铁路客运专线双块式无砟轨道施工工法(轨排法)

'ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法双块式无砟轨道施工工法范明明王保林赵忠华胡忠辉王纯玉1前言温福客运专线中铁十九局集团公司无砟轨道工区担负温福线霞浦隧道全线的无砟轨道施工。霞浦隧道内正线铺设60kg/m无螺栓孔新轨，采用CRTSⅠ型（温福Ⅰ型）双块式无砟轨道，WJ-7A型扣件（研线0603A），设计范围是：DK155+349~DK168+448，全长13099m。隧道内(单线)共设2095块标准道床板，每块标准道床板长度为6.23m，道床板间设20mm宽伸缩缝，用沥青木板填塞；另在出口端设一块异型道床板，异型板长度为5.25m。在隧道两端出口处分别设置25m长的过渡段（其中5m在无砟轨道上，20m为有砟轨道，有砟范围分别是DK155+329~DK155+349，DK168+448~DK168+468）；过渡段设两根25m长、50kg/m辅助轨，辅助轨伸入隧道内5m,采用双块式温福施（轨）2型轨枕，WJ-7A型（研线0603A）扣件；20m有砟轨道范围铺设秦沈客运专线Ⅲ-GD型轨枕，采用弹条Ⅱ型扣件，辅助轨采用扣板式扣件（研线0304），辅助轨距离基本轨520mm。2工法特点2.1利用本工法确保无砟轨道高平顺性的特性2.2明确双块式无砟轨道的施工工艺，并对各个流程的施工具有指导作用2.3明确双块式无砟轨道施工的操作要点。2.4利用本工法成功的提高了双块式无砟轨道施工的工效，缩短了双块式无砟轨道的施工工期，加快了施工进度。3适用范围本工法适用于客运专线双块式无砟轨道的施工。4工艺原理本工程采用集机械化、人工化施工优点于一身的“轨道排架法”进行施工。工前对隧道内的CPⅢ控制网进行复测。利用CPⅢ控制网控制轨面高程与轨道中线，以此为基础，铺设钢筋，轨排对位，安装模板，浇筑混凝土。保证轨道高精度、高平顺性、耐久性。5施工工艺5.1工艺流程 ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法 ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法设置中心桩和标桩道床板下层钢筋网预制吊装轨枕、分枕、组装轨排、运轨道材料准备、分配、运输钢筋网焊接道床板上层钢筋预制安装横向模板粗调侧模、端模刷涂脱模剂、安装吊装对位现场取样做试件拆轨道排架与模板转移养生振捣、抹面、成形清洗浇筑混凝土清理现场精调并锁定轨道排架 ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法5.2操作要点5.2.1施工准备5.2.1.1整修隧道。无砟轨道施工前对隧道衬砌内轮廓净空断面进行检查，对洞内结构物、设施、设备进行检查，有侵限及结构遗漏项目提前进行处理。对渗漏水、混凝土裂纹提前修补堵漏，同时疏通中心排水沟，并对底板进行凿毛、冲洗、清扫。5.2.1.2隧道基底变形观测与估评。隧道主体工程完工后，必须对隧道基底设施进行沉降观测，绘制沉降曲线，提出沉降变形观测资料及分折评估报告。观测点布置与观测频次：隧道内一般地段沉降观测断面的布设根据地质围岩级别确定，Ⅲ级围岩每400m、Ⅳ级围岩每300m、Ⅴ级围岩每200m布设一个观测断面，断层破碎带等不良地质区段适当加密布设。每个观测断面在相对应的两侧边墙处设一对沉降观测点，沉降水准的测量精度为±1mm，读数取至0.1mm，观测频次每周一次，不少于3个月，沉降稳定后可不再进行观测。