Patent Application
20160348322
The present invention refers to the construction and maintenance of infrastructures, in general, with reference to the railway field. In particular, the present invention refers to the maintenance of existing railway bridges. In practice, the invention aims at proposing a new method for waterproofing of the above mentioned bridges, which is more efficacious, economic and rapid to apply with respect to the actually available and implemented ones.
The National Railway Network, like in many other European and extra-European countries, is well developed in the territory in a capillary way. Our territory has a particularly varied distribution of mountain ranges, which has caused the construction of numerous bridges and viaducts.
Among the most frequent types of bridges there are arch bridges (see
Although many of the actually used bridges were built and operated many years ago (many of them date back to before the second world war), they are kept in static conditions sufficient to ensure the safety of trains passing on them, in spite of the present railway traffic.
However, the arch bridges and deck bridges are often troubled by the state of general maintenance, often characterized by conditions of strong deterioration of materials and structural elements they are made of. These problems of the maintenance conditions manifest themselves as broken bricks, corroded reinforcements, washed away mortars, crumbled concrete, etc. In most cases, the above mentioned deterioration conditions can be traced back to only one cause, that is the infiltration and stagnation of rainwater, due to the loss of efficiency of the waterproofing system and separation of rainwater.
In detail, as it is well known to those skilled in the art, over the supporting structure of any bridge 1, there is a ballast M, made of gravel or crushed stone 2 of big dimensions, accumulated between the opposite containment walls 3, 4. Such a structure can be obviously recognized in
In more recent operations, the bitumen is applied by a spraying machine (not shown in the Figure). A sheet of nonwoven fabric (likewise not shown) is then applied over the layer of bitumen. This allows acting over the first layer of bitumen without getting stuck with it, as it would be obvious otherwise. Then the spraying machine carries out a second coat applying another layer of bitumen.
An alternative version, not shown, includes the use of prefabricated bituminous membranes, made in rolls and laid out one beside another, with suitable overlaying borders welded in place.
In brief, until the seventies, the works were done using cast bitumen and sand, passing, up to present times, to the use of prefabricated fibre-reinforced bituminous membranes (still used nowadays in the construction of new bridges). In the last years, from about 2010 on, bituminous membranes made in place are used (bitumen+TNT+bitumen), which is a very effective solution, but feasible only on particularly wide surfaces, due to the necessity to spread very hot bitumen, by means of a tanker heated to 160°-180° C.
For works in areas of a certain extension, however, the application of the sheaths made in place has been recently used again, with bitumens of new generation reinforced with the inclusion of special fabrics.
In any case, due to the not appropriate resistance to the stresses transmitted by the crushed stone situated above and constituting the ballast, the bitumen sheath must be covered with a protection layer 8, sometimes made of concrete, reinforced if necessary and, on the other hand, in other cases, more often, of bituminous conglomerate.
On the other hand, for the same reasons, the sheath 7 must be placed on a rigid support 9, which in the bridges with decks is constituted by the slab of reinforced concrete, whereas in the arch bridges is made by the shoulder of the arch, in general of concrete.
Giving a right inclination to the support 9 of the sheath and consequently, to the same sheath 7, the rainwater intercepted thereby at the base of the ballast M is conveyed out of the bridge and discharged below it.
This traditional system, of simple and immediate application, presents however a number of drawbacks, which determine in fact the loss of efficiency of the waterproofing system as a whole.
A first drawback is an insufficient duration of the service life of the layer of the waterproofing bitumen. Statistically, it has been noticed that in 20-30 years from their production, the so formed sheaths gradually lose their functionality.
This happens either due to the loss of the material elasticity or due to the possible breaking of the protective layer, as well as due to the possible excessive movements of the support and possible accidental damages caused by the works on the railway line.
Substantially, the rainwater falling on the railway line penetrates the collection barrier, which is no longer effective and consequently does not prevent infiltrations, instead of being intercepted and collected by the waterproofing system to be later conveyed by means of a drainage network and removal system.
After having overcome the barrier, normally formed by a layer of bitumen, the water reaches the structural parts of the bridge and spreads and stagnates between the various elements with all the resulting problems.
