WO2005001203A1

WO2005001203A1 - Method for producing a rail track for rail vehicles

Info

Publication number: WO2005001203A1
Application number: PCT/EP2004/005889
Authority: WO
Inventors: Stefan Knittel
Original assignee: Rte Technologie Gmbh
Priority date: 2003-06-26
Filing date: 2004-06-01
Publication date: 2005-01-06
Also published as: EP1636424A1; ATE420993T1; EP1636424B1; DE10328895A1; DE502004008874D1

Abstract

The invention relates to a method for producing a rail track for rail vehicles. Said method is characterised in that recesses (13) for fastening elements (16) are first formed in a concrete carrier plate, rail fastening plates (15) are then laid over the recesses, and the rail fastening elements (16) are inserted into the recesses (13) through said plates, and in that the rails (20) are then connected to the fastening plates (15) and adjusted to the correct height and lateral position, whereupon the recesses (13) receiving the fastening elements with play and the intermediate regions (22) formed between the rail fastening plates and the concrete carrier plate after the adjustment of the rails are filled with a hardening, low-shrinkage, fatigue-resistant, flowable joint mortar.

Description

Title: Process for the production of a railroad track for rail vehicles

The invention relates to a method for producing a track carriageway for rail vehicles, as is used in particular for modern high-speed lines as a so-called fixed carriageway.

Solid carriageway is generally understood to mean a railway superstructure in which the ballast is replaced by another material, for example concrete or asphalt, which, in contrast to the ballast, is only slightly deformable. Various types of construction are known for the solid carriageway, for example, embedded systems such as the Rheda type with its two modifications Rheda-Sengeberg and Rheda-Berlin, or the Heitkamp and Züblin systems, in which the classic track grating is aligned in a concrete trough and then by pouring filler concrete into it the gaps remaining between the concrete trough and sleepers are permanently stabilized. In addition to these stored systems, there are also superimposed systems, for example the Sato system, in which the track grating is laid either with Y-steel sleepers or conventional self-service sleepers on an asphalt base layer that is manufactured to a precise height and can also be milled off if required. The interlocking with the asphalt base course takes place by means of flat irons, which are cast in milled grooves. There is also the Trac type, in which the track is also supported on an asphalt base course, with fixation using dowel blocks. follows, which are embedded in recesses in the base layer and engage in the underside of the sleepers in neoprene shoes. The dowel stones are poured into these depressions, which are made in the still hot asphalt.

All known, so-called "top down" methods for producing a solid roadway have in common that the amount of work, the amount of material to be used and the time which must be invested in the production of such a roadway are all very large, which makes the production of a solid track for rail vehicles very expensive. With the cheaper "bottom-up" method, solid tracks can only be produced with unsatisfactory inaccuracies, which require a systematic compensation by means of intermediate layers.

The object of the invention is therefore to provide a method for producing a track carriageway for rail vehicles, with which a solid carriageway can be produced more easily, more quickly, more cheaply and with clearly defined interfaces between the trades than with the known construction methods.

To achieve this object, the method according to the invention has the following method steps:

- Manufacture of a concrete slab extending in the direction of the carriageway;

- Making recesses in the concrete slab in the area of the later track attachment points;

- Placing rail fastening plates on the concrete support plate, the rail fastening plates being provided or provided with fastening elements whose transverse cut is smaller than that of the recesses and which protrude into the recesses with play;

- Attaching rails to the rail fastening plates and then aligning the rails connected to the fastening plates into their desired height and side position by means of track straightening elements acting between two fastening plates;

- Filling the gaps between the fastening plates and the concrete support plate and the recesses which take up the fastening elements with play with a hardening, low-shrinkage and well-flowing grout; and

- possibly . Disassembly of the track straightening elements after hardening of the grout.

In the method according to the invention, fewer operations are required than in the known methods, which makes it particularly economical, and the work can also be carried out in a time-separated manner. It is not necessary to support the rails after their alignment on support bodies, which then remain in the casting compound after subsequent casting, because the casting in the method according to the invention takes place only below the fastening plates between them and the concrete support plate, while the rails between two successive ones Fastening plates remain completely free.

The concrete base plate can preferably be produced continuously with a pre-filled concrete paver. The recesses are expediently made in the set, fresh concrete, which is due to the hardness of the loading that has not yet been fully tons can be done with simple tools. The recesses are expediently drilled as holes in the concrete.