按《客运专线无砟轨道铁路工程施工质量验收标准》要求，施工开始三个月前对隧道及过渡段基础进行变形观测与评估，预测的隧道基础工后沉降值不应大于15mm。5.2.1.3混凝土配合比设计霞浦隧道双块式无砟轨道道床采用C40混凝土，采用浙江金圆R42.5水泥，赛江中粗砂，粗骨料采用5~16、16~31.5mm碱骨料低的碎石。根据混凝土的强度等级、耐久性等要求和原材料品质以及施工工艺进行配合比设计。配制的混凝土应满足设计强度，耐久性指标和施工工艺要求。5.2.1.4轨道施工人员的技术培训施工前对作业人员进行岗前技术安全培训，学习无砟轨道施工的有关专业知识、规范、指南、标准，进行各项工作施工程序、技术规定与标准、控制措施的交底，以及有关设备的使用等。培训合格人员方可上岗。5.2.1.5具轨施工法成套设备进场、安装、调试。5.2.2测量设置CPⅢ控制网，一般情况，CPⅢ控制网邀请第三方进行测设，我方予以积极配合。待测设完毕，我方按照相关规定进行复测。CPⅢ控制网复测分为平面控制、高程控制两组同时进行。采集的数据由内业人员用平差软件，三人分别使用软件对数据进行处理，如数据处理结果不符，找出不符原因并进行处理。直到三人数据处理结果相符。将复测成果同设计院提交的CPIII测量成果进行比对，较差不超限的测量成果方可作为最终成果，否则找出成果不符原因并联系相关单位对CPIII点进行重复测量，然后再将测量成果进行对比。如此循环往复，直到CPIII点成果相符为止。测量结果必须经过评估后方可使用。5.2.2.2施工测量施工测量主要包括，轨排尺寸测量，线路中线放样测量，轨排定位精确测量和竣工测量。5.2.3轨排组装5.2.3.1组装轨排工序轨枕存放→对轨枕质量、尺寸验收标识→轨枕装车前移→移动式机械自动分枕平台就位→1#铺装机组吊装轨枕→机械自动分枕→人工配合电动搬手安装扣件→检查几何尺寸及精度。5.2.3.2轨排铺设安装调试工序2#铺装机吊装轨排就位→轨排初调→精调小车检测精调→固车轨排支架→二次检测微调→验收→安装侧面端头模板。5.2.3.3轨排组装工艺流程A工作内容 ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法本工序作业主要内容包括：（1）施工准备（2）卸枕；（3）分枕；（4）上排架；⑸安装扣件。5.2.3.4轨排组装质量要求A轨枕质量及尺寸验收双块式轨枕在工厂预制加工，进货后严格按制成品接收和检验程序办理，合格后方可使用。存枕场安排专人检查验收、保管、发货。检查轨枕时要填写检查记录，及是时清理更换不合格品。轨枕混凝土表面要光滑平整，桁架规整齐全，混凝土抗压强度和弹性模量应满足设计要求，氯离子含渗透值应小于1000C，预埋套管抗拔力应不小于100KN。各部尺寸允许偏差见下表序号检查项目设计值(mm)允许偏差值(mm)1砼轨枕块顶面长度656+4、-22砼轨枕块底面长度722+4、-23砼轨枕块顶面宽度245±24砼轨枕块底面宽度288±25砼轨枕块高度145±36预埋套管与上表面垂直度90°±1°7砼轨枕块两预埋套管横向中心间距382±18砼轨枕块两预埋套管纵向中心间距0±0.59钢轨内侧两砼轨枕块上预埋套管中心间距1132±110下排钢筋距轨枕顶面距离205±311轨枕两个混凝土块上表面水平对齐，不允许有扭曲或折角。用2200mm×200mm平钢板进行检测，当平钢板与轨枕上表面靠贴时，任何一角(或一边)不允许有大于1mm的缝。注：1）轨枕外观质量和各部尺寸，用精度不低于0.1mm的量具测量，使用统一的量具。2）检验批次同等条件生产的不多于1000根为一批，外观质量和各部尺寸的检验数量为10根，待检验批量不少于100根。