LU500744B1 - A Construction Method of Ballastless Track with Replaceable Support Block by Tunnel Boot Method - Google Patents

Abstract

A construction method of ballastless track with replaceable support block by tunnel boot method, and the main construction process is as follows: pre-embedded reinforcement at the base -- roughening or scabbling at the base -- embedding the connecting reinforcement -- erecting the reinforcement mesh at the lower layer of the track ballast -- assembling the track bent on site -- erecting the track bent and roughly adjusting it in place -- erecting the longitudinal and transverse reinforcement at the upper layer -- erecting the track ballast formwork -- fine adjusting and fixing the track bent -- pouring the track ballast concrete and trowelling -- loosening the fasteners after initial setting -- concrete curing -- demolishing and transporting the formwork. Through the above method, the invention solves the technical problem of replacement difficulty of the support block in the prior art, and provides a replaceable support block, which is constructed by the boot method.

Description

A Construction Method of Ballastless Track with Replaceable Support Block by Tunnel Boot Method Technical Field

[0001] The invention relates to a construction method of ballastless track with support block, in particular to a real-time monitoring and alarm device for the loosening and falling off of hob bolts of shield machine based on the Internet of Things technology. Background Technology

[0002] The existing support block construction in the tunnel generally adopts the construction method of integral forming for sleepers. In the subsequent operation process, the damage of sleepers is an inevitable common phenomenon. After the sleepers are damaged, the sleepers need to be replaced as a whole. It has a high replacement construction intensity, and a long replacement construction period, which affects the normal operation of the railway.

Summary of the Invention

[0003] In view of the above problems, the invention provides a construction method of ballastless track with replaceable support block by tunnel boot method. During the process of opening and operation, if the sleepers are found to be damaged and need to be replaced, the support block can be directly separated for replacement due to the function of rubber boots outside the support block, so as to ensure the convenience of sleeper replacement.

[0004] In order to achieve the above purpose, the technical solutions adopted by the invention are: a construction method of ballastless track with replaceable support block by tunnel boot method, and the steps are as follows:

[0005] 1) Preparation Outside the Tunnel:

[0006] 1.1) Process the support block outside the tunnel, and sleeve the rubber boots at the bottom of the original support block;

[0007] 1.2) The standby sleepers are composed of support blocks, and the sleepers are assembled to form a track bent:

[0008] 2) Construction in the Tunnel:

[0009] 2.1) Tunnel invert treatment;

[0010] 2.2) Binding of reinforcement at the top of the track ballast;

[0011] 2.3) Set up the gantry crane walking tracks along the extension direction inside the tunnel;

[0012] 2.4) Conduct the assembly and transportation, erection of track bent and rough adjustment of track bent successively with the cooperation of the double gantry cranes set in the front and rear;

[0013] 2.5) Binding of reinforcement at the top of the track ballast;

[0014] 2.6) Fine adjustment and fixation of track bent;

[0015] 2.7) Use the single gantry crane to transport the external concrete into the tunnel for the 1 pouring of track ballast concrete; LU500744

[0016] 2.8) Curing of track ballast concrete;

[0017] 2.9) Demolition of formwork and track bent;

[0018] 3) Demolition and Replacement of Problem Support Block:

[0019] 3.1) Demount the track at the corresponding position and retain the bolts in the track positioning assembly;

[0020] 3.2) Use the jack to jack up the support block that needs to be replaced, and replace it with a new support block.

[0021] The specific methods in Step 2.1) are as follows:

[0022] 2.1.1) Roughening or Scabbling at the Base:

[0023] Perform scabbling treatment within the width of the track ballast plate of the concrete surface of the inverted arch filling layer and wash it with high-pressure water, keep it moist for more than 2 hours; the scabbling area can not be less than 75%, and the scabbling depth can not be less than 5mm;

[0024] 2.1.2) Embedding the Reinforcement: drill holes, clear holes, inject the embedded reinforcement glue, embed the reinforcement and solidify successively;

[0025] Drilling: embed the reinforcement within 200m from the opening of the hole, and detect the reinforcement in the structure with a reinforcement detector at the determined drilling position, the spacing of every one fastener is a row, and the longitudinal spacing is adjusted according to the spacing of the fasteners, each row is located in the middle of the fasteners, with four in each row, and the layout spacing is 430mm and 1080mm respectively from the left and right of the center line of the line; the hole diameter is 25mm and the hole depth is 210mm.

[0026] The Step 2.4) comprises:

[0027] 2.4.1) Assembly and Transportation

[0028] Hoisting: hoist the standby sleepers on the track bent assembly platform with a crane and a special lifting appliance for sleepers;

[0029] Evening Sleepers;

[0030] Installation: the track positioning assembly composed of T-head bolts, gauge apron and sub-track base plate is installed on the top of the support block;

[0031] Hoist the track bent, and manually cooperate with the gantry crane to place the track bent on the sleeper,

[0032] Adjust the configuration table according to the left and right positions of the single steel rail to place the insulated gauge blocks with appropriate specifications;

[0033] Install the elastic fasteners, flat washers and nuts, and tighten the nuts to fasten the elastic fasteners;

[0034] Tighten the fasteners;

[0035] The gantry crane hoists the assembled track bent to the predetermined place for positioning and laying.