Cross joints for controlled cracking can be provided in the fresh concrete of the base plate. The distance between the transverse joints depends on the specific requirements of the respective project. In order to achieve a particularly high strength of the connection during the later fastening of the fastening plates with the fastening elements, it may be advantageous to provide the recesses or the like with undercuts lying below the upper side of the carrier plate. to produce, the undercuts can be produced particularly easily by being drilled in the form of threads by means of a tapping tool.

Each rail fastening plate is preferably provided with at least two fastening elements. Before inserting the fasteners into the recesses, these are expedient or the like from any contamination. cleaned, so that it is ensured that the fastening elements engage in the recesses, preferably with approximately the same amount of play in all directions between themselves and the surrounding walls of the recesses. Screw bolts, which are inserted through the rail fastening plates and screwed onto the dowels, can preferably serve as fastening elements. In this case, the procedure is preferably such that the screw bolts are prestressed in their dowels before the recesses are filled with the grout with the fastening elements protruding into them.

The fastening elements can protrude into the recesses on their circumference with undercuts, in particular grooves, grooves and the like. be provided so that after filling the recesses and hardening the potting masses are positively locked. Before filling the gaps and the recesses, the rail fastening plates or the like are coated with formwork sleeves in a particularly preferred embodiment of the method according to the invention. surrounded, so that it is ensured that the casting compound is actually only filled in where it is actually needed, namely between the concrete support plate and the rail fastening plates, without being able to flow laterally therefrom. Shuttering sleeves made of elastic material have proven themselves, for example tire-like rubber sleeves, which can preferably be provided with an anti-adhesive layer at least on their inside so that they can be easily removed again after the casting has hardened and, if necessary, reused. For this it is of course necessary that the sleeves are open or can be opened at least at one point in order to be able to pull them laterally under the rails after the sealing compound has hardened.

As track straightening elements, those that have been supported directly on the concrete support plate have proven themselves. This makes it possible to design the mounting plates very flat with a considerably smaller thickness than conventional rail sleepers, so that the rail base is only slightly above the concrete support plate in the finished track.

The right and left rails of the track can be connected to one another by means of tie rods, it then being possible for at least some of the track straightening elements not to act on the rails themselves but on the tie rods. The rails or the track grating are preferably aligned in at least two stages, with a first rough adjustment stage and a subsequent fine adjustment stage. In order to make the potting particularly easy, the rail fastening plates and / or the formwork sleeves can be provided with filling openings, in which case the potting mortar can then be filled in through the filling openings. The rail fastening plates and / or the formwork sleeves are preferably provided with ventilation holes, the introduction of grouting being stopped when grouting emerges from the highest ventilation hole of a formwork sleeve or fastening plate. After the grouting has hardened, the formwork sleeves can be expediently removed, as already mentioned. A quick-hardening grout is preferably used as grout, so that it is possible to remove the track straightening elements in the track section that has just been produced after a short hardening time and to continue with the track installation in the next track section.

Further features and advantages of the invention will become apparent from the following description and the drawing, in which a preferred embodiment of the method according to the invention is explained in more detail using an example.

It shows :

Figure 1 is a perspective view of a concrete support plate for a track on a solid carriageway manufactured in the context of the manufacturing method according to the invention.

FIG. 2 shows a cross-section of a rail deposited on the concrete support plate according to FIG. 1, provided with fastening plates and fastening elements, before it is aligned and fastened to the concrete support plate; and Fig. 3 shows the subject of Fig. 2 after alignment and attachment of the rail, also in section.

To carry out the method according to the invention, the concrete support plate designated in its entirety with 10, which extends in the direction of the later carriageway, is first produced using a concrete paver (not shown). These pavers, some of which are tachymeter-controlled, are used extensively (e.g. road construction, trough when building the Rheda slab track) and will therefore not be explained in more detail here. In the embodiment shown, the concrete support plate 10 is designed for a single-track route; it is of course also possible to make the concrete slab so wide that two or more tracks can be arranged next to each other on it.

At the top of the support plate, this is provided with transverse joints 11 introduced into the still fresh concrete, which ensure that uncontrolled crack formation cannot occur, but that cracks, such as are unavoidable due to thermal or mechanical loads, only on such Places occur where they are harmless to the strength of the overall structure. The joint spacing is defined for the respective project from the requirements. Reinforcement 12 in the lower area of the concrete support plate 10 ensures its required strength.

