RU2263737C1 - Ballastless bridge deck panel and method of panel forming - Google Patents

Abstract

FIELD: building, particularly ballastless bridge deck adapted for laying rail track on reinforced concrete panels of railroad metal span structures and panel production method.

SUBSTANCE: panel is formed as concrete structure having rectangular cross-section and reinforcement arranged in two levels. The panel has width of not more than 3.2 m and length of not more than 2.0 m. The panel includes two rows of rain lugs formed on upper surface thereof and conical orifices arranged in designed succession and adapted to receive fastening members, which secure panel to span structure beams, defining ovals in plane. The orifices are created by steel releasable void formers provided with ring-bolts. Paraffin layer is applied on void formers. The panel also has conical orifices defining rounds in plane and adapted to secure flange rail to panel. Above orifices are created by steel removable void formers having paraffin layers. The panel includes orifices defining ovals in plane and adapted to connect rails to panel. The orifices are created by retained void formers of plastic material, preferably of polyethylene, and are fitted with embedded saddle-shaped washer provided before void formers installation in mould. Method for panel production involves arranging void formers in heat-insulated mould not above layer of concrete mix pouring in the mould, wherein void formers have vertical orifices and void formed tops are closed with sealing caps preferably formed of rubber; fastening void formers with lugs made in mold bottom plate by bolts passing through orifices; laying reinforcement frame in the mould; pouring concrete mix and smoothing thereof by concrete vibrating screed to obtain smooth panel surface in contact areas between the panel and bridge span beams; performing heat and moisture treatment along with providing equal temperatures along panel section during heating system operation with taking into consideration possible timeouts with duration of not more than 3 hours; removing panel from mould by engaging ring-bolts arranged in orifices of void formers adapted to secure panel to bridge span panels and conveying the ready panel to storage facility by panel ring-bolt engagement.

EFFECT: increased performance characteristics, particularly improved reliability and increased service life, enhanced manufacturability along with reduced labor inputs.

2 cl, 6 dwg

Description

The invention relates to the field of construction, in particular to a device ballastless bridge for laying rail tracks on railway metal spans of bridges on reinforced concrete slabs and the technology of manufacturing such a plate.

A known non-ballast bridge canvas plate and a method for its manufacture, made of reinforced concrete and having holes perpendicular to its supporting surface for attachment rods formed by hollow formers installed during its formation (SU No. 1183597, IPC 4 E 01 D 7/12, 1985).

The closest known one is a plate of ballast-free bridge canvas and a method for its manufacture, made of reinforced concrete and having vertical through holes for tie rods with thrust nuts, and supporting platforms for placing a rail track (SU No. 1229249, IPC 4 E 01 D 7/12 , 1986).

Known slabs have a low operational crack resistance of the upper zone of concrete due to the technology of their manufacture due to insufficient reinforcement. In addition, due to the need for early removal of void formers (no later than two hours after concreting), cracks may appear around the holes formed by them. It is difficult to obtain a smooth concrete surface in places of design support of the slab on the beams of the span due to the difficulty of smoothing the concrete surface with a vibrorail.

The objective of this technical solution is to improve the operational characteristics of the plate, in particular, ensuring reliability and durability, as well as improving the manufacturability of their manufacture while reducing the complexity.

The technical result achieved is a consequence of the combined use in the manufacture of the slab of the design of hollow formers, eliminating the need for their early removal and, as a consequence, the elimination of cracks in fresh concrete also due to the presence on hollow formers to form holes for fastening the plate to the beams of the span before installing them in the mold a paraffin layer, as well as the use of non-removable plastic void formers to form holes for fastening the rail to the plate, each before installing them lay the saddle washer, excluding unwinding of the mounting bolts in the operation.

This is achieved in the plate of ballastless bridge canvas in that it is made in the form of a rectangular, in plan, reinforced at least in two levels of reinforced concrete structures with a width of not more than 3.2 m and a length of not more than 2.0 m, including two rows of rail tides formed from the side of its upper surface and located in a sequence of conical openings for the fastening elements of the plate to the beams of the superstructure, having an oval shape in cross section, formed by steel having a ring -bolts with extractable hollow formers with a layer of paraffin deposited on them, round in cross section of conical holes for attaching a countersink to the plate, also formed by steel removable hollow formers with a layer of paraffin on them, and holes for fastening the rail to the plate, formed with non-removable hollow plastic, preferably polyethylene, and having a embedded saddle washer placed in them before installation in the form.

In the method of manufacturing the indicated plate of ballastless bridge web, this is achieved by the fact that it includes placing in a thermally insulated form void formers not higher than the level of laying the concrete mixture in the mold, having sealing caps closed on top, preferably made of rubber, through vertical holes, fastening the void formers to the bosses of the mold pallet with bolts passed through the through holes, laying in the form of a reinforcing cage, laying concrete mixture and its leveling and smoothing with a vibrating rail about obtaining a flat surface in places where the plate rests on the beams of the superstructure, heat and humidity treatment to ensure equal temperatures along the height of the cross section of the plate with an operating system for heating it, taking into account possible interruptions in operation for no more than 3 hours, removing the plate from the mold for an eye bolts attached to the hollow core for holes for fastening the plate to the beams of the superstructure, and transferring the finished plate to the warehouse for the same eyebolts.