[0036] The Step 2.4) comprises: 40 [0037] 2.4.2) Erection of Track Bent

[0038] Layout of Track Bent: the gantry crane hoists the track bents from the flat car and transports them to the laying site, and roughly locates them according to the center line and the elevation, and the error is controlled within the elevation of -10 + OMm and the center line of 10mm; the fishplates are used for connection between adjacent track bents, 4 sets of bolts are installed at 45 each joint, which are preliminarily tightened, and reserve 30~10mm in the joint gap; adjust the end position of each group of track bent according to the accurate mileage.

[0039] Installation of Track Direction Lock: use the track direction lock to fix the horizontal direction of the track bent, one end of the track direction lock is supported on the cross beam of the 2 track bent, and the other end is supported on the side wall of the tunnel or the steel reinforcing #80744 set on the tunnel base plate.

[0040] The Step 2.4) comprises:

[0041] 2.4.3) Rough Adjustment of Track Bent: use the center line point of the track to refer to the center line benchmark on the track bent frame to adjust the positioning of the bent center line, and adjust the left and right track direction lock; rotate the vertical support screw for rough adjustment of elevation direction; use the transverse and vertical adjustment mechanism of track bent to complete the rough adjustment of track bent, which is performed in the sequence of center line first and horizontal last, and the track position error after rough adjustment is controlled within the elevation of - 5~0mm and the center line of 5mm.

[0042] The fine adjustment of track bent in Step 2.6):

[0043] 2.6.1) Measuring the Track Data: the track state measuring instrument is placed on the track and the prism is installed; use the total station to measure the prism of track state measuring instrument; the trolley automatically measures the gauge, superelevation and horizontal position, receives the observation data, calculates the track plane position, level, superelevation, gauge and other data through the supporting software, and quickly feeds back the error value to the computer display screen of the track state measuring instrument to guide the track adjustment;

[0044] 2.6.2) Adjusting the Center Line: use the open-ended wrench to adjust the left and right track direction locks and adjust the track center line; during the adjustment process, the total station has been measuring the prism of the track state measuring instrument, receiving the observation data, and quickly feeding back the error value to the computer display screen of the track state measuring instrument through the supporting software, until the error value meets the requirements, and then the adjustment ends; adjust the center line in place on the tight side, and tighten the loose side under the monitoring of the instrument;

[0045] 2.6.3) Elevation Adjustment: after rough adjustment, the top elevation is slightly lower than the designed top elevation, use the socket wrench to rotate the vertical screw to adjust the track level and superelevation, after adjustment, check the tightness state between the screw and the concrete.

[0046] The beneficial effects of the invention are:

[0047] 1. In the long tunnel with narrow working space, the ballastless track with replaceable support block by tunnel boot method is adopted. When replacing the sleepers for line maintenance and repair, only the support block needs to be replaced. Compared with the conventional ballastless track ballast, the support block has smaller volume, lighter weight, more convenient for transportation, shorter replacement time and less interference to traffic.

[0048] 2. The replaceable support block is constructed by boot method, which reduces the quantity of track ballast maintenance and saves the maintenance cost.

Brief Description of Drawings

[0049] Figure 1: a structural diagram of the invention. 40 [0050] Figure 2: a construction flow chart of the invention.

[0051] Figure 3: a reinforcement drawing of the Embodiment 1.

[0052] Figure 4: a diagram of rough adjustment of track bent of the Embodiment 1.

[0053] Figure 5: a schematic diagram of expansion joint.

[0054] Figure 6: a side view of Figure 5.

45 [0055] In the figures: 1-Rubber boots; 2-Concrete support block; 3-Gauge apron; 4-Type I! elastic fastener; 5-T-head bolt; 6-Cap nut; 7-Gauge block; 8-Sub-track foot pad; 9-Pre-embedded 3 iron base; 10-Sub-block foot pad. LU500744 Detailed Description of the Presently Preferred Embodiments

[0056] A construction method of ballastless track with replaceable support block by tunnel boot method, and the steps are as follows:

[0057] 1) Preparation Outside the Tunnel:

[0058] 1.1) Process the support block outside the tunnel, and sleeve the rubber boots at the bottom of the original support block;

[0059] 1.2) The standby sleepers are composed of support blocks, and the sleepers are assembled to form a track bent;

[0060] 2) Construction in the Tunnel:

[0061] 2.1) Tunnel invert treatment, and the specific methods in Step 2.1) are as follows:

[0062] 2.1.1) Roughening or Scabbling at the Base:

[0063] Perform scabbling treatment within the width of the track ballast plate of the concrete surface of the inverted arch filling layer and wash it with high-pressure water, keep it moist for more than 2 hours; the scabbling area can not be less than 75%, and the scabbling depth can not be less than 5mm;

[0064] 2.1.2) Embedding the Reinforcement: drill holes, clear holes, inject the embedded reinforcement glue, embed the reinforcement and solidify successively;

[0065] Drilling: embed the reinforcement within 200m from the opening of the hole, and detect the reinforcement in the structure with a reinforcement detector at the determined drilling position, the spacing of every one fastener is a row, and the longitudinal spacing is adjusted according to the spacing of the fasteners, each row is located in the middle of the fasteners, with four in each row, and the layout spacing is 430mm and 1080mm respectively from the left and right of the center line of the line; the hole diameter is 25mm and the hole depth is 210mm.

[0066] 2.2) Binding of reinforcement at the top of the track ballast;

[0067] 2.3) Set up the gantry crane walking tracks along the extension direction inside the tunnel;

[0068] 2.4) Conduct the assembly and transportation, erection of track bent and rough adjustment of track bent successively with the cooperation of the double gantry cranes set in the front and rear;

[0069] 2.4.1) Assembly and Transportation

[0070] Hoisting: hoist the standby sleepers on the track bent assembly platform with a crane and a special lifting appliance for sleepers;

[0071] Evening Sleepers;

[0072] Installation: the track positioning assembly composed of T-head bolts, gauge apron and sub-track base plate is installed on the top of the support block;

[0073] Hoist the track bent, and manually cooperate with the gantry crane to place the track bent on the sleeper; 40 [0074] Adjust the configuration table according to the left and right positions of the single steel rail to place the insulated gauge blocks with appropriate specifications; 4

[0075] Install the elastic fasteners, flat washers and nuts, and tighten the nuts to fasten th&500744 elastic fasteners;

[0076] Tighten the fasteners;

[0077] The gantry crane hoists the assembled track bent to the predetermined place for positioning and laying.

[0078] 2.4.2) Erection of Track Bent

[0079] Layout of Track Bent: the gantry crane hoists the track bents from the flat car and transports them to the laying site, and roughly locates them according to the center line and the elevation, and the error is controlled within the elevation of -10~0mm and the center line of 10mm; the fishplates are used for connection between adjacent track bents, 4 sets of bolts are installed at each joint, which are preliminarily tightened, and reserve 30~10mm in the joint gap; adjust the end position of each group of track bent according to the accurate mileage.

[0080] Installation of Track Direction Lock: use the track direction lock to fix the horizontal direction of the track bent, one end of the track direction lock is supported on the cross beam of the track bent, and the other end is supported on the side wall of the tunnel or the steel reinforcing rod set on the tunnel base plate.

[0081] 2.4.3) Rough Adjustment of Track Bent: use the center line point of the track to refer to the center line benchmark on the track bent frame to adjust the positioning of the bent center line, and adjust the left and right track direction lock; rotate the vertical support screw for rough adjustment of elevation direction; use the transverse and vertical adjustment mechanism of track bent to complete the rough adjustment of track bent, which is performed in the sequence of center line first and horizontal last, and the track position error after rough adjustment is controlled within the elevation of - 5 ~ 0mm and the center line of 5mm.

[0082] 2.5) Binding of reinforcement at the top of the track ballast;

[0083] 2.6) Fine adjustment and fixation of track bent;

[0084] The fine adjustment of track bent in Step 2.6):

[0085] 2.6.1) Measuring the Track Data: the track state measuring instrument is placed on the track and the prism is installed; use the total station to measure the prism of track state measuring instrument; the trolley automatically measures the gauge, superelevation and horizontal position, receives the observation data, calculates the track plane position, level, superelevation, gauge and other data through the supporting software, and quickly feeds back the error value to the computer display screen of the track state measuring instrument to guide the track adjustment;

[0086] 2.6.2) Adjusting the Center Line: use the open-ended wrench to adjust the left and right track direction locks and adjust the track center line; during the adjustment process, the total station has been measuring the prism of the track state measuring instrument, receiving the observation data, and quickly feeding back the error value to the computer display screen of the track state measuring instrument through the supporting software, until the error value meets the requirements, and then the adjustment ends; adjust the center line in place on the tight side, and 40 tighten the loose side under the monitoring of the instrument;

[0087] 2.6.3) Elevation Adjustment: after rough adjustment, the top elevation is slightly lower than the designed top elevation, use the socket wrench to rotate the vertical screw to adjust the track level and superelevation, after adjustment, check the tightness state between the screw and the concrete.

5

[0088] 2.7) Use the single gantry crane to transport the external concrete into the tunnel 197500744 the pouring of track ballast concrete;

[0089] 2.8) Curing of track ballast concrete;

[0090] 2.9) Demolition of formwork and track bent;

[0091] 3) Demolition and Replacement of Problem Support Block:

[0092] 3.1) Demount the track at the corresponding position and retain the bolts in the track positioning assembly;

[0093] 3.2) Use the jack to jack up the support block that needs to be replaced, and replace it with a new support block.

