Patent Application
20160348321
The invention, as its title indicates, relates to a method for concreting railway slab track, proceeding from an initial position in which the assembly formed by the rails fixed to the sleepers and/or fastening elements (which are called premounted track or skeleton track), once laid and premounted on an existing base or base plate (bed of the future slab track) and then perfectly positioned with precision and fixed by means of fixing/fastening means in the final suspended position, concreting of the assembly takes place, thus constituting the concrete slab which forms the support means which replace the ballast of a traditional track. In other embodiments, independent concrete blocks or fastening plates of the rail are mounted instead of the sleepers, (the track width being established until the setting of the concrete by way of provisional elements called “false sleepers” in these latter cases), or even any other system which either discretely or continuously serves for fastening the rail and serves as reference thereof with the concrete and once the system has been positioned with precision in each case, either with the premounted rail or even without it, concreting takes place.
The invention also relates to a system for concreting a railway slab track which joins a series of apparatuses which allow the concrete to be transported from one supply point or area to the concreting point or area as well as for carrying out the pouring of the concrete in a controlled and uniform manner, distributing it over the skeleton track (between the sleepers or fastening system which is used in each case) to the required level, the latter having been previously suitably position with the strict tolerances required and fixed in the final suspended position thereof to form the so-called railway slab track once the concrete has set.
The slab track allows high geometric quality to be obtained and reduces the maintenance costs with the respect to ballast track (amongst other advantages such as eliminating the problem of ballast flight, etc.), however, the cost of the construction thereof is higher. In Spain, slab track is not generally used, but it is used in particular areas such as for example in tunnels, in which the problem and cost of maintenance of the ballast track are especially high, particularly on high speed lines.
At present, there are various methods for carrying out the concreting of slab track, which are described in general below:
In the case of there being sufficient space at the side of the track under construction, for example in the case of a tunnel with a double track when the first of the two tracks is intended to be constructed, the concreting can be carried out by means of direct pouring, the trucks with concrete accessing through the lateral space to the pouring point and then withdrawing, in the case of all this being possible—including the necessary maneuvers and crossings. In these cases, the concreting of the second track can be carried out from the first already constructed track, using concrete tanks implemented on towed or motorized railway platforms.
In the cases where direct pouring is not possible due to lack of space, an alternative is to concrete by means of pumping the concrete. To this end, a static pump can be used which is placed in the interior of the tunnel, or in proximity thereto, which carries out the pumping of the concrete by way of a pipe or tube to the concreting point. As the concreting point advances, it is necessary to supplement the tube, the pump also being able to move to advanced positions as the execution of the concreting advances. In order to bring the concrete to the pump, it is necessary to use concrete mixer trucks, in the case where there is space for this, or either railway platforms equipped with tanks towed by means of a towing or motorized vehicle along the adjacent track already constructed or along the track itself that is under construction on the area where the concrete has already set, in this case they can travel only to the area where the concrete has already acquired sufficient resistance, concreted with sufficient time in advance.
The sections of pipe have to be cleaned in the interior thereof, moved, connected and disconnected, the total pipe length being modified, sections implemented or removed as the work advances, which is very laborious.
The lack of space is the main problem for carrying out these works appropriately. In the case of tunnels with a single track, the problem is heightened even further. In these tunnels, the difficulty of the work is greater, the options very limited and the yields of concreting are reduced.
The traditional methods of concreting slab track described are laborious, the mechanical means and above all manpower required are high, the degree of automation is low and the yields are limited. The logistics of the supply and pouring process of the concrete is not efficient, interferences among the different activities being frequent. The coordination of the tasks is complex, the stoppages are usually frequent due to various reasons and the stoppage times can be long. Other noteworthy problems are those associated with pumping the concrete in the case where this system is used: blockages in the pipe, etc. Moreover, it should be pointed out that one problem in any of the many stages of the process usually causes the interruption of the concreting, with the consequences which these stoppages cause under these conditions.
An alternative to the methods described is the one used in the construction of the Guadarrama tunnels, with a single track, by means of a method consisting of introducing a complete train with mixers to the point where a static pump is situated close to the concreting point. The train travels along a provisional auxiliary track which must be constructed expressly for this purpose in parallel to the track which is desired to be concreted, on one side of the same, and in the narrow space present for it—the distance between the two rails thereof must be reduced.