The deterioration conditions that are triggered by the water, do not progress regularly over time, but manifest an exponential progression, becoming rapidly evident only in already irreparable conditions, which threaten to jeopardize or jeopardize the bridge safety. At this point, the bridge repair cannot be avoided any more and the costs as well as the consequences on the railway services are usually heavy.
Moreover, the intensification of the railway traffic causes negative effects due to two substantial reasons. First of all, higher frequency of trains transiting on the section of railway line along the bridge, contributes to more rapid damage of the waterproofing means, thus accelerating the bridge deterioration. Secondly, the higher frequency of passages and the stronger needs to respect timetables and to optimize the use of the rolling stock, make it more difficult to plan and carry out the maintenance operations.
Taking into consideration that the average life of a bridge can easily reach 80-100 years and even more, it is clear that in order to achieve such long life, the waterproofing system of each bridge must be reconstructed even more times during its operational life.
However, this operation is not easy to carry out and is hindered, if not even prevented by the only possible executive modes of the operation, which constitute a second drawback of the traditional waterproofing systems. Actually, in order to carry out waterproofing again, it is necessary to decommission the railway line for a sufficiently long period of time, that is 3 to 4 days for smaller bridges, but for longer periods of time, up to 10 days for the longer bridges. In fact, it is necessary to dismount the tracks, remove completely the gravel 2 of the ballast M, cast again the bitumen 7, spread the protective layer of concrete or asphalt and reposition the ballast and tracks.
The removal of the gravel or crushed stone 2 that composes the ballast does not involve only a small thickness thereof, but is radical, up to the supporting structure, thus causing non negligible difficulties and especially spending a lot of time.
However, long times are caused also by the fact that the concrete and bitumen used to place the impermeable layer and to protect it, need technical times for setting and hardening, which can prolong for days and also after the repositioning of the railway line.
Consequently, the restoring of suitable waterproofing conditions with the traditional systems is extremely difficult and in some cases impossible, due to the necessary times, which cause too long interruptions of service, in fact, impracticable on the busiest lines.
In any case, even a regular maintenance of the bridge does not resolve the problem, since it does not eliminate the reason of its decay, resulting from a progressive inefficiency of the waterproofing system. Once the maintenance operation has been completed, the deterioration situation that has made it necessary, will repeat in a short time.
The problems pointed out in the introductory note become extremely important if their extension is considered, since, for example in Italy there are about ten thousands bridges in these conditions.
A method conceived some time ago provides the use of a suitable machine for maintenance of tracks, mounted on a train and modified so that, moving on the bridge, it resets the waterproofing system. In detail, the machine raises the track and removes the crushed stone situated under it along the section in which it has been raised. Then the method provides manual introduction of sheets of nonwoven fabric, having suitable solidity and thickness and on these sheets of fabric a traditional sheath is made, of the prefabricated bituminous type or of epoxy type made by spraying technique. Subsequently, other sheets of nonwoven fabric are applied and finally the machine arranges again the crushed stone and tracks.
Although this gives a solution as far as the implementation times are concerned, however, this method does not allow to obtain satisfying efficiency results, also because the operation is carried out on one track at a time, thus on a limited width of the railway line, making it necessary to reconstruct the continuity between the waterproofing layers in different moments, so as to prevent the infiltrations which would occur in any case.
Another waterproofing method, which can be applied to railway bridges and known from the British Patent Application no. GB 2 258 874, includes the injection, below the tracks, of a liquid material, capable of polymerizing and creating an impermeable mass.
However, this method involves a series of drawbacks, even quite obvious and is not used in practice. This mass, which is impervious in itself, usually includes a part of the ballast and cannot become a continuous covering that ensures total waterproofing. Neither a sufficiently accurate application at the sides of the ballast can be assured, so that the water could penetrate sideways. Moreover, the liquid must be injected forcefully with subsequent applications at distances from one another. In this way, giving assurance that the application will not be a fragmented patchwork, thus thwarting the whole work, is practically impossible. Furthermore, the mechanical resistance of the mass to the continuous stresses deriving from the passage of trains is not assured on the medium-long term.