[0094] Embodiment 1:

[0095] The Gada Tunnel is located in Zhanang County, Shannan Prefecture on the left side of the Yarlung Zangbo River in the southeast of the Qinghai-Tibet Plateau. It is located in an inactive fault zone, the entrance mileage is DK73+503, the exit mileage is DK74+623, the total length is 1120m, and it is a single-hole passenger railway tunnel. Considering the difficulty of sleeper replacement during the maintenance and repair of the line in the tunnel due to long operation time and narrow working space, we adopted the ballastless track with replaceable support block by tunnel boot method in the structural construction of the tunnel line, and completed the replacement of the damaged support block during the renovation to ensure the good condition of the line.

[0096] |. Construction Process Flow

[0097] The main construction process flow of ballastless track with elastic support block is as follows: pre-embedded reinforcement at the base -- roughening or scabbling at the base -- embedding the connecting reinforcement -- erecting the reinforcement mesh at the lower layer of the track ballast -- assembling the track bent on site -- erecting the track bent and roughly adjusting it in place -- erecting the longitudinal and transverse reinforcement at the upper layer -- erecting the track ballast formwork -- fine adjusting and fixing the track bent -- pouring the track ballast concrete and trowelling -- loosening the fasteners after initial setting -- concrete curing -- demolishing and transporting the formwork.

[0098] II. Key Points of Operation

[0099] 2.1) Tunnel Invert Treatment;

[0100] 1. Roughening or Scabbling at the Base

[0101] Perform scabbling treatment within the width of the track ballast plate of the concrete surface of the inverted arch filling layer and wash it with high-pressure water, keep it moist for more than 2 hours, and there is no sundries and ponding. The scabbling area can not be less than 75%, and the scabbling depth can not be less than 5mm.

[0102] 2. Embedding the Reinforcement

[0103] Drilling: embed the reinforcement within 200m from the opening of the hole when the concrete surface meets the scabbling requirements, and detect the reinforcement in the structure with a reinforcement detector at the determined drilling position to avoid damaging the 40 Main stressed reinforcement. The spacing of every one fastener is a row, and the longitudinal spacing is adjusted according to the spacing of the fasteners, each row is located in the middle of the fasteners, with four in each row, and the layout spacing is 430mm and 1080mm respectively from the left and right of the center line of the line. The hole diameter is 25mm and the hole depth is 210mm. 6

[0104] Clearing Hole: clean the hole with compressed air, brush it with a metal bristle 197500744 three times and blow it for three times to ensure that the hole wall is clean and free of floating dust, free water or slurry.

[0105] Injecting the Embedded Reinforcement Glue: when injecting the glue, inject the glue from the bottom of the hole until 2/3 of the hole volume is filled.

[0106] Embed the Reinforcement: slowly insert the prepared HRB400@20 reinforcement with a length of 380mm into the bottom of the hole, and install it within the specified initial setting time, so that the embedded reinforcement glue is evenly attached to the surface of the reinforcement and the gap of the concrete hole. The reinforcement is inserted for 200mm and exposed for 180mm. See Figure 3.

[0107] Curing: it is forbidden to disturb the installed reinforcement within the specified curing time.

[0108] 2.2) Erecting the reinforcement mesh at the lower layer of the track ballast

[0109] The reinforcement mesh at the lower layer of the track ballast plate adopts 15 pieces of HRB400¢@16 reinforcement and longitudinal HRB400@12 reinforcement, the erection reinforcement adopts the HRB400@10 reinforcement, the insulating clamps are set at the junction of longitudinal and transverse reinforcement and erection reinforcement, and they are bound firmly with insulating wires. Arrange the prefabricated concrete cushion blocks in quincunx shape, with no less than 4 blocks/m?, and ensure that the reinforcement protection layer is not less than 35mm.

[0110] 2.3) Assembly and Transportation of Track Bent

[0111] 1. Hoisting, hoist the standby sleepers on the track bent assembly platform with a crane and a special lifting appliance for sleepers, and it needs to hoist and operate at a low speed during hoisting;

[0112] 2. Evening sleepers, artificially even sleepers according to the positioning line and fixtures of the sleeper blocks on the assembly platform, and the sleepers are square;

[0113] 3. Remove the dirt on the truck bearing surface between the two pre-embedded iron stands of the sleeper and the mortar in the pre-embedded iron stand, and install the T-head bolts, gauge apron and sub-track base plate. In case of standard gauge, the outside of the gauge apron adopts the No.7, and the inside adopts the No.11.

[0114] 4. Hoist the track bent, and manually cooperate with the gantry crane to place the track bent on the sleeper stably and slowly;

[0115] 5. Adjust the configuration table according to the left and right positions of the single steel rail to place the insulated gauge blocks with appropriate specifications; in case of standard gauge, the outside of the insulated gauge block adopts the No.14, and the inside adopts the No.10.