The work and the outline of the process are similar to those of the traditional method already described, with some particularities:
This method involves an improvement with respect to the traditional methods when it is necessary to concrete sections of great length since introducing a train full with mixers avoids discontinuous supply. However, on the other hand, it has significant disadvantages which ultimately limit its competitiveness:
Among the recent developments intended to improve the application of concrete, the particular work of the new tunnel at the base of San Gottardo stands out. This is a railway tunnel beneath the Swiss Alps. The length of the infrastructure is 57 km and with a total of 151.84 km of tunnel and galleries it is the longest railway tunnel in the world. The slab track is currently being implemented and the German method is being used for concreting the track, using a train with unprecedented dimensions (24 mixers). The improvement variant consists of introducing a system for allowing the loading of the train within the tunnel itself, at the mouth of the same. This avoid the train having to exit the tunnel and cover great distances when it has to be reloaded. However, the system still has all the drawbacks described, even being heightened, given the implemented dimensions. Bringing the loading point of the train closer is all that has been achieved, but if we consider the lengths of the tunnel, each time the train has to reload, the stoppage time (movement+loading+return) amounts to many hours, time during which the concreting remains interrupted.
In the patent literature, we can see document EP 0715023 in which a mobile concrete mixing machine is described for concreting housing mechanisms for railway tracks with the aid of shuttering during the course of the construction of a superstructure system without ballast with a concrete roadway slab for at least one railway track. This machine has a portal frame with lateral uprights extending in the direction of manufacture and crossbars which connect them above, being mounted on moving assemblies, preferably on caterpillars such that the frame of the machine is moved in the direction of manufacture and eventually in the return direction. On the longitudinal frame, there are sliding rails for a gantry crane and on these a gantry crane is guided. A plurality or number of concreting frames is housed on the frame which can be moved in the direction of manufacture and have mechanisms for vertical adjustment.
In conclusion, the slab track concreting system existing at present have substantial disadvantages and it is necessary to develop alternative methods which allow the process to be optimized. Therefore, the slab track concreting process requires an alternative which improves the existing methods and avoids the disadvantages thereof.
The new method should optimize the supply and provision of concrete by minimizing the risk of stoppages and waiting times, it should allow the maximum utilization of the space and avoid interferences between the different tasks, it should be flexible for different situations, dimensionable and scalable for works of different length and sizes and should provide high yields; the development of new specific equipment to be able to carry out this new method and optimally applying the concrete is also necessary, with a limited cost and without the risk of blockages. It would also be desirable to achieve maximum automation of the process. This method and the equipment necessary for carrying it out are the object of the present invention.
The method for concreting object of the present invention presents the utilization of the space on the track under construction itself for supplying and applying the concrete. To this end, the equipment responsible for transporting and applying the concrete travels in a self-propelled manner and by means of railway wheels on two rails or guide profiles, auxiliary rails, situated one at each side of the track under construction and parallel thereto, transporting the concrete, transferring it, in case it is necessary, and ultimately applying it at the desired point (all of which following different possible strategies/configurations). This concept therefore allows, since the concreting equipment is not supported on the rails of the track itself, travel to take place on the track under construction during any step of said construction, even when the premounted track is suspended pending concreting, thereby providing the space on the same which is not available in other methods, thus minimizing the problem associated with the lack of space and the interference with other works.
Lastly, the concreting of the slab track is carried out by pouring concrete from the vertical itself of the track under construction, on the assembly formed by the rails fixed to the sleepers and/or fixing systems, which is commonly known as skeleton track, which have been previously laid and premounted on the existing base which forms the base plate of the future slab track, the assembly being positioned with precision and being fixed by means of support means in a suspended position. Once the concrete has set, it constitutes the slab which forms the support means which replaces the ballast of a traditional track.
The conceived process comprises the following steps:
In terms of the location thereof, the concrete supply point to the system can be established at any area of the tunnel or even at the exterior of the same, that is to say, it will be located at a point on the auxiliary rails of the track under construction or adjacent thereto, to which it is possible to introduce the concrete from the exterior. It will therefore be located either at the mouth of the tunnel (or even outside the same, extending the auxiliary rails outside the tunnel) or in the interior of the same. In this last case, the supply point will be an internal point to which it is possible to introduce the concrete from the exterior using traditional methods: either the point to which the concrete mixer trucks can access, the point to which a train with mixers or platforms which transport concrete can access, travelling along the adjacent track in the case of it being a tunnel with 2 or more tracks, along the track itself to a concreting point with sufficient time in advance such that it has already acquired the sufficient consistency for it to be passable or along an auxiliary track at a side of the track under construction either a point in an area with ventilation shafts, in an area with gaps or gangways connected with the parallel tunnel for example in a tunnel with 2 tubes, 1 track per tube or in any other types of openings by way of which it is possible to introduce the concrete by traditional methods, etc.
