阅读说明：本技术 一种不中断运行条件下地铁无砟道床整体置换方法 (Integral replacement method for ballastless track bed of subway under uninterrupted operation condition ) 是由 娄会彬 郭积程 谭诗雨 杨艳丽 王森荣 张世杰 朱彬 于 2019-10-14 设计创作，主要内容包括：本发明公开了一种不中断运行条件下地铁无砟道床整体置换方法,其特征在于,包括如下步骤：S1、钢支墩槽开槽；S2、钢支墩安装；S3、道床板分区清除；S4、道床板分区浇筑；S5、钢支墩切割；S6、道床修整。通过在相邻的既有轨枕之间、钢轨的下方开槽,设置钢支墩和扣配件组装件对钢轨进行临时支撑,可以在不中断运行的条件下对既有的病害道床板进行清除,并重新浇筑新道床,道床的整体置换方便,施工效率高,能够在天窗期内快速完成。(The invention discloses a method for integrally replacing a ballastless track bed of a subway under the condition of uninterrupted operation, which is characterized by comprising the following steps of: s1, grooving the steel buttress groove; s2, mounting a steel buttress; s3, removing the ballast bed plate in a partition manner; s4, pouring the roadbed slab in a partition manner; s5, cutting the steel buttress; and S6, track bed trimming. Through between adjacent existing sleeper, the below fluting of rail, set up steel buttress and detain accessory built-up member and support the rail temporarily, can clear away existing disease railway roadbed board under the condition of uninterrupted duty to pour new railway roadbed again, the whole replacement of railway roadbed is convenient, and the efficiency of construction is high, can accomplish fast in the skylight.)

1. The integral replacement method of the ballastless track bed of the subway under the uninterrupted operation condition is characterized by comprising the following steps:

s1, grooving of steel buttress grooves:

chiseling and removing concrete of a ballast bed between adjacent existing sleepers and below a steel rail until a bottom plate interface below the ballast bed to form a steel buttress groove;

s2, mounting a steel buttress:

in a steel buttress groove, positioning the steel buttress and fastening fittings on the steel buttress groove, anchoring the lower end of the steel buttress and hanging the upper end of the steel buttress on a steel rail, then erecting a mold in the groove to pour the steel buttress, after the concrete is initially set, removing a rubber base plate between the top of the steel buttress and an iron base plate before the next road, and emptying the steel buttress and the iron base plate, wherein the newly poured concrete is not influenced by the operation of a train in the daytime;

s3, removing the ballast bed plate in a partition manner:

in order to ensure the stability of the geometric shape and position of the track in the process of removing the track bed slab, the track bed slab is removed in a subarea mode under the condition that the steel rail is not detached, the track bed slab is divided into two sections, and the flowing water construction is carried out in a subarea circulating mode; clearing away the bed plate of the area 1 road under the condition of ensuring that all temporary steel buttresses, the area 2 sleepers and the steel rails are stressed normally;

s4, pouring the ballast bed slab in a partition mode:

the method comprises the following steps of performing partition pouring on a track bed board under the condition that a steel rail is not disassembled, dividing into two areas, constructing in a partition circulating mode, pouring concrete, chiseling a first area for pouring, and constructing by adopting early-strength polymer concrete for pouring the track bed;

s5, cutting the steel buttress:

removing the upper buckle fittings of the steel buttress, and installing new runner bed buckle fittings; cutting the steel buttress, and pouring a steel buttress groove;

and S6, track bed trimming.

2. The method for integrally replacing the ballastless track bed of the subway under the uninterrupted operation condition as claimed in claim 1, wherein:

step S1 includes the following steps:

s1.1, protecting steel rails and fasteners in a replacement work area;

s1.2, drilling a plurality of holes in the track bed between the adjacent existing sleepers and on the inner side and the outer side of the steel rail;

s1.3, performing concrete chiseling on each group of drilling areas to form a steel buttress groove;

s1.4, leveling a structural bottom plate;

s1.5, removing slag and transporting outwards, so that a flat ballast bed-bottom plate interface can be seen.