[0116] 6. Apply oil to the thread part of T-head bolts, install the elastic fasteners, flat washers and nuts, and tighten the nuts to fasten the elastic fasteners.

[0117] 7. Tighten the fasteners. The fastening of the elastic fasteners is based on the 40 contact between the lower jaw of the front end in the middle of the elastic fasteners and the insulating gauge blocks, and the tightening torque is about 150N-m (actually about 200N-m).

[0118] 8. Check the installation quality of track bent bolts and sleeper spacing. After passing the inspection, the gantry crane hoists the assembled track bent to the predetermined place for positioning and laying.

-_——

[0119] Pay attention to the assembly sequence of the vent and fastener parts, the distinctibh/500744 between the inner and outer sides of the gauge apron and insulating gauge block, the positive and negative of the sub-track base plate and the on-site control of the tightening torque.

[0120] 2.4) Erection of Track Bent

[0121] 1. Layout of Track Bent

[0122] The gantry crane hoists the track bents from the flat car and transports them to the laying site, and roughly locates them according to the center line and the elevation, and the error is controlled within the elevation of -10 ~ Omm and the center line of £10mm. The fishplates are used for connection between adjacent track bents, 4 sets of bolts are installed at each joint, which are preliminarily tightened, and reserve 30~10mm in the joint gap. Adjust the end position of each group of track bent according to the accurate mileage.

[0123] 2. Installation of Track Direction Lock

[0124] Use the track direction lock to fix the horizontal direction of the track bent, one end of the track direction lock is supported on the cross beam of the track bent, and the other end is supported on the steel reinforcing rod set on the tunnel base plate.

[0125] 2.5) Rough Adjustment of Track Bent

[0126] Use the center line point of the track to refer to the center line benchmark on the track bent frame to adjust the positioning of the bent center line, and adjust the left and right track direction lock; rotate the vertical support screw for rough adjustment of elevation direction; use the transverse and vertical adjustment mechanism of track bent to complete the rough adjustment of track bent, which is performed in the sequence of center line first and horizontal last, and the track position error after rough adjustment is controlled within the elevation of - 5 ~ Omm and the center line of 5mm. The rough adjustment sequence is shown in Figure 4: For two specific track bent frames, the rough adjustment sequence is: 1—>4—>5—>8—2—3—6—7—>1—>2—>3—>4—5—6—7—8.

[0127] 2.6) Binding of reinforcement at the top of the track ballast

[0128] The reinforcement mesh at the upper layer of the track ballast plate adopts 19 pieces of transverse HRB400@16 reinforcement and longitudinal HRB400¢12 reinforcement, the erection reinforcement adopts the HRB400@10 reinforcement, the insulating clamps are set at the junction of longitudinal and transverse reinforcement and erection reinforcement at the upper layer, and they are bound firmly with insulating wires. The reinforcement protection layer is not less than 35mm. This section of ballastless track is arranged with transverse reinforcement at the upper layer according to the fastener spacing of 600mm. When the fastener spacing is adjusted, the spacing between two adjacent transverse reinforcements on both sides of the sleeper remains unchanged, and the spacing between the two reinforcements between adjacent sleepers is adjusted to adapt to the change of the fastener spacing.

[0129] After the reinforcements are all bound, the insulation performance test of the reinforcements should be conducted to ensure that the insulation measures of the reinforcements meet the requirements. Meanwhile, the track circuit transmission distance test 40 Should be conducted before concrete pouring on the track ballast plate, and the measured value of the insulation resistance of the insulating reinforcement should be greater than 2MQ.

[0130] Pay attention to the stirrup spacing around the support block, the gap between the block and the boot (1cm) and the thickness of the protective layer of the top and top reinforcement to ensure that it meets the design requirements. During construction, the actual -_——

thickness of the track ballast plate should be verified first, when the actual thickness is within th&'500744 allowable deviation range, the corresponding size of the reinforcement in the reinforcement cage should be adjusted reasonably to ensure that the thickness of the protection layer meets the design requirements.

[0131] 2.7) Installation of Formwork

[0132] 1. Formwork Inspection. Before formwork installation, the following inspections should be conducted: flatness of formwork, cleaning of formwork, painting of release agent, and replacement of damaged or bent formwork.

[0133] 2. Install longitudinal and transverse formwork. The longitudinal formwork adopts the formwork matched with the frame, which is numbered uniformly before leaving the factory to ensure the smoothness and straightness of the track bent frame.

