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1、CRTSIII型板式无砟轨道建造全新理念 New Ideas of the Construction of CRTSIII Ballastless Track,中铁二十三局集团有限公司 2011年1月 China Railway 23rd Bureau Group Co., Ltd January 2011,目 录 CONTENT 一、总体研发思想 、Overall Research and Development Thought 二、技术特点 、Technical Characteristics （一）结构简单 1.simple structure （二）施工便捷 2.convenient
2、construction （三）稳定耐久 3.stable durable （四）方便维修 4.easy maintenance 三、社会及经济效益 、Social and Economic Benefits,一、总体研发思想 、Overall Research and Development Thoughts,轨道交通是一种低碳、节能、环保的绿色交通。随着高速铁路时代的到来，为中国老百姓带来了更加方便、快捷、安全、舒适的出行选择。 Rail transit is one kind of low-carbon, energy-saving, environment-friendly green
3、 transportation. With the advent of high-speed railway age, it is more convenient, more comfortable, safer and faster for the common people to make a trip.,而高速铁道无砟轨道发展的技术路线，实质上就是始终坚持不断地追求轨道的高平顺性，和轨道结构纵向刚度均匀化的连续性。这是确保高速列车安全性和舒适性最关键的核心技术。 Thus the development of high-speed railway ballastless track, i
4、n fact, mainly focuses on high smoothness for the orbit and continuity of longitudinal rigidity homogenization for the rail structure which are the most crucial key technology to maintain the security and comfortability of high-speed train,因为，轨道几何尺寸的制造精度、安装误差和刚度变化是引起高速列车振动的根源。我们追求高速度的过程，就是不断的提高轨道精度和
5、轨道结构刚度均匀性，不断克服振动的过程。 Since the manufacture accuracy of the rail geometry size, installation errors and rigidity change are the root cause to result in vibration of high-speed train. That we pursuit high speed is to keep improving the precision and longitudinal rigidity homogenization for the rail st
6、ructure and overcoming the vibrations.,CRTSIII型板式无砟轨道技术特点，正是针对上述技术关键，吸取了以往各类无砟轨道优点，从而研发的一种结构简单、施工便捷、稳定耐久、方便维修的全新无砟轨道结构。 In view of the key techniques mentioned above, the technical characteristics of CRTS ballastless track which is developed as a kind of brand-new ballastless track of simple structu
7、re, convenient construction, easy maintenance, stabledurable has the advantage of all kinds of previous ballastless track.,总体的研发思想：就是“单元思路、纵连方式、双块受力”。其核心理论构架就是“路基纵连、桥隧单元、方便维修”。 The overall RD thought is Unite ideas, Longitudinal coupled, Double-block forced. Its core theoretical framework is longitu
8、dinal-coupled subgrade, bridge unit, easy maintenance.,二、CRTSIII型板式无砟轨道技术特点 、 Technical Characteristics of CRTS ballastless track,（一）结构简单 simple structure 1、结构组成 1、structure composition,轨道板：路基纵连，桥隧单元； Track slab: longitudinal-coupled subgrade, bridge tunnel unit 填充调整层：自密实混凝土； Packed adjustment layer
9、: self-compacting concrete 缓冲隔离层：与轨道板对应为单元； Buffer separating layer: the unit corresponded with track slab,底座及支承层：桥上单元，隧道内混凝土长单元（或直接采用隧底为基础），路基上为连续碾压混凝土； Pedestal and supporting layer: bridge unit, long unit of concrete inside the tunnel(or directly adopting the bottom of the tunnel as the foundatio
10、n), continuous rolling compaction concrete on the subgrade 限位结构：门型筋+凹凸槽钢筋混凝土。 Spacing structure: gate reinforcement + concave/convex groove-shaped reinforced concrete,其结构技术特点： Technical Characteristics ： （1）路基纵连结构 (1) longitudinal-coupled subgrade,路基结构是由散粒体填筑形成，路基表面刚度较小。若采用单元结构，列车通过时，由于路基表面刚度较低，对板端支
11、承反力，约束力不够，板端竖向位移较大，形成振动源，对高速列车安全性和舒适性影响较大。 The subgrade structure is made of granular materials and the surface rigidity of the subgrade is relatively low. If the unit structure is adopted, when the train passes on it, the supporting force at the end of slab and binding force are not enough so that
12、the vertical displacement at the end of slab is comparatively large, because of the low surface rigidity of the subgrade, which results in vibration source that has great influence on the safety and convenience of the high-speed train.,纵连结构可有效分散板下应力集中，降低应力峰值，提高轨道结构的整体性，增大轨道结构的连续刚度，可最经济、最合理、最有效的克服路基表