5.2.4轨排铺设安装调试工艺要求5.2.4.1轨排布设5.2.4.1主要工作内容本工序作业主要内容包括：（1）布设轨排；（2）安装横向调节器。5.2.4.2工艺步骤A布设轨排2＃铺装机组从移动式机械分枕平台上吊起轨排运至铺设地点，按中线和高程定位。相邻轨排间使用夹板联结，每个钢轨接头安装4套螺栓，先上轨缝处后上两端螺栓，初步拧紧，轨缝留6-10mm。每组轨排按准确里程调整轨排端头位置。 ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法B安装横向调节器在隧道中线每隔3m钻孔固定纵向工字钢梁，靠隧道中线侧的横向调节器的一端支撑至轨排的竖向螺杆上，另一端支顶到纵向工字钢梁上。靠边沟侧横向调节器安装支撑到边沟墙上。5.2.4.5工序质量标准及验收检验方法检查轨枕位置和里程点是否对应，保证轨排的具体位置。5.2.5轨排调整5.2.5.1工作内容本工序作业主要内容包括：（1）轨枕编号；（2）全站仪设站；（3）测量轨道数据；（4）调整中线；（5）调整高程。5.2.5.2工艺步骤A轨枕编号精调工作进行前首先对轨枕进行编号。编号采用红色油漆喷于轨枕上。B全站仪设站（图7.2.2-2）全站仪观测8对连续的CPⅢ点，自动平差、计算确定设站位置。如偏差大于1mm时，应重新设站。改变测站位置后，必须至少交叉观测后方利用过的4个控制点，并复测至少已完成精调的一组轨排，如偏差大于2mm时，应重新设站。为加快进度，每工作面宜配备2台具有自动搜索、跟踪、计算、传输数据功能的全站仪。13425876控制点CPⅢ全站仪设站点P图7.2.2-2全站仪设站示意图C测量轨道数据（图7.2.2-3）轨道状态测量仪放置于轨道上，安装棱镜。使用全站仪测量轨道状态测量仪棱镜，小车自动测量轨距、超高、水平位置，接收观测数据，通过配套软件，计算轨道平面位置、水平、超高、轨距等数据，将误差值迅速反馈到轨道状态测量仪的电脑显示屏幕上，指导轨道调整。D调整中线采用专用开口扳手调节左右横向调整器，调整轨道中线。一次调整2组，左右各配2人同时作业。E调整高程（图7.2.2-4）用普通六角螺帽扳手，旋转竖向螺杆，调整轨道水平、超高。粗调后顶面标高应略低于设计顶面标高。调整螺杆时要缓慢进行，旋转120°为高程变化1mm，调整后用手检查螺杆是否受力，如未受力则拧紧调整附近的螺杆。F工序质量标准及验收检验方法精调后轨道几何形位允许偏差应符合下列规定： ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法（1）轨顶高程与设计高程允许偏差：±2mm、紧靠站台为：0～2mm；（2）轨道中线与设计中线允许偏差为2mm；（3）无砟轨道静态平顺度标准应符合表7.2.5规定。无砟轨道静态平顺度检查表项目幅值(mm)设计速度高低轨向水平轨距350≥v＞200km/h221±1弦长（m）10m注：轨距变化率不得大于1‰。⑷轨面高程、轨道中线、线间距允许偏差及检验方法序号项目允许偏差（mm）检验方法1轨面高程±2专用检测仪器2轨道中线23线间距＋5G施工注意事项（1）所有测量仪器必须按相关标准实行定期标定。（2）测量区域尽量减少其它施工作业。（3）轨排精调后应采取防护措施，严禁踩踏和撞击。（4）轨排精调后应尽早浇筑混凝土，如果轨排受到外部扰动，或放置时间过长，或环境温度变化超过15℃时，必须重新检查确认仍合格后，方能浇筑混凝土。5.2.6安装模板5.2.6.1工作内容作业主要内容包括：（1）模板抽检；（2）安装横向模板；（3）安装纵向模板。