3. The method for integrally replacing the ballastless track bed of the subway under the uninterrupted operation condition according to any one of claims 1-2, wherein:

step S2 includes the following steps:

s2.1, temporarily installing a buckle fitting at the top of the steel buttress, adjusting the position of the buckle fitting-the whole steel buttress in a steel buttress groove, and suspending the buckle fitting on a steel rail;

s2.2, primarily drilling a positioning hole on the bottom plate below the ballast bed by adopting an electric drill through the anchoring hole on the bottom plate of the steel buttress;

s2.3, after the positioning is finished, removing the connection between the buckle fittings and the steel buttress;

s2.4, drilling holes in the positioning holes to form anchoring holes;

s2.5, assembling fastening accessories on the upper part of the steel buttress again, wherein the fastening accessories are hung on the steel rail; the steel buttress is firmly connected with the lower bottom plate of the ballast bed through anchor rods in the anchoring holes at the lower part of the steel buttress;

s2.6, pouring the steel buttress in the steel buttress groove in the formwork, after the concrete is initially set, removing the rubber base plate between the top of the steel buttress and the iron base plate before the next road, and emptying the steel buttress and the iron base plate, so that the newly poured concrete is not influenced by the operation of the train in the daytime.

4. The method for integrally replacing the ballastless track bed of the subway according to any one of claims 1-3, wherein:

step S3 includes the following steps:

s3.1, lifting the steel rail by adopting a track lifting device, and mounting a rubber base plate under an iron base plate; connecting and fastening the steel buttress and the buckle part;

s3.2, measuring and adjusting the geometric shape and position of the track by matching with line personnel until the requirement is met, and clearing the track bed; firstly, removing the existing ballast bed buckle accessories, chiseling the ballast bed buckle accessories by adopting an air compressor and an air pick crusher, and wrapping and protecting the steel rail in the chiseling process;

s3.3, removing slag and transporting outside.

5. The method for integrally replacing the ballastless track bed of the subway under the uninterrupted operation condition according to any one of claims 1-4, wherein:

step S4 includes the following steps:

s4.1, chiseling bare concrete of the bottom plate and ballast beds at two ends, and cleaning loose particles and dust;

s4.2, fixing the prefabricated short sleepers on the steel rails by using fastener fittings according to the distance between fasteners, binding and installing steel bars according to design requirements, and fixing the prefabricated short sleepers after finely adjusting the geometrical state of the rails by using steel buttresses;

s4.3, additionally arranging flat steel at the edge of the pouring area of the ballast bed, and welding the flat steel with all longitudinal steel bars; stray current terminals are welded on two sides of the flat steel and extend out of the bed surface; chiseling the existing ballast beds at two ends of the pouring area to expose the longitudinal reinforcing steel bar heads, and additionally arranging flat steel and stray current terminals;

s4.4, flushing sundries and dust on a bottom plate of the pouring area, and installing and fixing a side die at the end part of the pouring area;

s4.5, brushing an interface agent on the bottom plate concrete, the concrete at two ends of the track bed and the side wall of the sleeper by using a brush;

s4.6, pouring concrete in a partition mode;

s4.7, strictly prohibiting disturbance on the construction section line by personnel and machines before the concrete strength reaches 10MPa in the pouring process; after the secondary surface collection of the concrete is finished and the concrete is initially set to form strength, removing the fastening fittings of the newly-poured road bed before descending the road, and ensuring that the newly-poured road bed is not stressed;

and S4.8, covering a plastic film to prevent cracks from being generated due to too fast water loss, removing the film before the next process, and watering and maintaining.

6. The method for integrally replacing the ballastless track bed of the subway under the uninterrupted operation condition according to any one of claims 1-5, wherein:

step S5 includes the following steps:

s5.1, removing the upper buckle fittings of the steel buttress, and installing new runner bed buckle fittings;

s5.2, protecting the bottom and the side of the steel rail by using a shovel, and cutting the steel buttress by using oxyacetylene flame;

and S5.3, pouring the steel buttress grooves by adopting early-strength polymer concrete, and leveling by referring to the road bed surface.

