each rail support unit including at least one wheel on the underside of the rail support unit; and a plurality of longitudinally spaced rollers having a laterally aligned roll axis for supporting the rail as it extends longitudinally from the end rail laying trailer unit.

9. A rail laying train assembly comprising : a train of rail laying trailer units fixed together longitudinally; a plurality of wheels under the train to support the assembly and allow wheeled motion a plurality of rollers for supporting at least one length of rail at a plurality of points spaced along the length of rail allowing the rail to be rolled longitudinally on the rollers; and a plurality of guides for laterally locating the at least one length of rail.

10. A rail laying train assembly according to claim 9 wherein the rail laying trailer units are connected together by articulated joints.

11. A rail laying train assembly according to claim 9 or 10 wherein the rail laying trailer units include a plurality of units according to claim 6 fixed together and wherein the unit at one end of the frame is an end rail laying trailer unit according to claim 8.

12. A rail lifting beam comprising: a longitudinal beam made up of a plurality of modular sections; a plurality of lifting points longitudinally spaced along the beam for lifting the beam; and

a plurality of rail carrying units spaced longitudinally along the beam, each rail carrying unit comprising a pair of lateral members extending downwardly from the beam and defining a pair of laterally opposed holes, and a rail support pin passing through the laterally opposed holes to support a rail from below.

13. A rail support system for supporting a stack of rails comprising: a base unit having cross beam with a base surface and an upper surface and a plurality of pins spaced along the cross beam extending from the upper surface; and a plurality of intermediate units having a cross beam with a lower surface and an upper surface and a plurality of pins spaced along the cross beam extending from the upper and lower surfaces; wherein the shape and spacing of the pins is arranged to hold and support rails between adjacent pins at a suitable spacing for lifting.

14. A single rail laying trailer, comprising: a longitudinal frame ; a plurality of longitudinally spaced wheels for supporting the frame; a plurality of longitudinally spaced rail supports fixed to the frame above the wheels, each rail support including a pair of laterally opposed guides and a roller between the guides with its axis aligned laterally for supporting a rail whilst allowing longitudinal movement; and a plurality of guide wheels laterally of the frame.

15. A method of aligning track using a rail alignment support having a plurality of laterally spaced clamps for gripping a corresponding plurality of longitudinal rails from above and adjustable supports for supporting the rail alignment supports, the method comprising : fixing the rail alignment support to a plurality of laterally spaced rails from above using the plurality of clamps; adjusting the adjustable supports to align the rails, and fixing the rails in place in their aligned position.

16. A method according to claim 15 including fixing a plurality of rail alignment supports to the rails longitudinally spaced from one another

17. A method according to claim 15 or 16 for aligning within channels of a slab track system, including supporting a shell extending under the rail within the channel, wherein the step of fixing the rails in place includes filling the gap between the shell and the inner side of the channel with fixing material.

18. A method of laying track, including: mounting a rail section on rollers on a wheeled rail laying train on a track bed; moving the wheeled rail laying train longitudinally with respect to the rail

section to remove the wheeled rail laying train from under the rail section to lay the rail ZD section on the track bed.

19. A method according to claim 18 further comprising mounting a further rail section on the wheeled rail laying train in alignment with the original rail section when part only of the original rail section is still on the wheeled rail laying train and welding the further rail section to the original section.

20. A method according to claim 18 or 19 further comprising aligning the laid rail sections using a method according to claim 15 or 16.

21. A method of laying slab track into a channel using a method according to any of claim 15 to 20.

22. A method of laying slab track according to claim 21 when dependent on claim 18,19 or 20 including engaging the wheels of the wheeled rail laying train in the channels of the slab track to guide the longitudinal motion of the wheeled rail laying train.