5.2.6.2工艺步骤A模板抽检模板安装前应先进行以下检查工作：模板平整度；模板清洗情况；脱模剂涂刷情况；更换损坏或弯折的模板。B安装横向模板单元缝位置必须准确放样、划线标注。横向模板为2cm的隔板，隔板上端通过卡扣与工具轨相连，下端用钢筋固定。C-7-安装纵向模板纵向模板采用小型组合式模板，人工进行安装，在安装前调整轨道排架横梁两端的模板超高调节螺栓，保证纵向模板安装槽垂直地面。道床板模板安装检查表序号项目允许偏差（mm）备注1顶面高程±5均为模板内侧面的允许偏差2宽度±53中线位置25.2.7模板拆除5.2.7.1拆模条件 ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法A当道床混凝土强度不低于5MPa，且能保证道床板棱角完整。B拆模时混凝土表层与环境之间的温差小于20℃。C拆模时道床板混凝土强度、龄期、温差等技术参数均由试验室控制。5.2.7.2拆模顺序A首先拆除端模及隔板堵头模，松开拉螺杆和两边支撑，然后再拆除两边侧模。侧模拆除由两端逐块向中间进行。因为模板属大面、小厚度钢结构，侧向刚度不大，所以在拆除、存放等作业时要防止模板发生塑性变形。B拆模原则：模板以一条线为轴线往外侧移动，其余各点逐渐脱离道床板，轴心可为模板上口或下口。混凝土浇注完毕8～12小时后，即可拆除固定螺栓或模具。C模板拆除质量要求（1）拆模时道床板不出现硬伤掉角。（2）拆模过程中注意保持模板不变形。（3）拆模后，地面无零散配件。（4）禁止使用撬棍直接垫在混凝土上撬模板。（5）模板拆除后，要整齐存放，防止变形。5.2.8混凝土浇筑5.2.8.1作业内容及程序钢筋、模板定位→搅拌站拌和砼→砼输送车运输砼→泵送浇注砼→振捣→抹面→拆边模及轨道排架→养护5.2.8.2技术要求A严格按照试验室出具的配合比准确称量混凝土原材料，其最大允许偏差应符合下列规定（按重量计）：胶凝材料（水泥、矿物掺合料等）±1%；外加剂±1%；粗、细骨料±2%；拌合水±1%；B混凝土拌合站计量设备验收合格，运转正常。混凝土的所有原材料（砂、石、水泥、水及外加剂）必须附合相应的标准要求。C混凝土拌合站必须提供符合配合比要求的混凝土，试验室及工地试验人员承担混凝土的试验工作，每班测定坍落度不少于2次，同一配合比每班次应至少取一组试件。D确保道床板结构尺寸正确，强度、刚度、抗裂性能满足设计要求。5.2.8.3浇注前的准备施工前准备工作有：基面清洗，筋定位，板定位。5.2.8.4混凝土施工A混凝土搅拌先将砂、水泥、矿物掺和料投入搅拌机，经搅拌后加入水，并将其搅拌成砂浆，待砂浆充分拌合后投入碎石，搅拌至均匀为止。此顺序为搅拌机自动控制，每阶段搅拌时间悄宜少于30s，总搅拌时间不宜少于2min,也不宜于超过3min。B混凝土坍落度由试验室确定，搅拌站首盘混凝土必须测定，在浇筑地点每50m3混凝土取样测定一次，混凝土坍落度为100~140mm。C混凝土计量搅拌混凝土采用L1000型拌合机，拌合机在使用时，起动并等运转正常后再下料，严禁带负荷起动或超搅拌。计量器具按规定定期检定。搅拌机经大修、中修后，需要对计量器具重新进行标定。每一工班正式称量前，均需对计量设备进行校核。D混凝土运输a混凝土采用8m3混凝土罐车进行运输，随拌随用。每天工作后或浇筑过程中断60min及以上时间再进行搅拌混凝土时，必须再次清洗搅拌筒。b ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法混凝土运输设备的运输能力与混凝土凝结速度和浇注速度相匹配，以保证浇筑过程连续进行。