13、面刚度降低所带来的振动问题。 The longitudinal-coupled structure can distribute stress concentration effectively and reduce stress peak to improve the integrity of the rail structure and increase its continuous rigidity. And it can most economically, reasonably, and effectively solve the problems brought by the de
14、creasing surface rigidity of the subgrade.,采用的是一种柔性的纵连结构。温升温降时，轨道板纵向可移动（具有单元自由伸缩效果），竖向受限则不能移动。若基础有沉降，柔性纵连结构有较强的跟随性。 One kind of flexible longitudinal-coupled structure is adopted. At the time of temperature rise or drop, track slab can move towards the longitudinal direction (the effect of free unit
15、 expansion), whereas the vertical movement is limited. If foundation settlement occurs, flexible longitudinal-coupled structure has strong following performance.,（2）桥隧单元结构 (2) bridge and tunnel unit structure 桥梁及隧底结构表面刚度较大，为轨道板采用单元结构提供了良好的条件。由于桥隧表面刚度大，对单元板端的约束力较强。 The surface rigidity of bridge and
16、tunnel is high, which provide favorable conditions for the unit structure applied into track slab. Because of the high surface rigidity of bridge and tunnel, the binding force at the end of slab is strong.,列车通过时，板端竖向位移较小，产生的振动是安全、舒适可接受的范围内。 While the train passes by, the vertical displacement at the
17、 end of slab is small. And the vibration caused from it is within the limit of safety and comfortability. 单元板结构不仅可简化桥上、隧内轨道结构，降低建造难度，而且还可降低造价。 Unit slab structure can not only simplify upper-bridge and inner-tunnel trail structure and lower the difficulty of construction, but also reduce project cos
18、ts.,可最有效的克服连续结构受温度力造成的复杂问题等。 The series complex problems brought by continuous structure under temperature force can be solved most effectively,（3）自密实混凝土取代了CA砂浆 (3) self-compacting concrete replacement CA mortar 传统的CA砂浆调整层，只能提供极为有限的弹性，对轨道刚度过渡缓冲作用微小。 Traditional adjustment layer of CA mortar can only
19、 provide very limited flexibility and have a slight effect on buffering transition rigidity of the rail structure.,传统的CA砂浆层与轨道板之间极易产生离缝等破损病害，给运营安全及维修带来了极大的危害和困难。 Some damages like cracks occur between traditional CA mortar and track slab, which brings a lot of harm and problems to operation safety a
20、nd maintenance.,自密实混凝土弹模25000Mpa，与高弹CA砂浆弹模10000Mpa，所能提供的弹性相当。 Self-compacting concrete whose elastic modulus is 25000MPa can provide the same flexibility with the high-flexibility CA mortar that of 10000MPa.,自密实混凝土与轨道板形成牢固的复合板结构，轨道板与混凝土基础间不再有薄弱的夹心层，使轨道结构受力更趋合理。 Self-compacting concrete and track sla
21、b shape into substantial compound structure so that there will be no weak sandwich layer between them that tend to bear load well.,采用自密实混凝土取代CA砂浆作为填充调整层，不仅简化了结构，节省了原材料，减少了对环境的污染，而且与“I”、“II”相比，仅填充调整层可降低造价70%。 Self-compacting concrete instead of CA mortar as packed adjustment layer can not only simpli
22、fy the structure, save raw materials and cut down the pollution to the environment, but also reduce 70 percent of costs of packed adjustment layer compared with CRTSor CRTS.,（4）钢筋混凝土底座或支承层所用钢筋可节省80%。 (4) The reinforcement of which reinforced concrete pedestal is made is scaled down 80 percent. 桥梁上设置
23、混凝土底座，仅仅是为了防排水、超高和设置限位凹槽功能需求，所以底座钢筋可大大减少。 To set concrete pedestal on the bridge which can greatly save the amount of reinforcement used in pedestal is to meet the need of waterproof drainage, super elevation and displacement limited groove.,隧道内限位凹槽可直接设置在仰拱上，仅限位机构需配置钢筋，所以底座钢筋可大大减少。 The displacement
24、limited groove inside the tunnel can be set on the invert arch directly. And it is just displacement limited structure that needs collocating reinforcement. Consequently, the need of reinforcement in pedestal diminishes consumedly.,路基上采用的是碾压混凝土做为支承层结构，因此，也仅是限位凹槽内需配置钢筋，所以支承层钢筋可大大减少。 The supporting st
25、ructure is made of continuous rolling compaction concrete. And the reinforcement is just needed in displacement limited groove. Therefore the reinforcement used in supporting layer is saved greatly.,较“I”型（120t）、“II”型（240t）相比，III型底座钢筋可节省8090%，不仅工程材料用量减少，工程造价降低，且节能减排指标可实现每单线百公里可减少二氧化碳排放量15360t（96t/单线k