7. The method for integrally replacing the ballastless track bed of the subway under the uninterrupted operation condition according to any one of claims 1-6, wherein:

step S6 includes the following steps:

and (4) finishing a newly-poured track bed in a construction area, including a track bed drainage ditch and a track bed surface, and simultaneously cleaning concrete remained on the sleeper blocks and the fasteners.

8. The method for integrally replacing the ballastless track bed of the subway according to claim 3, wherein:

step S2.5 comprises the following steps:

s2.5.1, injecting bar planting glue into the anchoring hole;

s2.5.2, sleeving the anchor rod into the steel buttress bottom plate anchoring hole, installing a buckle fitting and a steel buttress, connecting the steel buttress with the buckle fitting through a high-strength stud and a nut, and suspending the steel buttress on the steel rail;

s2.5.3, pressing the anchor rod into the anchoring hole filled with the bar planting glue, and connecting the upper part of the anchor rod with the steel buttress bottom plate through a nut to ensure that the anchor rod exceeds the nut by at least 2 threads;

s2.5.4, after the bar planting is gelled and fixed to form strength, the nut on the upper part of the anchor rod is screwed down to ensure that the steel buttress is firmly connected with the station bottom plate.

9. The method for integrally replacing the ballastless track bed of the subway under the uninterrupted operation condition as claimed in claim 8, wherein:

in the step S2.5, if the bar planting glue is not solidified to form strength within the time of one skylight, the nut cannot be screwed, the stud and the nut connected with the steel buttress and the fastening part need to be dismounted before the next pass, the steel buttress is dropped to ensure that the operation of the train in the daytime is not influenced, after the bar planting glue is formed at the next skylight to form strength, the steel buttress is remounted, and the nut on the anchor rod is screwed.

Technical Field

The invention belongs to the technical field of ballastless tracks in track traffic, and particularly relates to a method for integrally replacing a subway ballastless track bed under an uninterrupted operation condition.

Background

High-speed railway and urban rail transit commonly adopt whole railway roadbed structure, and the disease appears in the ballastless track in the use, and design ballastless track transformation etc. need demolish existing whole railway roadbed, replace to new railway roadbed structure in urban rail transit.

The patent application CN201710160657.8 discloses a cutting and transporting method for a high-speed rail ballastless track maintenance integral track bed, which only provides a cutting and transporting method for the track bed, but does not reflect the problem of subsequent line recovery; the method is carried out under the condition that the steel rail is cut under the condition of necessity, and the influence on an operation line is large, so that the method is difficult to implement in skylight time.

During the track is demolishd, need guarantee the operation safety of the uninterrupted operation of circuit and train, reduce the adverse effect to transport capacity and driving organization during transformation, this is the difficult problem that is used for in the trade to solve.

Disclosure of Invention

Aiming at least one of the defects or improvement requirements in the prior art, the invention provides a method for integrally replacing a ballastless track bed of a subway under the condition of uninterrupted operation.

To achieve the above object, according to one aspect of the present invention, there is provided a method for replacing a ballast-less track bed of a subway without interrupting the operation, comprising the steps of:

s1, grooving of steel buttress grooves:

chiseling and removing concrete of a ballast bed between adjacent existing sleepers and below a steel rail until a bottom plate interface below the ballast bed to form a steel buttress groove;

s2, mounting a steel buttress:

in a steel buttress groove, positioning the steel buttress and fastening fittings on the steel buttress groove, anchoring the lower end of the steel buttress and hanging the upper end of the steel buttress on a steel rail, then erecting a mold in the groove to pour the steel buttress, after the concrete is initially set, removing a rubber base plate between the top of the steel buttress and an iron base plate before the next road, and emptying the steel buttress and the iron base plate, wherein the newly poured concrete is not influenced by the operation of a train in the daytime;

s3, removing the ballast bed plate in a partition manner:

in order to ensure the stability of the geometric shape and position of the track in the process of removing the track bed slab, the track bed slab is removed in a subarea mode under the condition that the steel rail is not detached, the track bed slab is divided into two sections, and the flowing water construction is carried out in a subarea circulating mode; clearing away the bed plate of the area 1 road under the condition of ensuring that all temporary steel buttresses, the area 2 sleepers and the steel rails are stressed normally;

s4, pouring the ballast bed slab in a partition mode:

the method comprises the following steps of performing partition pouring on a track bed board under the condition that a steel rail is not disassembled, dividing into two areas, constructing in a partition circulating mode, pouring concrete, chiseling a first area for pouring, and constructing by adopting early-strength polymer concrete for pouring the track bed;

s5, cutting the steel buttress:

removing the upper buckle fittings of the steel buttress, and installing new runner bed buckle fittings; cutting the steel buttress, and pouring a steel buttress groove;

and S6, track bed trimming.

Preferably, step S1 includes the steps of:

s1.1, protecting steel rails and fasteners in a replacement work area;

s1.2, drilling a plurality of holes in the track bed between the adjacent existing sleepers and on the inner side and the outer side of the steel rail;

s1.3, performing concrete chiseling on each group of drilling areas to form a steel buttress groove;

s1.4, leveling a structural bottom plate;

s1.5, removing slag and transporting outwards, so that a flat ballast bed-bottom plate interface can be seen.

Preferably, step S2 includes the steps of:

s2.1, temporarily installing a buckle fitting at the top of the steel buttress, adjusting the position of the buckle fitting-the whole steel buttress in a steel buttress groove, and suspending the buckle fitting on a steel rail;

s2.2, primarily drilling a positioning hole on the bottom plate below the ballast bed by adopting an electric drill through the anchoring hole on the bottom plate of the steel buttress;

s2.3, after the positioning is finished, removing the connection between the buckle fittings and the steel buttress;

s2.4, drilling holes in the positioning holes to form anchoring holes;

s2.5, assembling fastening accessories on the upper part of the steel buttress again, wherein the fastening accessories are hung on the steel rail; the steel buttress is firmly connected with the lower bottom plate of the ballast bed through anchor rods in the anchoring holes at the lower part of the steel buttress;

s2.6, pouring the steel buttress in the steel buttress groove in the formwork, after the concrete is initially set, removing the rubber base plate between the top of the steel buttress and the iron base plate before the next road, and emptying the steel buttress and the iron base plate, so that the newly poured concrete is not influenced by the operation of the train in the daytime.

Preferably, step S3 includes the steps of:

s3.1, lifting the steel rail by adopting a track lifting device, and mounting a rubber base plate under an iron base plate; connecting and fastening the steel buttress and the buckle part;

s3.2, measuring and adjusting the geometric shape and position of the track by matching with line personnel until the requirement is met, and clearing the track bed; firstly, removing the existing ballast bed buckle accessories, chiseling the ballast bed buckle accessories by adopting an air compressor and an air pick crusher, and wrapping and protecting the steel rail in the chiseling process;

s3.3, removing slag and transporting outside.

Preferably, step S4 includes the steps of:

s4.1, chiseling bare concrete of the bottom plate and ballast beds at two ends, and cleaning loose particles and dust;

s4.2, fixing the prefabricated short sleepers on the steel rails by using fastener fittings according to the distance between fasteners, binding and installing steel bars according to design requirements, and fixing the prefabricated short sleepers after finely adjusting the geometrical state of the rails by using steel buttresses;

s4.3, additionally arranging flat steel at the edge of the pouring area of the ballast bed, and welding the flat steel with all longitudinal steel bars; stray current terminals are welded on two sides of the flat steel and extend out of the bed surface; chiseling the existing ballast beds at two ends of the pouring area to expose the longitudinal reinforcing steel bar heads, and additionally arranging flat steel and stray current terminals;

s4.4, flushing sundries and dust on a bottom plate of the pouring area, and installing and fixing a side die at the end part of the pouring area;