[0134] 3. The track ballast plate adopts blocking structure and overall pouring, the split length is about 6m within a range of 200m from the opening of the hole, and the split length is about 12m within a range of more than 200m from the opening of the hole. The expansion joint of the track ballast plate is filled with closed-hole polyethylene plastic foam board and sealed with silicone joint filling sealing material, and the contact surface between the silicone joint filling sealing material and the concrete is brushed with the bonding agent. When constructing the expansion joint of the track ballast, it should be ensured that the expansion joint is perpendicular to the center of the line, located between the two support blocks and in the middle, and should not be skewed. After the expansion chain is sealed, the sealing surface should be flush with the top surface of the track ballast and should not protrude from the surface of the track ballast. In case of tunnel deformation joint, the expansion joint of the track ballast should be aligned. The expansion joint is located between the support blocks and in the middle, and should not be skewed. The plate length can be adjusted appropriately, the adjustment range of the plate length should be 1.2m, and the spacing of fasteners should not be greater than 600mm. (The support block should not be placed at deformation joint/construction joint)

[0135] Pay attention to the chamfering position treatment of the longitudinal formwork to ensure that the lines are straight and beautiful. The transverse expansion joint should adopt appropriate materials to ensure that they are no deformed and meet the construction of subsequent processes. As shown in Figures 5-6.

[0136] 2.8) Fine adjustment of track bent

[0137] 1. Measure the track data. The track state measuring instrument is placed on the track and the prism is installed. Use the total station to measure the prism of track state measuring instrument. The trolley automatically measures the gauge, superelevation and horizontal position, receives the observation data, calculates the track plane position, level, superelevation, gauge and other data through the supporting software, and quickly feeds back the error value to the computer display screen of the track state measuring instrument to guide the track adjustment.

[0138] 2. Adjust the center line. Use the open-ended wrench to adjust the left and right track 40 direction locks and adjust the track center line, adjust two groups at a time, and assign two people on the left and right to work at the same time. During the adjustment process, the total station has been measuring the prism of the track state measuring instrument, receiving the observation data, and quickly feeding back the error value to the computer display screen of the track state measuring instrument through the supporting software, until the error value meets the 45 requirements, and then the adjustment ends; adjust the center line in place on the tight side, and tighten the loose side under the monitoring of the instrument, during this process, the adjusted 9 center line should not be disturbed. LU500744

[0139] 3. Elevation adjustment: After rough adjustment, the top elevation is slightly lower than the designed top elevation. Use the socket wrench to rotate the vertical screw to adjust the track level and superelevation (loosen the ultra-high adjuster, adjust the inclination of the track bent to Make the track bent frame reach the designed elevation, and tighten the vertical screws on both sides to make the vertical screws perpendicular to the ground). After adjustment, manually check whether the screw is closely attached to the concrete to ensure that the bottom of the screw is not suspended. When adjusting the stud, it should be conducted slowly, and the elevation change is 1mm by rotating 120 ° . (Center line before elevation)

[0140] Precautions:

[0141] 1) Fine adjustment sequence. It is the same as rough adjustment sequence.

[0142] 2) Sequential transition method. After the adjustment of the previous station, 8 to 10 peices of sleepers adjusted in the previous station should be overlapped during the adjustment of the next station.

[0143] 3) Stop other construction operations in the measurement area.

[0144] 4) After the track bent is fine adjusted in place, a fixing device should be installed to prevent the track bent from moving laterally and floating upward during concrete pouring.

[0145] 5) After the fine adjustment of the track bent, protective measures such as setting up a fence (color pennant) and hanging the sign of “Fine Adjustment Area, No Crossing” should be taken to ensure that the track bent is not trampled and impacted.

[0146] 6) The concrete should be poured as soon as possible after the fine adjustment of the track bent. If the track bent is disturbed by the outside, or the placing time is too long (12h), or the ambient temperature changes more than 15 °C, the concrete can be poured only after it is re-checked and confirmed to be qualified.

[0147] 2.9) Pouring of Concrete

[0148] 1. Construction preparation. Before pouring, clean up the sundries on the pouring surface, sprinkle water before pouring to moisten it, and no ponding is allowed. In order to ensure a good combination of sleepers and fresh concrete, the sleepers need be sprayed several times before pouring. Cover the sleepers, fasteners and steel rails with protective covers, and wrap the steel rails and frame beams with plastic cloth. Check whether each adjusting screw on the track bent is suspended. The elevation of the top surface of the track ballast plate adopts a fixed slope ruler to place the top surface of the steel rail and scrape the concrete surface.

