1、CRTSIII型板式无砟轨道建造全型板式无砟轨道建造全新理念新理念一、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 transportation.With the advent of high-speed railway age,it is more conveni
2、ent,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,in fact,mainly focuses on high smoothness for the orbit and continuity of longitudin
3、al 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,install
4、ation 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 structure 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
5、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 structure,convenient construction,easy maintenance,stabledurable has the advantage of all kinds o
6、f 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 longitudinal-coupled subgrade,bridge unit,easy maintenance.二、CRTSIII型板式无砟轨道技术特点、Technical Characteristics
7、 of CRTS ballastless track（一）结构简单 simple structure 1、结构组成 1、structure composition-252-780-542-542-622-252-547自密实混凝土厚100mm支撑层厚240mm详图 A2800隔离层L型卷材厚1.5mm轨道板厚190mm弹性垫层10mm3%3%3%3%轨道中心线钢轨 176扣件 38轨道板 190自密实混凝土 1002500支承层 2385000.0600承轨槽 38路基基床表层路基基床底层SAMI厚80mm3100防水层l轨道板：路基纵连，桥隧单元；lTrack slab:longitudin
8、al-coupled subgrade,bridge tunnel unit l填充调整层：自密实混凝土；lPacked adjustment layer:self-compacting concretel缓冲隔离层：与轨道板对应为单元；lBuffer 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 th
9、e tunnel(or directly adopting the bottom of the tunnel as the foundation),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
10、 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
11、the end of slab and binding force are not enough so that 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
12、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,an
13、d effectively solve the problems brought by the decreasing 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 l
14、ongitudinal direction(the effect of free unit 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
15、较强。The surface rigidity of bridge and 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,
16、the vertical displacement at the 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
17、,but also reduce project costs.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 laye
18、r of CA mortar can only 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 t
19、o operation safety and 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 concre
20、te and track slab 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 n
21、ot only simplify 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 perce
22、nt.桥梁上设置混凝土底座，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 displacem
23、ent 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 str
24、ucture 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km1.6
25、t100km）；若与II型板相比，每单线百公里可减排：216t/单线km1.6t100km=34560t。(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 curved 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 bran
26、d 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 slab.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 scal
27、able steel mould is adopted to materialize the slab of high precision spatial curved surface,which simplifies the manufacture processing and lowers 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 futu
28、re.（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 process 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
29、 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型板式无砟轨道施工工艺框图Flow chart of the construction craft of CRTS ballastless track
30、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 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
31、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
32、 made by prefabrication technology of 2-D scalable steel mould.And the average work efficiency of one mould production is 1.5-1.8 per 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
33、 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漏斗。Perfusion construction of self-compacting concrete adopts general construction equipments,namely,concrete mixing station,tank truck,pump truck and transferring perfusion
34、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 with 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 e
35、fficiency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 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
36、 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 i
37、nfused while applying self-compacting concrete,which increases the work efficiency of 300 percent.（三）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。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 con
38、sists 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 pedestal,which results in the contact constraint of the compound slab and pedestal with suff
39、icient 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 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
40、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 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
41、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-compacting 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
42、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 whose 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
43、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 temperature force and environment variation on the rail structure and provides the basic conditions for its lifetime of
44、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 lifetime of CRTS ballastless track structure reaches 100 years on the basic condition of maintenance.（四）方便、维修 、easy ma
45、intenance 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，希望适应范围广，并建立在长期稳定的基础上，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。其次，通过国内外工程实测调查显示，普通混凝土使用寿命在30-50年就会
46、出现明显老化，对无砟轨道混凝土结构耐久性会造成严重影响。In addition,the actual measurement survey at home and abroad shows that general concrete will be aging significantly after about 30 to 50 years in service,which may influence the durability of concrete structure of the ballastless track severely.又由于无砟轨道结构所处工作环境非常恶劣，且无砟轨道其
47、他部分也同样会出现磨损。And during to the working conditions of the ballastless track structure is very poor,the other parts will be worn-out meanwhile.因此，要清楚的认识无砟轨道哪些部件正常使用年限？哪些部位在什么样情况下需要维修？哪些部件在什么时间需要更换？这是非常重要的。Which part and in what condition it needs maintenance,as well as when to replace worn components,s
48、hould be recognized.Those are very important issues for us.“使用年限及养护维修周期框图使用年限及养护维修周期框图”Flow chart for maintenance period as bellow 2、维修思路和方便的维修方法 2.maintenance thoughts and method （1）采用单元结构、或柔性连接结构和分离式结构的维修思路 (1)the maintenance approach of unit structure,flexible link structure and separated structu
49、re有挡肩双向后张预应力轨道板门型钢筋底座或支承层自密实钢筋混凝土钢轨缓冲隔离层扣件系统单元+分离式结构、与柔性纵连+分离式结构，在其自密实混凝土（复合板）与底座（或支承层）之间设置了缓冲隔离层，实现了无砟轨道道床的可维修性。Unit separated structure,flexible separated structure and buffering separating layer set between self-compacting concrete(compound slab)and pedestal(supporting layer)make the maintainabil
50、ity of the bed of ballastless track come true.当基础出现了较大的沉降，而扣件已不能调整时（超出扣件的最大调高能力），可将复合板整体抬升到所需高度，通过在复合板下灌注树脂砂浆，即可确保无砟轨道的快速维修，又能保证不中断行车。When large settlement of foundation appears and the fastening cant be adjusted(excess of maximum adjustment capacity of fastening),compound slab can be lifted to requ