26、m1.6t100km）；若与II型板相比，每单线百公里可减排：216t/单线km1.6t100km=34560t。 The amount of reinforcement used in pedestal of CRTS can be saved 8090 percent compared with that of CRTS(weight 120t)or CRTS(weight 240t). Not only are construction materials saved and costs drop off, but also it can hit the target of energy
27、 saving and emission reduction that the emission of CO2 can be reduced 15360t per single-line 100 kilometers(96t/single-line km1.6t100km), while that of CRTSis 34560t (216t/single-line km1.6t100km).,(5)有挡肩空间曲面轨道板采用预制技术 (5) Prefabrication technology is applied into track slab of shoulder spatial curv
28、ed surface. 不分开式扣件系统与后张双向预应力轨道板巧妙结合 Non-separated fastening system and post-tensioned prestressed track slab are combined skillfully.,全新绝缘技术措施 ALL brand new insulation technolog 轨道板下预留门型钢筋，板端预留连接剪力板 Gate reinforcement is reserved under the track slab and shear plate is reserved at the end of the sla
29、b.,有挡肩承轨槽不采用打磨措施，通过二维可调钢模采用预制技术实现高精度空间曲面板，简化了工艺，较低了制造成本。 Grinding measures arent applied into shoulder rail ditch, but prefabrication technology by 2-D scalable steel mould is adopted to materialize the slab of high precision spatial curved surface, which simplifies the manufacture processing and lo
30、wers the construction costs.,（6）采用了“缓冲隔离层”技术，为日后实现维修创造了必要的条件。 (6) Buffer separating layer technology is applied to create conditions for maintenance in the future.,（二）施工便捷 、convenience construction 1、因为取消了CA砂浆，即取消了复杂的制造工艺和专用的CA砂浆搅拌车及相应工装。 1. CA mortar is not adopted so that complex manufacturing pro
31、cess and specific CA mortar agitator truck together with relative equipment are canceled.,而采用的自密实混凝土，均为成熟的施工工艺，通过混凝土搅拌站、运输罐车及泵车就可灌注。 The mature construction craft is applied into self-compacting concrete which can be infused by concrete mixing station, tank truck and pump truck. 2、CRTSIII型板式无砟轨道施工工艺
32、十分简单。 2. The construction craft of CRTS ballastless track is very simple.,CRTSIII型板式无砟轨道施工工艺框图 Flow chart of the construction craft of CRTS ballastless track,CPIII测设与其他无砟轨道相同。 The CP setting out is the same with other kind of ballastless track 混凝土底座可采用带自动测控的混凝土浇筑一体机。支承层采用碾压砼为宜。 The unity machine of
33、concrete cast of automatic measurement and control is applied to the concrete bed plate. The roller compaction concrete is better for the supporting layer.,隔离层与限位凹槽采用人工铺设施工。 Separating layer and displacement limited concave groove are constructed artificially.,高精度有挡肩后张双向预应力空间曲面轨道板通过采用二维可调钢模预制技术产生，不需
34、要打磨工艺和打磨设备，且单模生产平均工效可实现1.5-1.8块/日。 Without grinding crafts and equipments, the track slab of high precision shoulder post-tensioned prestressed spatial curved space is made by prefabrication technology of 2-D scalable steel mould. And the average work efficiency of one mould production is 1.5-1.8 pe
35、r day.,铺设、精调轨道板与CRTSI型和CRTSII型相同，但为防止灌注填充层时上浮，均应加强固定工装及工艺。 The way of track slab pavement and fine adjustment is the same with CRTSor. In order to prevent perfusion packed layers uplifting, fixed equipments and crafts should be intensified,自密实混凝土灌注施工，均采用通用混凝土施工设备，混凝土搅拌站，混凝土运输罐车，混凝土泵车（或地泵）和自密实混凝土中转灌注
36、漏斗。 Perfusion construction of self-compacting concrete adopts general construction equipments, namely, concrete mixing station, tank truck, pump truck and transferring perfusion funnel of self-compacting concrete.,铺设长钢轨以及无缝线路施工与其他相同。 The way of long rail pavement and CWR construction is identical wi
37、th others. 钢轨精调需要采用重载式轨道测量仪（轨道几何状态测量仪）。 Heavy-haul rail measuring apparatus (rail geometry condition measurement instrument)is adopted for rail fine adjustment.,3、施工效率 3. construction efficiency 因CRTSIII型轨道板板长优化，原32m梁需铺设7块轨道板，而现场只需铺设6块。24m梁原铺设6块，现只铺设5块。直接综合工效提高16%。 For the optimization of the length