The U.S. Pat. No. 4,366,846 describes a system for the containment and collection of liquids, for example, produced from petroleum, which can be applied to a section of railway line. The system comprises, among other things, a layer of waterproof material spread under the ballast, in contact with the solid sublayer.
Although the technical problem tackled by the aforesaid document can be partially traced back to that of the present invention, the solution proposed by the document is included among the conventional ones as described above. In fact, in order to implement the system proposed by the above mentioned patent, the ballast must be completely removed, therefore, the problem of the mechanical resistance in respect of the combined action exerted by the crushed stone forming the same ballast from above and from below, especially during the passage of trains and in the long run, is not encountered.
The document U.S. Pat. No. 4,388,357 describes likewise a system of waterproofed containment, aimed at collecting oil products, etc., which can be applied to a railway line. As far as waterproofing aspects are concerned, the characteristics of the proposed solution are substantially the same as those proposed by the present document, as well as the drawbacks resulting therefrom.
Therefore, the object of the present invention is to propose a different method for waterproofing bridges, which is rapid to carry out and effective in its functionality, but which can first of all stop any progressive deterioration of the bridges allowing subsequent renewal operations.
In substance, the proposed method must be quick in the implementation of the waterproofing system; in addition, it must require low costs of the used materials and the implementation as a whole.
Another requirement of the proposed method is the system adaptability to different types of bridges and to different geometries.
Finally, a suitable durability is required, especially with respect to the costs and installation expenses.
As it can be deduced from claim 1, in a first aspect the above mentioned method means to resolve this technical problem by relying on only one element with both sheath, waterproofing function and protection and support functions; in a second aspect, the method aims at allowing a dry installation, which does not need times for setting or hardening of the materials being used.
The invention is also aimed at protecting a material for waterproofing the above mentioned bridges, according to the contents of the claims.
The characteristics of the invention, which have not appeared from what has been previously said, will become evident from the following description, with reference to the enclosed drawing tables, in which:
With reference to the above mentioned Figures, reference numeral 1 indicates, by way of example, an arch bridge (
In accordance with the method proposed by the present invention, the operation on the track can be advantageously carried out in automatic way, by the machines already used for alignment (not shown in the drawings).
First the tracks 6 are sectioned in pieces of 18-20 meters by cutting with oxyacetylene torch, along each span C of the bridge 1 (
Then, the tracks are moved to the side, in an area which is not involved in the restoration; the tracks are moved by a machine called loading platform. The loading platform, which lifts, and a mechanical shovel, which shifts and moves away, remove a layer of crushed stone 2 to the extent necessary for the method under discussion. Such extent exceeds a little the depth of the layer normally removed for the ordinary maintenance of the tracks, but not more than that. The removal depths typically acceptable are comprised between 50 and 80 centimetres.
Afterwards, the material of cured rubber in sheets 10 is laid in one layer, without any concrete support layer or covering/protection layer of bitumen conglomerate.
The quality of the used rubber, which includes a particular compound, prepared on purpose to give resistance to the perforation, relieves from the necessity of using concrete support levels below and layers of bituminous conglomerate above, since it is self-protected and avoids perforations, tearing, cracks, etc.
This allows the maintenance operation with the restoration of the waterproofing system to be carried out in few hours for those bridges for which the traditional system required a few days.
Since the crushed stone 2 has rather irregular forms, it is to be expected that the rubber must adapt itself assuming shapes that correspond to the shapes of the crushed stone lying thereon and to the shapes of the crushed stone situated under it.
With reference to
If the transversal and longitudinal dimensions of the bridge do not allow reasonably the assembly, transport and subsequent laying of a single sheet, smaller sheets are produced, rolled up and transported to the place. They must be subsequently joined to one another and to the sides of the railway line of the bridge, along which they must be installed.
A first possible joint (
The bottom of the receiving seat 13 could be recessed with respect to the profile of the shaped extension 12, which could be flattened in its outermost part, in such a way as to leave a cavity 14, once the coupling has been obtained, aimed at being filled with a hardening and sealing liquid injected in a subsequent moment.