The location of the supply point can always be the same or it can vary as a function of the advance of the concreting, of the needs in this aspect and of the possibilities in terms of possible concrete supply points available.
In terms of the device or hopper for receiving the concrete, it could directly be the device or hopper responsible for carrying out the transport of the concrete, or it could be a receiving device or hopper per se which in this case would have the function of “regulating tank of the concrete”, that is to say, storing the discontinuous supply coming from the exterior and carrying out the transfer to the transport device or hopper when it is required. In this last case, the “receiving” hopper could move on the auxiliary parallel rails or on the principal track if the concrete which forms the slab is already conveniently set in this area, it can also remain static on the auxiliary rails, on the rails of the track or even at a lateral point adjacent to both.
In the case that the transport device is not responsible for receiving/regulating, it will be necessary to carry out the transfer of concrete from the latter to the former, for which the receiving device itself will be provided with means for transferring the content thereof to the transport device or hopper, such as a conveyor belt, direct discharge, etc. In the case of the transport device being responsible for also carrying out the receiving, it will not be necessary to transfer the concrete to it.
Both the receiving and transport devices could be a single device or various devices as a function of the different configurations which are set up.
The following step consists of the pouring of the concrete on the track under construction in a controlled manner, distributing it uniformly along the same to form the concrete slab, this operation being carried out by means of at least one device or hopper which moves in an autonomous and controlled manner on the auxiliary rails.
The transport and pouring of the concrete could be carried out by means of the same device or hopper, in which case this could have at least two advance speeds, one fast in order to carry out the transport and return journeys and another slower speed which will be used when it pours the concrete on the track under construction. It is also possible to carry out the pouring of concrete by means of a specific device or hopper for this, in which case the transport of the concrete from the supply point to said concreting device or hopper is carried out by means of a specific device or hopper for transporting which we could called a satellite device or hopper which is provided with means for transferring the content thereto to the concreting device or hopper. Any of these devices or hoppers moves by rolling on auxiliary rails.
In this way, in one of the possible configurations, the same device can be responsible for carrying out the receiving of the concrete at the supply point, the transport to the pouring point and the pouring itself of the concrete. In this case, it is not necessary to carry out any transfer of concrete between devices, and the single device will be equipped with at least two speeds (fast for transporting and returning and slow for the concreting). In this configuration, being considered a supply point, only one device can be used (concreting at a “front” of the track under construction) or two devices can be used (concreting at two front, at both sides of the supply point) or even more.
In this last configuration of the process (two concreting devices or hoppers being used simultaneously), with the supply point situated at an internal area of the tunnel), the two devices will be responsible for concrete at the supply point and will each transfer it to each side of the same. Once the respective initially fixed pouring points have been reached, they carry out the return concreting, that is to say, at both sides from the initial points to the supply point, that is to say, in opposite directions. Both devices will return to the supply point once the concrete has been depleted in order to be reloaded, transporting the concrete once again to the pouring point and once again proceeding to pour the concrete, thereby advancing both concreting fronts until completing the concreting of this section (contained between the two initial points fixed at both sides of the supply point and preferably, although not exclusively, equidistant from the same). The use of two devices means the productivity of this operation is doubled. The loading of concrete at the supply point of the two devices in this last case could be carried out in an alternative manner, for which purpose they can be offset in time. Alternative configurations based on this described configuration can be used with slight variants: such as the two devices concreting, approaching the supply point, the two in the same direction or even carrying it out at the same side of the supply point.
Once the concrete has been poured, the traditional vibrating operations are carried out, floating and the rest of the work required for the correct finishing of the slab. These operations can be carried out according to traditional methods, using conventional means operated by operators; however, the present invention provides for self-propelled platforms which move on the two auxiliary rails following the pouring devices or hoppers, behind them in the direction of advance of the concreting. These platforms will have the means required for carrying out these operations as well as the required operators, who can carry out the operations manually from the self-propelled platform with conventional means, or in the following manner the vibrating means could be provided vertically on supports movable on the self-propelled platform and carry out the vibrating with greater automation; in order to carry out the floating in a more automated manner, the possibility of incorporating a tray movable on the platform is also provided for.