38、 of track slab of CRTS, the original beam of 32m needs paving 7 track slabs, while 6 track slabs are needed now. 6 track slabs are paved on the beam of 24m originally, while 5 track slabs are needed now. The direct integrative work efficiency is increased 16 percent.,原灌注CA砂浆，一个工作面每天（16h）平均灌注30块轨道板。而
39、改为自密实混凝土，一个工作面每天（16h）平均可灌注80-100块，提高工效300%。 While infusing CA mortar originally, 30 track slabs can be done per day (16h) within one working surface averagely. Whereas 80 to 100 track slabs can be infused while applying self-compacting concrete, which increases the work efficiency of 300 percent.,（三
40、）稳定、耐久 、 stabledurable,1、结构体系具有较强的稳定性 1. The structure system has relatively strong stability.,不分开式扣件与有挡肩轨道板有机结合，更有利于确保钢轨在高速列车动荷载作用下趋于安全稳定。 Organic combination of non-separated fastening and shoulder track slab is more conductive to ensuring the safety and stability of the rail under the high -speed
41、 train dynamic load.,通过自密实混凝土与轨道板间的有效连接，组成具有更强稳定的复合板。 The more stable compound slab consists of effective combination of self-compacting layer and track slab,在复合板与底座之间设置嵌入式限位凹凸台，实现复合板与基础底座在纵、横向上具有足够强度的接触性约束。 The displacement limited concave/convex groove is embedded between the compound slab and ped
42、estal, which results in the contact constraint of the compound slab and pedestal with sufficient intensity in the longitudinal and horizontal level.,隔离层的合理约束连接，可缓解梁体受温度力作用对轨道板的影响。同时，又可缓解列车动荷载作用对桥梁的影响。 The reasonable constraint link of the sepatrting layer can release the influence of the beam on the
43、 track slab, as well as that of the train dynamic load on the bridge,底座与梁面（或隧道底面）的基础固定连接，实现了整个无砟轨道系统与梁面（或隧底）的整体稳定性结合。 The fixed connection between pedestal and surface of the beam (or the bottom of the tunnel) realizes the stable integral combination.,2、结构体系具有良好的耐久性 2. The structure system has good
44、durability. 轨道板采用双向后张部分预应力结构，为不开裂设计思想，使用寿命可达到100年。 The track slab whose service life is 100 years is one kind of bidirectional post-tensioned partially prestressed structure, the design of no-crack.,轨道板下填充调整层由自密实混凝土取代CA砂浆，使用寿命可达到100年。 The life time of the packed adjustment layer made of self-compact
45、ing layer in place of CA mortar is 100 years .,自密实混凝土同轨道板形成牢固的复合板结构，轨道结构更稳定，列车冲击动荷载对轨道板的影响更小，能提高其耐久性，使用寿命可达到100年。 The firmly fixed compound structure of the track slab and self-compacting structure stablizes the rail structure greatly. Impact load of the train has less influence on the track slab wh
46、ose lifetime is up to 100 years and improve its durability.,“桥隧单元结构，路基柔性纵连结构”，确保了道床板结构均具有单元思想，使温度力和环境变化对轨道结构影响变的更小，提供了可以达到100年寿命的基础条件。 Bridge tunnel unit structure and flexible longitudinal coupled structure of the subgrade guarantee unit perception of the slab, which lightens the effect of temperat
47、ure force and environment variation on the rail structure and provides the basic conditions for its lifetime of 100 years.,在轨道板（复合板）与底座（或支承层）之间设置了缓冲隔离层，确保了能够在养护维修的基础条件下，使CRTS型板式无砟轨道结构使用寿命达到100年。 Separating layer set between track slab (compound slab) and pedestal (supporting layer) ensures that the
48、lifetime of CRTS ballastless track structure reaches 100 years on the basic condition of maintenance.,（四）方便、维修 、 easy maintenance 1、作为一种全新的无砟轨道系统，为什么要考虑维修？ 1. As a brand new ballastless track system, why will its maintenance be taken into consideration?,是因为，中国地域宽广，温度区跨度大，地质条件也非常复杂。做为中国的高速铁路无砟轨道系统，希望
49、适应范围广，并建立在长期稳定的基础上， The reasons are as follows. China whose geological conditions are very complicated has a vast territory and long-span temperature distribution. As Chinese high- speed railway ballastless track system, its hoped to adapt to the extensive coverage and be founded on long-term stability,但是长期稳定的基础是不太容易实现，所以，新型无砟轨道系统必须把具备维修方便条件及功能、且适应较大调整的能力，作为高铁无砟轨道重要的核心技术。 However the basis of long-term stability is not easy to achieve. As a result, new type of ballastl