s4.5, brushing an interface agent on the bottom plate concrete, the concrete at two ends of the track bed and the side wall of the sleeper by using a brush;

s4.6, pouring concrete in a partition mode;

s4.7, strictly prohibiting disturbance on the construction section line by personnel and machines before the concrete strength reaches 10MPa in the pouring process; after the secondary surface collection of the concrete is finished and the concrete is initially set to form strength, removing the fastening fittings of the newly-poured road bed before descending the road, and ensuring that the newly-poured road bed is not stressed;

and S4.8, covering a plastic film to prevent cracks from being generated due to too fast water loss, removing the film before the next process, and watering and maintaining.

Preferably, step S5 includes the steps of:

s5.1, removing the upper buckle fittings of the steel buttress, and installing new runner bed buckle fittings;

s5.2, protecting the bottom and the side of the steel rail by using a shovel, and cutting the steel buttress by using oxyacetylene flame;

and S5.3, pouring the steel buttress grooves by adopting early-strength polymer concrete, and leveling by referring to the road bed surface.

Preferably, step S6 includes the steps of:

and (4) finishing a newly-poured track bed in a construction area, including a track bed drainage ditch and a track bed surface, and simultaneously cleaning concrete remained on the sleeper blocks and the fasteners.

Preferably, step S2.5 comprises the steps of:

s2.5.1, injecting bar planting glue into the anchoring hole;

s2.5.2, sleeving the anchor rod into the steel buttress bottom plate anchoring hole, installing a buckle fitting and a steel buttress, connecting the steel buttress with the buckle fitting through a high-strength stud and a nut, and suspending the steel buttress on the steel rail;

s2.5.3, pressing the anchor rod into the anchoring hole filled with the bar planting glue, and connecting the upper part of the anchor rod with the steel buttress bottom plate through a nut to ensure that the anchor rod exceeds the nut by at least 2 threads;

s2.5.4, after the bar planting is gelled and fixed to form strength, the nut on the upper part of the anchor rod is screwed down to ensure that the steel buttress is firmly connected with the station bottom plate.

Preferably, in step S2.5, if the steel bar planting glue has not solidified to form strength within a skylight time, the nut cannot be tightened, the stud and the nut connected with the steel buttress and the fastening part need to be removed before the next pass, the steel buttress is dropped down to ensure that the steel buttress does not affect the operation of the train in the daytime, and after the steel bar planting glue forms strength at the next skylight point, the steel buttress is reinstalled, and the nut on the anchor rod is tightened.

The above-described preferred features may be combined with each other as long as they do not conflict with each other.

Generally, compared with the prior art, the above technical solution conceived by the present invention has the following beneficial effects:

1. according to the method for integrally replacing the ballastless track bed of the subway under the uninterrupted operation condition, the grooves are formed between the adjacent existing sleepers and below the steel rail, the steel buttress and the fastener assembly part are arranged to temporarily support the steel rail, the existing damaged track bed plate can be removed under the uninterrupted operation condition, a new track bed is poured again, the integral replacement of the track bed is convenient, the construction efficiency is high, and the method can be quickly completed in a skylight period.

2. According to the method for integrally replacing the ballastless track bed of the subway under the uninterrupted operation condition, when the existing track bed plate is removed, a partition removing mode is adopted, and the flow construction is performed in a partition circulating mode, so that the normal stress of the steel rail is ensured, the stability of the geometric shape and position of the track in the track bed plate removing process is ensured, meanwhile, the operation area and the non-operation area are not influenced with each other, and the construction speed is accelerated.

3. According to the method for integrally replacing the ballastless track bed of the subway under the uninterrupted operation condition, when a new track bed plate is poured, a partition pouring mode is adopted, construction is carried out and concrete is poured in a partition circulating mode, a first area is chiseled, a first area is poured, the solidification time of the concrete is fully utilized, and the operation efficiency is improved; early strength polymer concrete is used for pouring the track bed in the construction, and the concrete strength is ensured to meet the traffic passing requirement within 2 hours.

