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J Slab Track - Taiwan HSR PDF

The document provides details on the construction of trackwork for a rail system, including road bed, rails, slabs, and ballast. It discusses the installation of various components like projection concrete, rails assembly using flash welding, setting J-slabs with tolerances of 1mm, filling gaps with caulk and concrete-asphaltic mortar, installing rubber shoes and fasteners below rails, and leveling cant for smooth riding. Technical support was provided by Philippe Desgranges on the construction process.

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Gaurav Srivastava
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299 views49 pages

J Slab Track - Taiwan HSR PDF

The document provides details on the construction of trackwork for a rail system, including road bed, rails, slabs, and ballast. It discusses the installation of various components like projection concrete, rails assembly using flash welding, setting J-slabs with tolerances of 1mm, filling gaps with caulk and concrete-asphaltic mortar, installing rubber shoes and fasteners below rails, and leveling cant for smooth riding. Technical support was provided by Philippe Desgranges on the construction process.

Uploaded by

Gaurav Srivastava
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as PDF, TXT or read online on Scribd
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T230

Trackwork
(site visit on T240 in very brief…)
Does not take into consideration
technical issues, mix designs,
progress, dimensions, work
fronts, testing, monitoring, etc.

By Bob Prevost & Kevin Sweeney


Technical Support and great help : Philippe Desgranges (T240 – SSE)

23 October 2003

Content

✓ Road Bed, Protection Layer &


Projection Concrete
✓ Rails Assembly

✓ J-Slabs

✓ Survey & CA Mortar

✓ Rails Installation

✓ Ballast
OCS Poles and Power
✓

Road Bed, Protection


Layer & Projection
Concrete
Road Bed, Protection Layer & Projection Concrete

Girder cross-section drawing identifying in red the major components

Road Bed, Protection Layer & Projection Concrete

Light rebar D13-D19 installation – Road bed is built directly onto the girder
deck (no anchorage) - 10m length x 3.2 wide, with average 300mm thick

Road Bed, Protection Layer & Projection Concrete

Rebar installation for Projection Concrete (typ. ~520mm dia. x 230mm high)

Road Bed, Protection Layer & Projection Concrete

Typical Projection Concrete rebar in between Road Bed joints and girder
Expansion Joints (EJ heavily reinforced due to double shear forces)

Road Bed, Protection Layer & Projection Concrete

Chamfer

Road Bed formwork and with chamfer (cover to rebar: 50mm). Rebar
projecting outside of formwork for Protection Layer

Road Bed, Protection Layer & Projection Concrete

Joint filler (10mm thick) between Road Bed slabs

Road Bed, Protection Layer & Projection Concrete

Concreted by
pump from
ground level

Road Bed concrete completed. Project Concrete rebar exposed (“green-


cut” bottom of Project Concrete for second pour bonding)

Road Bed, Protection Layer & Projection Concrete

Survey
benchmark will
be installed on
top of projection
Concrete

Projection Concrete rebar in Expansion Joint area

Road Bed, Protection Layer & Projection Concrete

Projection Concrete completed (150mm width Expansion Joint)

Road Bed, Protection Layer & Projection Concrete

Protection Layer rebar and girder shear bar connectors

Road Bed, Protection Layer & Projection Concrete

The site will get messy before


completion

Completed: Road Bed, Protection Layer and projection Concrete

Rails Assembly
Rails Assembly

Rail ends are cleaned and


ready for “flash-welds)

Rails (20m length x 60kg/m) stored on site with rail assembly line

Rails Assembly

20m rails “flash- 20m rails storage


welded” storage

Rails are lifted onto girders and rail assembly line may commence

Rails Assembly

Two 20m rails assembled back-to-back, then “flash-welded” together

Rails Assembly

Rails are “fused” together – equipment verifying rails connection and levels

Rails Assembly

Wheel grinded
(not acceptable)

A series of NDT are


undertaken to verify the
welds and rail geometry

Rails sections rolled out of “flash-weld” machine into storage – once 10 no.
of 20m rails are fused (200m), they will be stored in assembly line

Rails Assembly

200m rail section transported by the “long-rail” equipment

Rails Assembly

Rail transported by the “long-rail” equipment – rails placed in their


temporary position on top of Road Bed

Rails Assembly

Rail temporarily placed on Road Bed

J-Slabs
J-Slabs
Quick J-Slab factory
production: 300kg/cm2, 5m
length, rail fasteners anchors
set in factory, J-Slab are
turned upside down when
placed on site

Rail for J-Slab


gantry crane

J-Slab: 5m X 2.2m X
190mm thick

Temporary rail used for J-Slab slab-laying-vehicle while other permanent


rails are temporarily set on the Protection Slab to move J-Slab gantry crane

J-Slabs

Rail fasteners assembled at the J-Slab factory


(pull-out tests not carried out yet)

J-Slabs

J-Slab gantry crane on temporary rails sets J-


Slabs in their preliminary alignment

J-Slabs

J-Slab mini-gantry crane sets J-Slabs in their final location – screw-jacks


leveling top final position

J-Slabs

Tolerances: ±1mm (up/down),


±5mm (Projection Concrete &
J-Slab) and ±2mm
(longitudinal)

J-Slab space between Road Bed (~65mm) – wedging projection


Concrete (space of ~45mm)

Survey & CA Mortar


Survey & CA Mortar

Final survey before CA Mortar – survey data shown on Derailment Wall (HR:
High Rail, HS: High Slab, W: Gauge Width) taken from top of Projection
Concrete and derived from Secondary Control Points

Survey & CA Mortar

Final survey before CA Mortar (Concrete-Asphaltic) injection (gap ~65mm)

Survey & CA Mortar

CA Mortar injection (portable equipment – gravity fed)

Survey & CA Mortar

Must ensure that CA


Mortar covers the J-
Slab’s bottom surface
completely (outlet on
highest point)

CA Mortar solidified – 2 CA Mortar pack per J-Slab

Survey & CA Mortar

Projection Concrete gap (~45mm) filled with “liquid-caulking” then solidifies

Rail Installation
Rail Installation

22mm rubber + 1mm stainless steel

Rubber Shoe installed below rail (typ. 100mmX100mmX23mm)

Rail Installation

665mm between fasteners – 1,435mm gauge

Rail Installation

Fasteners

Rail Installation

Final product

Rail Installation

“Fish-Tail-Plates” to compensate for 200m rail gap adjustment


(will be welded to ensure smooth surface)

Rail Installation

1’1”
difference

same same

Cant: very important that the Cant is well leveled (comparison: Philip at
5’1” and Bob at 6’2” are of similar height in the curves)

Ballast
Ballast

Ballast, also know as Noise Absorption was not carried out yet on
T240, therefore no photographs are available

OCS Poles and Power


OCS Poles and Power

OCS Poles (Overhead Catinery System) are installed


before the Road Bed

Basics

OCS Poles cableing

Basics

OCS Poles gantry crane (working platform)

End

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