运输过程中确保混凝土不发生离析、漏浆、严重泌水及坍落度损失过多等现象，运至浇筑地点的混凝土仍保持均匀和规定的坍落度。当运至现场的混凝土发生离析现象时，应在浇筑前对混凝土进行二次搅拌，但不得二次加水。c采用混凝土罐车运送已搅拌好的混凝土，运输过程中以2~4r/min的转速搅动；当搅拌车到达浇灌现场时，高速旋转20~30s后再将混凝土拌合物喂输送泵料斗中；运输车每天使用完后进行清洗。d根据混凝土性能的具体情况确定混凝土拌合物滞留或浇筑间断时限。混凝土拌合物滞留时限一般不超过1h，浇筑简短时限一般不超过2h。e运输混凝土过程中尽量减少混凝土等待时间，保持连续浇筑混凝土，必要时可降低浇筑速度以维持浇筑的连续性。f混凝土浇筑E混凝土浇筑前做好如下准备工作：输送泵布管确保平顺，尽量采用大角度布管；输送泵浇筑口采用橡胶软管，浇筑混凝土时可以调整浇筑口至轨枕距离，并控制在20cm左右。泵送混凝土前，应选用水泥浆或与泵送混凝土配合比相同但粗骨料减少50%的混凝土通过管道。混凝土在浇筑前，使用防护罩保护钢轨及轨枕不被混凝土污染。混凝土浇筑前仔细检查模板、支架、钢筋、预埋件的紧固度和钢筋保护层垫块的位置、数量等，并严格执行“三检制度”。F浇筑混凝土符合下列规定：混凝土保持从起始端一个轨枕的浇筑口浇灌，直至轨枕顶面下1.0cm，振捣密实后移至下一个轨枕浇筑口中。施工时严格要求在第一个轨枕下混凝土未密实之前，不要将浇筑口移至下一个浇筑口；每板道床浇筑时要设置专人进行补仓或清走剩余混凝土。混凝土浇筑需连续进行，因故障间歇时间要小于前层混凝土的初凝时间或重塑的时间；必要时可降低泵送速度以维持泵送的连续性，如停泵时间超过15min，应每隔4~5min开泵一次。道床板单线每浇筑115m取一组试件，养护试件的试验龄期为56d。G混凝土振捣A混凝土浇筑过程中，随时对混凝土进行振捣并使其均匀密实。对轨枕底部及其周围位置的混凝土要加强振捣，确保混凝土密实。B振捣时防止振捣捧触碰轨排与支撑架，插点布置均匀，不要漏振。同时需注意轨排几何状态的变化，保证轨排、模板、支撑架的稳定牢固，并随时监测。如有变位，立即停止浇筑和振捣，并在混凝土初凝前完成修整工作。C振捣混凝土时，符合下列规定：采用插入式振捣器振捣混凝土时，插入振捣器的移动间距不宜于于振捣器作用半径的1.5倍，且插入混凝土内的深度约为20cm，与侧模保持50~100mm的距离。当振动完毕需变换振捣棒在混凝土拌合物中的水平位置时，边振动边竖向缓慢提出振动棒，禁止将振捣棒放在拌合和物内平拖及用振捣棒驱赶混凝土。每一振点的振捣延续时间为20~30s，以混凝土不再沉落，不出现汽泡，表面呈现浮浆为度，防止过振、漏振。混凝土浇筑振捣密实后，表面需抹平，抹面形成设计的横向排水坡，在抹面的同时清理钢轨、轨枕、扣件和支撑架等表面的灰浆。H道床板混凝土养护每浇筑10~12m混凝土振捣密实，表面经收面之后，在12小时内覆盖和喷雾洒水养护，洒水次数应能保持混凝土处于湿润状态，初凝后立即解开夹板螺栓，松开扣件等固定装置，保湿养护不少于7天。养生初期1~2天内采用塑料薄膜复盖，后期采用土工布复盖，不允许绒状材料直接覆盖在新鲜的混凝土表面之上。I道床板模板拆除 ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法侧模应在混凝土强度达到2.5Mpa以上，其表面及棱角不因拆模而受损时，方可拆模；混凝土强度达到5Mpa时，方可拆除轨道排架或调整器，在未达到设计强度的70%前，严禁在道床板上行车和碰撞轨道部件。遗留的螺栓孔采用高强度无收缩砂浆封堵。