Drawings

FIG. 1 is a schematic flow chart of a method for replacing a ballastless track bed of a subway integrally under uninterrupted operation conditions according to an embodiment of the invention;

fig. 2 is a schematic view of removing a track bed plate in a partition manner in the method for integrally replacing a ballastless track bed of a subway under the uninterrupted operation condition in the embodiment of the present invention.

Detailed Description

In order to make the objects, technical solutions and advantages of the present invention more apparent, the present invention is described in further detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are merely illustrative of the invention and are not intended to limit the invention. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other. The present invention will be described in further detail with reference to specific embodiments.

As a preferred embodiment of the present invention, as shown in fig. 1, the present invention provides a method for replacing a ballast-less ballast bed of a subway without interrupting the operation, which specifically includes the following steps.

1. Steel buttress groove slotting

The processing steps are as follows: protecting steel rails and fasteners → drilling holes on two sides → chiseling → leveling a station bottom plate → slag removal and outward transportation.

(1) Rail and fastener protection

And steel rails, fasteners and the like in the groove range are wrapped and protected by rubber sleeves.

(2) Two-sided drilling

The steel buttress slotting dimension is 320mm multiplied by 900mm, and in order to ensure that the two side rail pillow blocks are not damaged in the slotting process, the edge of the slot in the vertical line direction is drilled by a water drill. The diameter of the drilled hole is 110mm, the depth is 300mm, and about 11 holes (8 holes on the outer side and 3 holes on the inner side) need to be drilled in each steel buttress groove.

(3) Chisel remover

And (4) performing concrete chiseling on the steel buttress groove after drilling by adopting an electric draft, wherein the chiseling depth is 300 mm. In the period, the cutting machine is adopted to cut off the chiseled existing ballast bed reinforcing steel bars.

(4) Structural floor leveling

And after the steel buttress groove is grooved to the depth (300mm) of the station bottom plate, leveling the structural bottom plate by adopting tools such as an electric pick, a small hammer and the like.

(5) Slag removal for outward transportation

Manual slag removal is adopted, and the construction area is removed in time. After removal of the ballast bed residual concrete, a smooth ballast bed-floor interface should be found.

2. Steel buttress installation

The processing steps are as follows: installing a buckle fitting and a steel buttress → positioning an anchoring hole → dismantling the buckle fitting and the steel buttress → drilling an anchoring hole → installing the buckle fitting and the steel buttress → pouring the steel buttress.

(1) Installation buckle fitting and steel buttress

The steel buttress is connected with a fastener system through a high-strength stud M30 and a large hexagon nut and is suspended on a steel rail. After the installation is finished, the position of the whole fastener-steel buttress is adjusted.

(2) Anchoring hole location

And positioning the anchoring holes by adopting an electric drill through the anchoring holes on the bottom plate of the steel buttress.

(3) Demolish and detain accessory and steel buttress

After the positioning of the anchoring holes in the station bottom plate is completed, drilling the anchoring holes in the station bottom plate for convenience, and removing the fastening fittings and the steel buttress.

(4) Drilling of anchoring holes

And drilling by adopting a water drill according to the positioning hole. The diameter of the drilled hole is 32mm, the depth is 180-200 mm, and 4 drilled holes are needed in each steel buttress groove. And after drilling is finished, cleaning accumulated water in the groove to ensure that the anchoring hole is dry.

(5) Installation buckle fitting and steel buttress

The installation sequence is as follows:

① the anchoring hole is filled with bar planting glue.

② the anchor rod with diameter of 16mm is sleeved in the anchor hole of the steel buttress soleplate, the fastener fittings and the steel buttress are installed, the steel buttress is connected with the fastener system through the high-strength stud M30 and the large hexagon nut, and is hung on the steel rail.

③ the anchor rod is pressed into the anchoring hole filled with the bar planting glue, the upper part of the anchor rod is connected with the steel buttress bottom plate through the nut, and the anchor rod is ensured to exceed the nut by at least 2 sections of threads.