After the concrete of the support plate 10 has set but has not yet hardened, recesses 13 are drilled from the top of the support plate in the area of the later track fastening points. However, drilling can also be carried out (with increased effort) at a later point in time after further curing. It can be seen that the recesses are located between two transverse joints. the, therefore not be arranged in areas where cracks are expected later. A tapping tool with a comparatively coarse thread is used as the drilling tool for the recesses, so that the recesses do not have a cylindrical shape, but rather have undercuts 14 in the form of the threads produced.

After the concrete support plate 10 has hardened, the recesses 13 of impurities such as drilling dust or the like which are located therein are first removed. cleaned. Subsequently, rail fastening plates 15 are placed on the concrete support plate, each consisting of two fastening elements 16 in the form of screw bolts 17 inserted from above through the fastening plate 15 through holes, onto whose threaded bolt sections projecting from the plate below are screwed dowels 18. The bolts 17 are slightly pretensioned in their dowels 18, all with approximately the same pretension. The dowels have circumferential grooves and grooves 19 on the outer circumference, as can be seen in FIGS. 2 and 3.

The rail mounting plates 15 are placed on the concrete support plate 10 so that the rail fastening elements 16 protrude into the recesses 13 made in the concrete support plate with play s. For this purpose, the diameter or the cross section of the recesses 13 is larger by the desired freedom from play than the cross section of the fastening elements or their dowels which surround the recesses. The backlash is chosen on the one hand so large that even taking into account manufacturing tolerances for the mounting plates and in the manufacture of the recesses at the locations provided for this purpose, the fastening elements of each mounting plate can be easily encased in the recesses provided for this purpose and the panels then also sufficiently wide can be moved sideways to to enable the later alignment of the track, on the other hand, the cross section of the recesses and thus the freedom from play should not be unnecessarily large in order not to unnecessarily increase the amount of grouting mortar later required for fastening the track.

After the rail fastening plates 15 have been placed on the concrete support plate in the manner described, the rails 20 are fastened to them in a manner known per se with rail fastening clamps 21. In this stage of the method illustrated in FIG. 2, the rail fastening plates 15 with the rails attached to them still lie essentially flat on the concrete support plate 10.

Next, the track or the rail tracks forming it can be aligned in the correct height and side position, the track spacing between the two rails also being set. The track and the rail inclination are adjusted with tie rods (not shown), with which the right and left rails of the track are connected to each other. The correct height of the rails above the concrete support plate is achieved by means of track straightening elements, which in the simplest case consist of wedges and which directly engage the rails between two fastening plates 15 and are supported directly on the concrete support plate. After the alignment, the rail fastening plates 15, which are already connected to the rails at this time, are at a distance above the concrete support plate and form an intermediate space 22 between them.

After the alignment process, formwork sleeves 22 are placed around the rail fastening plates, which in the preferred exemplary embodiment consist of an inside with an anti- Adhesive layer provided rubber strip, which is placed under the rails with a small distance around the rail mounting plates. Subsequently, the gaps 22 between the fastening plates 15 and the concrete support plate 10 are filled with a fast-hardening, low-shrinkage and well-flowing casting mortar, which also flows into the recesses receiving the fastening elements and also fills them. After hardening of the grout 24, the dowels 18 are positively locked in the recesses with the grout and there is a corresponding positive connection between the grout 24 and the walls of the recesses, because the grout has filled the undercuts provided therein and in the dowels. After the grouting mortar has hardened, the rail fastening plates lie snugly on it. The formwork collar 23 can be removed again after the grout has hardened, which is possible without any problems because of the non-stick coating. The screw bolts 17 can then be tightened again in their dowels 18 in order to pull the rail fastening plates with force against the concrete supporting plate or the hardened casting compound now located thereon.

It goes without saying that in cases in which fluctuations in the ambient temperature are to be expected during the hardening process of the grout, the bolts can be loosened in a manner known per se as soon as the grout has set and has reached a certain minimum strength. The rails can then move in their rail receptacles to compensate for changes in length, so that no constraining forces act on the fastening elements or the casting during the hardening of the grouting mortar.