In this way, the vibrating operation of the concrete is carried out after the pouring either in a conventional manner or in a more automated manner However, this method also allows the vibrating and floating means of the concrete to be mounted directly on the pouring devices or hoppers, actuated and supported from the hopper itself. It is also possible to even couple the self-propelled platform to the pouring hopper so that it pulls it. These two last possibilities can be used especially when hoppers intended exclusively for pouring the concrete are used.
The system required for the concreting of railway slab track using the method previously described comprises a series of essential devices
As has been previously described, it is envisaged that the transport devices or hoppers can be either the pouring devices or hoppers themselves with the capacity to move at a higher speed when they carry out this operation or specific devices or hoppers for the transport—satellite hoppers—in which case they must be provided with means for transferring concrete to the pouring hoppers. This gives rise to different possible configurations of the process and the selection of one option or another will depend on the external conditions present in each case or work and on the study of timings which is carried out, with the aim of achieving the maximum yield of concreting, various factors should be considered such as for example the distance to which the concrete supply point is from the pouring point (for example in a construction in which both points can always be relatively close, the option of using only pouring devices or hoppers for both operations could be considered; in other conditions, it may be preferable to use specific transport devices or hoppers—satellite hoppers—for transporting the concrete to the pouring device or hopper, thereby enabling the pouring process to also be continuous). The satellite hoppers will be equipped with outlet means for the content to transfer the concrete to the pouring device or hopper in an automatic and fast manner
All the devices or hoppers are preferably metallic and automotive structures. They are formed by: a peripheral structure with a regulatable width, formed by metallic profiles which are laterally supported by means of at least two wheels at each side on the corresponding auxiliary rail (that is to say, at least four wheels in total), it being responsible for carrying out the rolling of the device on the auxiliary rails and supporting the central structure; a central structure or hopper per se responsible for containing the concrete, supported on the peripheral structure, the internal width thereof is approximately equivalent or similar at the lower portion thereof to that of the slab which is going to be concreted and which incorporates means for suitably carrying out the operations with the concrete, either the loading, pouring or transfer thereof.
Provision is also made for the wheels to be mounted on two vertical support structures, or profiles, regulatable in height (either with the possibility of being supplemented or telescopic) such that the device or hopper can remain in a horizontal position or parallel to the plane of the track and in a stable position independent of the heights at which the two auxiliary rails are arranged.
In the interior of the central structure or hopper per se there are, at the bottom, a motorized endless screw, the revolutions of which are facilitated and regulated by the outlet flow, directing it and therefore controlling the concreting, in line with the opening of lower opening gates and with the advance speed of the device during the pouring. Provision is made for there to be one single or various pouring mouths arranged at the bottom, in this last case these mouths can be separated by blind areas matching the position of the rails and fastenings of the track under construction. These pouring mouths are controlled by gates, the opening of which is controlled by means of hydraulic actuations.
In order to complement the description being given and with the aim of facilitating the understanding of the characteristics of the invention, a set of drawings accompany the present description in which, in an illustrative and non-limiting manner, the following has been depicted:
In the figures, the basis of the method of the present invention for concreting the slab (3) of a slab track can be observed, said concreting is carried out on the previously mounted track, suspended and fixed in the final position (2), in a tunnel area (1), in which this type of track (2-3) is usually constructed in this manner, without a ballast. The concreting method envisages the placement of two rails (5) or guide profiles which we can call auxiliary rails, supported on the platforms, semi-platforms or lateral spaces (4) at one side and the other side of the track and the transfer and pouring of the concrete by means of devices or hoppers (6) which move along said rails in an autonomous manner and at a controlled speed.
The pouring operation is carried out by means of types of devices or hoppers (6) which are internally equipped at the bottom with a mechanism for controlling this operation; while the transport operations of the concrete from the supply point (PS) to the pouring point can be carried out by means of the pouring device or hopper (6) itself, in which case it is desirable for it to have at least two speeds for being able to carry out the transport at a greater speed than the pouring or by means of a specific device or hopper, which we can call a satellite device (7) which moves from the supply point (PS) to the pouring device or hopper (6), in which it deposits its load, for the purposes of which these types of devices or hoppers (7) are equipped with a lower pouring mechanism and a conveyor belt (72) to transfer the content thereof from the lower portion thereof to the upper mouth of the pouring device or hopper (6), or alternatively any other means for carrying out this transfer. This satellite device (7) can be one single device or it could even be various devices functioning in a chain.