④ after the bar planting is gelled and fixed to form strength, the nut on the upper part of the anchor rod is screwed down to ensure that the steel buttress is firmly connected with the station bottom plate.

Note: if the steel bar planting glue is not solidified to form strength in one skylight time, the screw cap cannot be screwed, the stud and the nut connected with the fastener system need to be detached before the next pass, the steel buttress falls down to ensure that the operation of the train in daytime is not influenced, and after the steel bar planting glue is formed at the next skylight point to form strength, the steel buttress is reinstalled, and the nut on the anchor rod is screwed.

(6) Pouring steel buttress

The early-strength polymer concrete is poured from one side of a vertical mold in a steel buttress groove, the bottom of the steel buttress is guaranteed to be closely contacted with the concrete, and the pouring height of the concrete is 1-2 cm higher than that of the anchor rod.

After the concrete is initially set, the rubber base plate under the iron base plate is detached before the concrete is placed on the next road, the steel buttress and the iron base plate are separated by 1-2 cm, and the newly cast concrete is not influenced by the running of the train in the daytime.

3. Removing ballast bed plate in different areas

As shown in fig. 2, in order to ensure the stability of the geometric shape and position of the track in the track bed slab removing process, the track bed slab is removed in a partition mode under the condition that the steel rail is not detached, the track bed slab is divided into two sections, and the flow construction is performed in a partition circulating mode. And under the condition of ensuring that all temporary steel buttresses, the 2 nd area sleepers and the steel rails are normally stressed, clearing away the bed boards of the 1 st area railway, and clearing away the bed boards of other areas.

The processing steps are as follows: installing steel buttress upper buckle fittings → removing the existing ballast bed → slag removal and outward transportation.

(1) Installing steel buttress upper buckle accessory

Lifting the steel rail by adopting a track lifting device, and mounting a rubber base plate under an iron base plate; the steel buttress is connected to the fastener system using high strength studs M30 and large hex nuts.

(2) Removal of existing ballast bed

And measuring and adjusting the geometric shape and position of the track by matching with line personnel until the requirement is met, and clearing the track bed. The method comprises the steps of firstly removing the existing ballast bed buckle accessories, chiseling the ballast bed buckle accessories by adopting an air compressor to be matched with an air pick crusher, chiseling the ballast bed buckle accessories to a depth of 300mm, and wrapping and protecting the steel rail in the chiseling process.

(3) Slag removal for outward transportation

Manual slag removal is adopted, and the construction area is removed in time.

4. Road bed board partition pouring

And (3) carrying out partition pouring on the track bed board under the condition that the steel rail is not disassembled, dividing the two areas, carrying out partition circulating construction and pouring concrete (chiseling the first area for pouring the first area), and adopting early-strength polymer concrete for pouring the track bed in order to ensure that the concrete strength reaches the traffic requirement within 2 hours. And weighing the materials used for the stirred concrete outside the line for later use according to the daily pouring process amount. The fasteners are required to be wrapped and protected in the pouring process.

The processing steps are as follows: chiseling concrete → processing and installing steel bars → installing stray current terminals → installing templates → spraying epoxy interface agent → pouring concrete → dismantling new pouring channel bed fasteners → watering and curing.

(1) Concrete chisel hair

And (4) chiseling exposed concrete of the bottom plate and the ballast beds at the two ends, and cleaning loose particles and dust.

(2) Reinforcing bar processing and installation

According to the fastener interval, utilize the knot accessory to fix prefabricated short sleeper on the rail, carry out reinforcement and installation according to the design requirement, utilize steel buttress fine adjustment track geometric state after-fixing simultaneously.

(3) Stray current terminal installation

Adding 50 multiplied by 8 flat steel at the edge of a pouring area of the ballast bed, and welding the flat steel with all longitudinal steel bars; stray current terminals are welded on two sides of the flat steel and extend 75mm out of the track bed surface.