A second possible solution, illustrated in
The lower surface of the connecting strip 18 can be pre-glued and covered with a protection film (not shown), which is removed on the application. Also the upper surface can be pre-glued and protected with a film, likewise removed when, in the end, the upper borders 16 of the recesses 15 are released.
The possible interspace 19 that remains between the two borders of the upper recesses 16 can be closed by the introduction of the polymer putty 20, so as to improve and assure the waterproofness.
Another solution, illustrated in
Once the joint between the various sheets of rubber 10 has been realized and the impermeable “carpet” has been obtained, it is necessary to fasten the borders 24 thereof to the containment walls 3, 4 of the ballast 2 (
The tightness between the borders 24 and the walls 3 is usually sufficient to prevent water passage, if there are plates situated over the border of the impervious carpet. In another case, as illustrated in a detailed way in
Apart the joint 11 between the various sheets of cured rubber as well as the joint of the impervious carpet with the containment walls 3, 4 of the ballast, it is necessary to provide for required inclinations (
In the optimal embodiment, the discharge pipes finish in a water removal system (not shown) in accordance with the method that will be obvious for those skilled in the art.
In the bridges with decks the inclination provided for the bridge during construction can be enough. On the other hand, in case of the arch bridges, it is necessary to remove the crushed stone 2 from the ballast to such an extent and with such a distribution as to obtain just an inclined configuration of the surface of the sheets 10 of rubber.
In both cases, a slight inclination toward one or both ends of the bridge 1 can be provided, in such a way as to collect the water in a corner area R of the impermeable carpet, i.e. the area in which the inlets 27 and the water collecting pipes are situated.
A different embodiment of the method according to the invention is illustrated in
The railway line or the section of line included in a railway bridge 1, comprises a first track 6a and a second track 6b, parallel to each other. The method for waterproofing according to the invention includes the following working steps, some of which have common characteristics with the working steps of the method according to the already described embodiment.
The beginning situation of the line or bridge 1 is illustrated in
In accordance with the method described herein, first of all a piece of the first track 6a is removed, together with the ties, in case there are any.
Then, the layer S of gravel or crushed stone 2 that forms the ballast M is made with the normal equipment, provided to the maintenance staff, from the side of the first track 6a and little beyond the centreline plane of said ballast M, up to a greater depth with respect to that normally achieved by periodic mixing of said gravel or crushed stone 2 during maintenance operations of the aforementioned tracks 6, thus leaving in place the possible remaining underlying portion of gravel or crushed stone 2 (see
After the above described step, in which the upper layer of the ballast from the side of the first track 6a is removed (however the operation can be carried out also before), a plurality of first under track crossties 55 are installed below the second track 6b.
Then a first vertical shoulder 51 is installed (still
Then a first sheet 101 of cured rubber is spread on the underlying part of gravel or crushed stone 2 of the part of ballast M, from the side of the first track 6a (
The first sheet 101 is laid while keeping a first edge 101a of the above mentioned sheet 101 raised against the wall of the first shoulder 51.
Then, a second vertical shoulder 52 is installed, beside the first shoulder 51, keeping the first edge 101a contained between the shoulders first 51 and second 52.
The gravel or crushed stone 2 removed previously, is subsequently repositioned on the first sheet 101 of cured rubber (
After or at the same time with the aforesaid step, in which the first track 6a is repositioned, a plurality of second under track crossties 56 are installed under the first track 6a. The second under track crossties 56 are also fastened to the second shoulder 52 in order to ensure that it remains in position also after the stresses imposed by trains passing on the first track 6a.
The subsequent step includes removal of a section of said second track 6b and of its ties possibly present (
In accordance with a procedure similar to that already described in relation to the first track 6a, a layer S of gravel or crushed stone 2, which constitutes the ballast M, is removed from the side of the second track 6b, up to a greater depth with respect to the one normally achieved by periodic mixing of said gravel or crushed stone 2 during the maintenance operations of the aforementioned tracks 6, leaving in place any possible remaining underlying portion of gravel or crushed stone 2.
Then, the first shoulder 51 is removed, leaving only the second shoulder 52 to support the stresses transmitted on the opposite side of the ballast M.