The invention is illustrated by drawings, where

figure 1 presents a plate ballastless bridge canvas, top view;

figure 2 shows a section 2-2 of figure 1;

figure 3 is a section 1-1 of figure 1;

Fig. 4 shows a steel-removable core former having an eye bolt for fastening elements of the plate to the beams of the superstructure;

figure 5 - steel removable void for mounting kontrugolok to the plate;

figure 6 - made of plastic non-removable void for forming holes for mounting the rail to the plate.

Plate 1 ballastless bridge canvas made in the form of a rectangular plan reinforced at least in two levels of reinforced concrete structures (figure 1) with a width of not more than 3.2 m and a length of not more than 2.0 m. Plate 1 includes two rows of rail tides 2, formed from the side of its upper surface and having holes 3 for fastening the rail to the plate 1. From the side of the same surface of the plate 1, in the sequence determined by the project (between tides with an offset from the longitudinal axis of the plate 1), there are conical holes 4 for the fastening elements eniya plate 1 to the beams of the superstructure. The holes 4 are oval in shape and formed by steel having eyebolts 5 removable hollow formers 6 with a layer of paraffin deposited on them. Conical round openings 7 in plan for attaching a countersink to the plate 1 are also formed by steel extractable void formers 8 with a layer of paraffin deposited on them.

Oval in plan of the hole 3 for fastening the rail to the plate 1 are formed by non-removable hollow formers 9 made of plastic, preferably polyethylene, and having a saddle-shaped washer 10 placed in them before installation in the form and excluding the unscrewing of the fixing bolts during operation.

The hollow core 6, 8 and 9 are bolted 11 to the boss 12, welded to the pallet (bottom) of the form 13. The holes of the core on the open surface of the concrete are closed with rubber sealing covers 14.

A method of manufacturing the specified plate ballastless bridge canvas is as follows. In a thermally insulated form, hollow formers 6, 8 and 9 are closed, closed through the top with sealing covers 14, and are not higher than the level of laying the concrete mixture in the mold. At the same time, the holders 6, 8 and 9 are fixed to the bosses of the pallet of the form 13 by bolts 11 passed through the through holes of the holders. The reinforcing cage is laid in a greased form 13, the concrete mixture is laid, leveled and smoothed with a vibrating bar until a flat surface is obtained at the points of support of plate 1 on the beams of the span. Thermal-humid treatment is performed to ensure equal temperatures along the height of the cross-section of the plate 1 with a working system for heating it (taking into account possible interruptions in operation for no more than 3 hours). Then the plate 1 is removed from the mold for the eyebolts 5, placed in the hole holders 6 holes for mounting the plate 1 to the beams of the span. Transfer of the finished plate to the warehouse is carried out for the same eyebolts 5. The use of hollow formers 6 to place the eyebolts in them allows eliminating possible defects (chips, cracks) of the plate 1 due to the formwork due to the loading in the plate reinforced with spiral reinforcement.

Claims (2)

1. A plate of ballast-free bridge canvas in the form of a reinforced concrete structure, rectangular in plan, at least in two levels of reinforced concrete structure with a width of not more than 3.2 m and a length of not more than 2.0 m, including two rows of rail tides formed from its upper surface , and located in a specific project sequence of conical holes for fastening elements of the plate to the beams of the superstructure, having an oval shape in plan, formed by steel, having eye bolts, removable hollow formers with a layer of paraffin on them, round in terms of conical holes for attaching a countersink to the plate, also formed by steel extractable hollow formers with a layer of paraffin deposited on them, and oval in plan of holes for fastening the rail to the plate, formed by removable hollow holders of plastic, preferably polyethylene, and having a embedded saddle washer placed in them before installation in the form. 2. A method of manufacturing a slab according to claim 1 of a ballast-free bridge web, comprising placing in a thermally insulated form having sealing caps closed on top, preferably through rubber, through vertical openings of the pore formers not higher than the level of laying the concrete mixture in the mold, fastening the pore formers to the pallets of the mold pallets with bolts passed through holes, laying in the form of a reinforcing cage, laying of concrete mixture and its leveling and smoothing with a vibrating bar to obtain a flat surface in places where the plate rests on the beams of the span, heat-moisture treatment to ensure equal temperatures along the height of the cross-section of the plate when the heating system is in operation, taking into account possible interruptions in operation for no more than 3 hours, removing the plate from the mold by eye bolts placed in hollow core for mounting holes slabs to spans, and transferring the finished slab to the warehouse for the same eyebolts.

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