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