The same way as already described, a second sheet 102 of cured rubber is laid on the underlying part of gravel or crushed stone 2 of the part of the ballast M from the side of said second track 6b. The second sheet has the same characteristics as the first sheet 101, and a second edge 102a of the second sheet 102 situated beside the first edge 101a of the first sheet 101 is kept raised.
The two edges, first 101a of the first sheet 101 and second 102a of the second sheet 102 are subsequently joined to each other in accordance with one of the above described techniques, or with another known joint technique, in such a way as to make the coupling of the first and second sheets stable and impervious.
The previously removed gravel or crushed stone 2 is subsequently repositioned on the second sheet 102 of cured rubber. Then, the above mentioned second track 6b and the ties possibly present of the previously removed section of railway line are repositioned.
Finally, the second under track crossties 56, the second shoulder 52 and the safety rail 53 are removed.
The outer lateral borders of the sheets 101,102 are fastened to the containment walls 3,4 of the line or bridge 1 according to what has been described in relation to the previous embodiment of the method.
At this point, the section of railway line or bridge 1 are perfectly waterproofed and the procedure can be applied to a subsequent section of line or another bridge to be waterproofed.
The above described embodiment of the invention advantageously allows waterproofing operations of the section of line or bridge 1 without the necessity to interrupt completely the traffic on the railway line, thus allowing the trains to transit alternatively on one of the tracks 6a or 6b, although at reduced speeds.
According to an advantageous version, which has not been illustrated in the enclosed drawings and which can be applied to all the above described embodiments of the invention, the whole extension of the “carpet” of rubber that must be placed in the ballast to restore the waterproofing system, considering a not too long bridge, can be assembled in a suitable seat, thus solving all the complications deriving from the necessity to connect the various sheets. The so obtained carpets can be wound on big rolls, transported to the working site and then applied to the bridge, from which the layer of ballast of the required thickness has been removed.
The obvious advantage of this way of constructing the carpet derives from the considerable reduction of time required for applying the sheath, since the positioning of the sheets 10 and their joint are not necessary. In fact, in this case it is sufficient to spread the sheath, possibly composed of two or more big sheets, if required by the bridge dimensions, and, after the borders have been fastened along the containment walls 3, 4, to place again the crushed stone 2 and tracks.
According to another advantageous version of the covering used for the waterproofing, a fabric or cloth is embedded in the sheets of rubber, in a known way, so as to further increase the resistance of the sheets 10 to tearing and perforation. In this way, the thickness of the sheet can be reduced with respect to that of a sheet 10 constituted only by cured rubber. For example, a total thickness that can be assumed for such covering, can be of about 3-4 millimetres.
Yet more advantageously, in the case of installation on a particularly busy railway line, or with a particularly heavy load traffic, the sheet 10 can be formed by overlaying two suitably stabilized sheets of the aforesaid rubber reinforced with canvas. The stabilization can be obtained by gluing of the two overlaying sheets, or by a subsequent vulcanization.
The thickness of the layer S (
An interesting consequence of the practical application of the present invention is the possibility of reutilization of the material already used and stocked in warehouses. In particular, this is the case of the rubber deriving from the enormous quantity of discarded tyres, which at present remain simply stored in very large areas, perhaps to be partly reutilized in one way or another. The method proposed by the present invention allows a reutilization in massive way of this polluting material, difficult to dispose of, even though it is used as a part of the total quantity of material being used, thus assuming also an ecologic value of primary importance.
Another advantageous effect of the invention derives from the fact that the vibrations transmitted by trains which pass on the bridge to the bridge structure can be reduced. The layer of rubber situated inside the ballast could form a shock absorber which avoids the direct transmission of the vibrations. The beneficial effect on the bridge structure and on the production and diffusion of noise appears obvious.
It is understood that what has been written above is a pure example and is not limiting, therefore possible versions of the method under discussion are considered within the protection field of the invention, as claimed hereinafter.
| Number | Date | Country | Kind |
|---|---|---|---|
| BO2014A000034 | Jan 2014 | IT | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/IB2015/050649 | 1/28/2015 | WO | 00 |