It can be seen that when the method according to the invention is carried out, a track in a solid carriageway with comparatively few and simple work steps can be produced, whereby a high installation performance can be achieved. The amount of building materials to be used, in particular the grouting mortar, is considerably less than in the case of known methods, since the grouting compound only has to be introduced directly at the rail fastening points below the rail fastening plates. In addition, a very clean and smooth concrete surface is already created by machine. A complex, manual smoothing between the sleepers is not necessary. With the method according to the invention, a particularly economical and fast method for producing a track on a solid track is created.

Claims

PATENT CLAIMS

1. A method for producing a railroad track for rail vehicles, with the following method steps:

- producing a concrete support plate (10) extending in the direction of the carriageway;

- Making recesses (13) in the concrete support plate (10) in the area of the later track attachment points;

- Placing rail fastening plates (15) on the concrete support plate, the rail fastening plates (15) being provided or provided with fastening elements (16) whose cross-section is smaller than that of the recesses (13) and which has play (s) in the recesses (13 ) protrude;

- Fastening rails (20) to the rail fastening plates (15) and then aligning the rails (20) connected to the fastening plates (15) into their desired height and lateral position by means of track straightening elements which act between two fastening plates (15) and possibly track supports;

- Filling the gaps (22) between the fastening plates (15) and the concrete support plate (10) and the recesses (13) receiving the fastening elements (16) with play with a hardening, low-shrinkage and well-flowing grout (24);

- If necessary, disassembly of the track straightening elements and track holder after the grouting mortar (24) has hardened.

2. The method according to claim 1, characterized in that the concrete support plate (10) is continuously produced with a ready-mixed concrete paver.

3. The method according to claim 1 or 2, characterized in that the recesses (13) are made in the set, fresh concrete.

4. The method according to any one of claims 1 to 3, characterized in that the recesses (13) are drilled as holes in the concrete.

5. The method according to any one of claims 1 to 4, characterized in that transverse joints (11) are provided for a controlled crack formation in the fresh concrete of the support plate (10).

6. The method according to any one of claims 1 to 5, characterized in that the recesses (13) with undercuts (14) or the like lying below the top of the support plate. getting produced.

7. The method according to claim 6, characterized in that the undercuts (14) are drilled in the form of threads by means of a tapping tool.

8. The method according to any one of claims 1 to 7, characterized in that each rail mounting plate (15) is or is provided with at least two fastening elements.

9. The method according to any one of claims 1 to 8, characterized in that the recesses (13) or the like before insertion of the fastening elements (16) of any contamination. getting cleaned.

10. The method according to any one of claims 1 to 9, characterized in that the fastening elements (16) from the rail fastening plates (15) inserted screw bolts

(17) and on these screwed dowels (18).

11. The method according to claim 10, characterized in that the bolts (17) in their dowels (18) are biased.

12. The method according to any one of claims 1 to 11, characterized in that the fastening elements (16) on their in the recesses (13) projecting area on their circumference with undercuts (19), in particular grooves, grooves and the like. are provided.

13. The method according to any one of claims 1 to 12, characterized in that before filling the gaps (22) and recesses (13), the rail mounting plates (15) with formwork sleeves (23) or the like. be surrounded.

14. The method according to claim 13, characterized in that the formwork sleeves (23) consist of elastic material.

15. The method according to any one of claims 1 to 14, characterized in that the track straightening elements are supported directly on the concrete support plate (10).

16. The method according to any one of claims 1 to 15, characterized in that the right and left rails (20) of the track are interconnected by means of tie rods.

17. The method according to claim 16, characterized in that at least a part of the track straightening elements acts on the tie rods.

18. The method according to any one of claims 1 to 17, characterized in that the rails (20) or the track grate are aligned in two stages, with a first rough adjustment stage and a subsequent fine adjustment stage.

19. The method according to any one of claims 1 to 18, characterized in that the rail fastening plates (15) and / or the formwork sleeves (23) are provided with filling openings and that the grout (24) is filled through the filling openings.

20. The method according to any one of claims 1 to 19, characterized in that the rail fastening plates (15) and / or the formwork sleeves (23) are provided with ventilation holes and that the introduction of grout (24) is terminated when grout from the most highly ventilation hole of a formwork collar or fastening plate emerges.

21. The method according to any one of claims 1 to 20, characterized in that the formwork sleeves (23) are removed after the hardening of the sealing mortar (24).

22. The method according to any one of claims 1 to 21, characterized in that a fast-curing grout (24) is used.