[0149] 2. Check and confirm the retest results of the track bent. Before pouring concrete, recheck the geometric parameters of the track, and readjust if it exceeds the allowable deviation;

[0150] 3. Concrete mixing and transportation. The track ballast plate concrete is concentratedly mixed by the mixing station and poured by hopper during construction. After the concrete is transported to the construction site by the concrete transport cart, the slump degree, air content and temperature index of each cart of concrete should be tested, and the material 40 can be unloaded only after it is qualified;

[0151] 4. Concrete cloth. It is conducted continuously from one end to the other end, the concrete is covered under each sleeper, and it is not allowed to flow from one side to the other. Pay attention to timely vibration during blanking, and the blanking should be uniform and slow, and should not impact the track bent and support block (especially strengthen the vibration at 10 the bottom and surrounding of the support block); LU500744

[0152] 5. Concrete vibration. The track ballast concrete uses four vibrators to vibrate manually, with an interval of about 2m between the front and rear areas. Two people in the front area use the ZD50 vibrator to vibrate symmetrically on the left and right, not one behind the other, and mainly tamp the reinforcement mesh at the bottom and lower part of the sleeper, and two people in the rear area use the ZD30 vibrator to mainly tamp the surrounding of the sleeper and the inner side of the formwork, and supplement the vibration for the lack of vibration. During tamping, avoid the vibrator from contacting the bent and sleeper, and deal with it timely when there is excess or insufficient concrete (the operator should not step on the support block and track vent, and make a horse stool with a length of 3.0m and a height of 0.8m on site);

[0153] 6. Trowelling. After the surface concrete is vibrated, repair and trowel the exposed surface of the concrete in time (trowelling in three times, rough trowelling of wood formwork, fine trowelling of steel formwork, trowelling and calendering before initial setting. A long handle trowel is used at the lower part of the track bent frame. In principle, it is not allowed to moisten the concrete surface with clean water and then trowel it. The elevation of the top surface of the track ballast close to the center line of the line in the straight section is controlled at 2mm below the brim of the hat, which is followed by the 1% gable slope. The elevation of the top surface of the track ballast in the curve section is controlled at 2mm below the brim of the hat, and the top surface of the track ballast should not be higher than the lower brim of the boots under any circumstances);

[0154] 7. Clean the track bent. After the trowelling is completed, clean the stained mortar on the track bents, sleepers and fasteners in time with a brush and moist rag to prevent pollution (it is forbidden to clean the track bents with water);

[0155] 8. Data collection and review. After the completion of concrete pouring and before the initial setting, use the fine adjustment trolley to collect the geometric shape data of the track again (the initial setting time is obtained through the test in principle);

[0156] 9. After the initial setting of concrete, loosen the support bolts for 1/4 ~1/2 circle, and then loosen the fasteners to avoid the damage to the concrete caused by steel rail expansion and contraction when the temperature changes, after the concrete reaches a certain strength (after final setting), tighten the fasteners for data collection, which is compared with the fine adjustment data.

[0157] 5.2.10 Curing of track ballast concrete

[0158] Cover and begin to water for curing within 12 hours after the completion of concrete pouring, and keep the concrete in a moist state. After the completion of concrete curing, the surface should be cleaned, the gap around the boot and the track ballast concrete should be sealed with silicone joint filling sealing material, and the gap shall be dry, clean, free of dust and sundries, etc. Special construction machines and tools should be used for the construction of the joint filling sealing material, and the sealing speed should be slow and uniform, avoid generating the bubbles as far as possible, so as to ensure that the silicone joint filling sealing material fits 40 well with the gap. For the curve superelevation section, it should be closed in sections from the high place to make the joint filling sealing material flow to the low place in sequence. The effective protective measures should be taken to prevent water and impurities from falling into the joint filling sealing material after sealing and before drying, and to avoid the damage to the joint filling sealing material in the next process. 45 [0159] 5.2.11 Demolition of formwork and track bent

[0160] The formwork can be demolished only when the concrete strength reaches more 11 than 5MPa, and the steel rail support frame can be demolished. After the formwork Lig500744 demolished, the external dimension of the track ballast plate should be checked, and the allowable deviation should meet the following requirements: Flatness: 3mm/m; top width: +10mm; height difference: +5mm. The falling blocks of the concrete track ballast in the demolition of the formwork due to collision should be further repaired, and the concrete or repairing agent with a higher-grade label should be used for repair.

[0161] The demolished formwork and truck vent should be calibrated, oiled and repaired in time, and the spare parts should be stacked neatly for use in the next construction section.

12

Claims (6)

. LU500744 Claims

1. A construction method of ballastless track with replaceable support block by tunnel boot method, which is characterized in that, the steps are as follows: 1) Preparation Outside the Tunnel:

1.1) Process the support block outside the tunnel, and sleeve the rubber boots at the bottom of the original support block;

1.2) The standby sleepers are composed of support blocks, and the sleepers are assembled to form a track bent; 2) Construction in the Tunnel:

2.1) Tunnel invert treatment;

2.2) Binding of reinforcement at the top of the track ballast;

2.3) Set up the gantry crane walking tracks along the extension direction inside the tunnel;

2.4) Conduct the assembly and transportation, erection of track bent and rough adjustment of track bent successively with the cooperation of the double gantry cranes set in the front and rear;

2.5) Binding of reinforcement at the top of the track ballast;

2.6) Fine adjustment and fixation of track bent;

2.7) Use the single gantry crane to transport the external concrete into the tunnel for the pouring of track ballast concrete;

2.8) Curing of track ballast concrete;

2.9) Demolition of formwork and track bent; 3) Demolition and Replacement of Problem Support Block:

3.1) Demount the track at the corresponding position and retain the bolts in the track positioning assembly:

3.2) Use the jack to jack up the support block that needs to be replaced, and replace it with a new support block.