The controlled concrete-pouring operation is observed in
In
This described configuration (
In
However, alternatively, this regulating device or hopper (8) could also move on the principal track (2) instead of on the auxiliary rails; in this case it could only do this on section concreted with sufficient time in advance and conveniently hardened, and therefore passable without therefore being able to surpass a certain point. Other alternatives would also be possible, for example setting up a regulating hopper on the adjacent track in the case that one exists, or directly at the side of the track without the possibility to move on rails (outside of the track and the auxiliary rails), etc.
Another alternative within this configuration consists of dispensing with the regulating device (8). In this case, the loading of the satellite device (7) would be carried out directly at the supply point, to which the concrete supply would arrive from the exterior by any of the means described or other possible means.
Another alternative within this configuration consists of dispensing with the satellite device (7), therefore the concrete pouring device (6) itself being responsible for carrying out the transport and pouring operations of the concrete. To this end, this device would have at least two speeds. In this case, the transport and pouring device would be loaded with concrete at the supply point (either receiving the concrete from the regulating device or directly from the external supply) it would transport the load to the pouring point, preferably at high speed, and once situated at the concreting point, the pouring of the concrete would be carried out at the required speed.
The apparatuses that form part of this system are observed in
In
On the lower portion of the hopper (60), means are observed for facilitating the pouring of the concrete constituted by a motorized endless screw (68), with the revolutions of which the pouring of the concrete is facilitated, also orientating the outlet thereof in the desired direction, thereby regulating the concreting in line with the advance speed of the device or hopper during the pouring, the quantity of concrete distributed on the track (2) under construction for forming the slab (3) of the same thus being controlled. The outlet mouth is closed by gates (69) which are actuated by means of hydraulic cylinders (67) which allow the discharge mouth to open and close, either completely or by sectors. In one preferred embodiment, there are three pouring mouths along the width of the hopper (60) separated by blind areas (63) which match the approximate position of the rails and the heads of the sleepers of the track under construction (2) with the aim of avoiding the pouring of concrete on these. The three mouths can be opened simultaneously, or independently in order to orientate the concreting to an area of the section as desired.
The central body or hopper (60) per se is formed by profiles or metallic plates. The interior walls of the hopper can be covered with sheets or antiadhesive material for preventing the concrete adhering to them and thus facilitating the pouring. This device can be disassembled, by separating the central body (60) from the peripheral structure (62).
The satellite device or hopper (7) used specifically for the transport of concrete and the regulating device or hopper (8) have a structure equivalent to the pouring device or hopper (6) depicted. They have two sets of wheels (71) and (81) respectively and in this case the pouring means deposit the content thereof on conveyor belts (72, 82) by way of which it is possible to transfer the concrete from the hopper (8) to the hopper (7) and from this hopper to the pouring hopper (6) as can be observed in
The pouring device (6) can also incorporate the vibrating means (9), on the rear part thereof, in the advance direction, which would be actuated for carrying out the vibrating of the concrete once it has been poured. The means for carrying out the floating could also be incorporated in the same place.
The present invention also provides for self-propelled platforms which move on the two auxiliary rails after the pouring devices or hoppers, behind them in the advance direction of the concreting. These platforms have the means required for carrying out these operations as well as the required operators who can carry out the operations from the self-propelled platform manually with conventional means or in the following manner: the vibrating means can be arranged vertically on supports movable on the self-propelled platform and carry out the vibrating with a greater degree of automation; in order to carry out the floating in a more automated manner, the possibility of incorporating a tray movable on the platform is also provided for.
In this way, the vibrating operation is carried out after the pouring either in a conventional manner, or in a more automated manner It is also even possible to couple the self-propelled platform to the pouring hopper so that both advance inseparably.
All the devices envisaged in the present invention are preferably automotive devices.
With the nature of the invention sufficiently described as well as a preferred exemplary embodiment, it is stated for the appropriate purposes that the materials, form, size and arrangement of the elements described could be modified, provided this does not involve an alteration of the essential characteristics of the invention which is claimed below.
| Number | Date | Country | Kind |
|---|---|---|---|
| 201530752 | May 2015 | ES | national |