In order to meet the communication requirement of a current-discharging electric net between the replaced track bed block and the existing track beds on the two sides, the existing track beds are chiseled at the two ends of a pouring area, the chiseled length is about 100mm, the longitudinal reinforcing steel bar heads are exposed for at least 60mm, and flat steel and stray current terminals are additionally arranged according to the same requirement.

(4) Formwork installation

And washing sundries and dust on a station bottom plate of the pouring area, and installing and fixing a side formwork at the end part of the pouring area. In order to ensure the appearance quality of newly-poured concrete, a permeable template cloth is stuck on the template.

(5) Spray-brushing epoxy interface agent

In order to improve the cohesiveness of new and old concrete, the brush is used for brushing the interface agent on the bottom plate concrete, the concrete at two ends of the ballast bed, the side walls of the sleeper and the like.

(6) Pouring concrete

And (3) adopting a partition mode to pour concrete (one section is removed in a chiseling mode for pouring), and adopting early-strength polymer concrete to pour the ballast bed for construction in order to ensure that the concrete strength meets the traffic-passing requirement within 2 hours.

The concrete is prepared by adopting a special mixer for concrete, the mixer is placed on the platform layer, the mixed concrete is discharged into the prefabricated wooden box through the wooden groove, and the wooden box is transported to a specified area for pouring concrete through the flat car.

(7) Dismantle new pouring channel bed and detain accessory

And (3) before the concrete strength reaches 10MPa in the pouring process, personnel and machines strictly forbid disturbing the construction section line. After the secondary surface collection of the concrete is finished and the concrete is initially solidified to form strength, the fastening fittings of the newly-poured track bed are removed before the next track, and the newly-poured track bed is ensured not to be stressed.

(8) Watering and curing

Covering with plastic film to prevent cracks due to too fast water loss, removing the film before next procedure, and watering for curing.

5. Cutting of steel buttress

The processing steps are as follows: installing and dismantling a fastener part → cutting a steel buttress → pouring a steel buttress groove.

(1) Buckle fitting installation and removal

And (5) removing the upper buckle fittings of the steel buttress and installing the buckle fittings of the new pouring gate bed.

(2) Cutting of steel buttress

And protecting the bottom and the side of the steel rail by using a shovel, and cutting the steel buttress by using oxyacetylene flame.

(3) Pouring of steel buttress groove

Early strength polymer concrete is adopted to pour the steel buttress groove, and leveling is carried out by referring to the road bed surface.

6. Ballast bed finishing

And (4) finishing a newly-poured track bed in a construction area, including a track bed drainage ditch and a track bed surface, and simultaneously cleaning concrete remained on the sleeper blocks and the fasteners.

According to the method for integrally replacing the ballastless track bed of the subway under the uninterrupted operation condition, the grooves are formed between the adjacent existing sleepers and below the steel rail, the steel buttress and the fastener assembly part are arranged to temporarily support the steel rail, the existing damaged track bed plate can be removed under the uninterrupted operation condition, a new track bed is poured again, the integral replacement of the track bed is convenient, the construction efficiency is high, and the method can be quickly completed in a skylight period.

When the existing track bed plate is removed, a partition removing mode is adopted, and the flow construction is carried out in a partition circulating mode, so that the normal stress of the steel rail is ensured, the stability of the geometric shape and position of the track in the track bed plate removing process is ensured, meanwhile, the operation area and the non-operation area are not influenced with each other, and the construction speed is accelerated.

When a new bed board is poured, a partition pouring mode is adopted, construction is carried out in a partition circulating mode, concrete is poured, a first area is chiseled off and a first area is poured, the setting time of the concrete is fully utilized, and the operation efficiency is improved; early strength polymer concrete is used for pouring the track bed in the construction, and the concrete strength is ensured to meet the traffic passing requirement within 2 hours.

It will be understood by those skilled in the art that the foregoing is only a preferred embodiment of the present invention, and is not intended to limit the invention, and that any modification, equivalent replacement, or improvement made within the spirit and principle of the present invention should be included in the scope of the present invention.