2. A construction method of ballastless track with replaceable support block by tunnel boot method as described in claim 1, which is characterized in that, the specific methods in Step 2.1) are as follows:

2.1.1) Roughening or Scabbling at the Base: Perform scabbling treatment within the width of the track ballast plate of the concrete surface of the inverted arch filling layer and wash it with high-pressure water, keep it moist for more than 2 hours; the scabbling area can not be less than 75%, and the scabbling depth can not be less than 5mm;

2.1.2) Embedding the Reinforcement: drill holes, clear holes, inject the embedded reinforcement glue, embed the reinforcement and solidify successively; Drilling: embed the reinforcement within 200m from the opening of the hole, and detect the reinforcement in the structure with a reinforcement detector at the determined drilling position, the spacing of every one fastener is a row, and the longitudinal spacing is adjusted according to the 40 spacing of the fasteners, each row is located in the middle of the fasteners, with four in each row, and the layout spacing is 430mm and 1080mm respectively from the left and right of the center line of the line; the hole diameter is 25mm and the hole depth is 210mm.

3. A construction method of ballastless track with replaceable support block by tunnel boot 13 method as described in claim 1, which is characterized in that, the Step 2.4) comprises: LU500744

2.4.1) Assembly and Transportation Hoisting: hoist the standby sleepers on the track bent assembly platform with a crane and a special lifting appliance for sleepers; Evening Sleepers; Installation: the track positioning assembly composed of T-head bolts, gauge apron and sub-track base plate is installed on the top of the support block; Hoist the track bent, and manually cooperate with the gantry crane to place the track bent on the sleeper; Adjust the configuration table according to the left and right positions of the single steel rail to place the insulated gauge blocks with appropriate specifications; Install the elastic fasteners, flat washers and nuts, and tighten the nuts to fasten the elastic fasteners; Tighten the Fasteners; The gantry crane hoists the assembled track bent to the predetermined place for positioning and laying.

4. A construction method of ballastless track with replaceable support block by tunnel boot method as described in claim 1, which is characterized in that, the Step 2.4) comprises:

2.4.2) Erection of Track Bent Layout of Track Bent: the gantry crane hoists the track bents from the flat car and transports them to the laying site, and roughly locates them according to the center line and the elevation, and the error is controlled within the elevation of -10~0mm and the center line of £10mm; the fishplates are used for connection between adjacent track bents, 4 sets of bolts are installed at each joint, which are preliminarily tightened, and reserve 30~10mm in the joint gap; adjust the end position of each group of track bent according to the accurate mileage.

Installation of Track Direction Lock: use the track direction lock to fix the horizontal direction of the track bent. One end of the track direction lock is supported on the cross beam of the track bent, and the other end is supported on the side wall of the tunnel or the steel reinforcing rod set on the tunnel base plate.

5. A construction method of ballastless track with replaceable support block by tunnel boot method as described in claim 1, which is characterized in that, the Step 2.4) comprises:

2.4.3) Rough Adjustment of Track Bent: use the center line point of the track to refer to the center line benchmark on the track bent frame to adjust the positioning of the bent center line, and adjust the left and right track direction lock; rotate the vertical support screw for rough adjustment of elevation direction; use the transverse and vertical adjustment mechanism of track bent to complete the rough adjustment of track bent, which is performed in the sequence of center line first and horizontal last, and the track position error after rough adjustment is controlled within the elevation of - 5~0mm and the center line of +5mm.

6. A construction method of ballastless track with replaceable support block by tunnel boot 40 method as described in claim 5, which is characterized in that, the fine adjustment of track bent in Step 2.6):

2.6.1) Measuring the Track Data: the track state measuring instrument is placed on the track 14 and the prism is installed; use the total station to measure the prism of track state measukidg00744 instrument; the trolley automatically measures the gauge, superelevation and horizontal position, receives the observation data, calculates the track plane position, level, superelevation, gauge and other data through the supporting software, and quickly feeds back the error value to the computer display screen of the track state measuring instrument to guide the track adjustment;

2.6.2) Adjusting the Center Line: use the open-ended wrench to adjust the left and right track direction locks and adjust the track center line; during the adjustment process, the total station has been measuring the prism of the track state measuring instrument, receiving the observation data, and quickly feeding back the error value to the computer display screen of the track state measuring instrument through the supporting software, until the error value meets the requirements, and then ends after adjustment; adjust the center line in place on the tight side, and tighten the loose side under the monitoring of the instrument;

2.6.3) Elevation Adjustment: after rough adjustment, the top elevation is slightly lower than the designed top elevation, use the socket wrench to rotate the vertical screw to adjust the track level and superelevation, after adjustment, check the tightness state between the screw and the concrete. 15