J验收标准混凝土道床板外形尺寸允许偏差序号检查项目允许偏差（mm）1顶面宽度±102中线位置23顶面与承轨台面相对高差±54伸缩缝位置±55平整度2（1m尺量）5.3劳力组织（表5.3-1）表5.3-1序号工作内容人数工班调配1混凝土面处理10单班作业2道床板钢筋网绑扎20单班作业3轨排架设与调整20两班倒作业4模板安装与拆卸20单班作业5龙门吊司机4两班倒作业6汽车吊司机2两班倒作业7混凝土搅拌10两班倒作业8混凝土运输6两班倒作业9混凝土灌注20两班倒作业10混凝土养生4单班作业11现指指挥协调2两班倒值班12质量检查员2两班倒值班13测量员5单班作业14安全员2两班倒作业15电工2两班倒作业16试验员3两班倒作业17材料员2两班倒值班18合计134 ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法6机具设备表6-2序号机械设备名称规格型号单位数量备注进口出口合计一、无砟轨道铺设成套设备1自行式铺装机组10t/40kw组2241#2#走行吊2多功能电控吊具架224吊轨排用3移动式机械分枕组装平台每次20根枕木台1124组合式轨道排架9.375m长组323264含工具轨、模板5调车平转桥台112选用二、其他机械、车辆、设备1叉车5t台1122平板运枕车10t辆2243混凝土搅拌站75L×2台224两斜井各24混凝土输送车6~8m3辆4485混凝土输送泵60m3/h台1126龙门吊走行轨38kg/mm4004008007进洞运输材料车台1128上下班车台2249洒水车台11210清淤农用车台22411空压机2.5m3/min台224底板凿毛用12轨检小车台112德国进口13工具、扣件吊桶个448自制14插入式振捣器台20204015精密水准仪台11216全站仪台11217手薄遥控复测全战仪套11218电焊机ZXG250台33619钢筋切断机GQ-40台11220双头电动搬手BS-Ⅱ台224 ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法21养护喷洒设备台11222钢轨钻孔机ZGD-Ⅲ台112可租用23发电机250kw台112自备电源24钢筋对焊机UN1-75台11225钢筋调直机GT4-10a台11226钢筋弯曲机GJ17-40台11227砂轮机MQ3235台2247质量控制7.1验收依据验收依据标准采用《客运专线无砟轨道铁路工程施工质量验收收暂行标准》《客运专线无砟轨道铁路工程施工技术指南》7.2质量保证措施7.2.1建立健全质量管理机构，完善质量管理体系；7.2.2建立健全岗位责任制度，做到责任到人7.2.3对每道工序做好工前技术交底，记好施工日志；7.2.4制定内控标准，严于规范和验标要求，并且督促落实。8安全措施8.1建立健全安全管理机构，完善安全保证体系；8.2加强安全教育，提高安全员安全意识与知识水平；8.3建立健全岗位责任制度，责任到人，并记好日志；8.4高空作业，安全用电等每项都进行安全技术交底，并且督促落实。9环保措施9.1临时工程必须按照设计统一规划、业主要求和施工环保的要求进行实施；9.2对施工机械和运输车辆安装消声器并加强维修保养，降低噪音；9.3临时房屋尽量减少占地对植被的破环，搞好临时便道的排水与绿化；9.4工程完工后，及时拆除全部临时房屋和临时施工设备，恢复植被，还施工前的青山绿水。10效益分析10.1社会效益温福铁路是我国东南铁路大动脉的关键点，缩短工期，就意味着，温福铁路的早日通车，早日缓解我国东南铁路的压力。10.2经济效益本工法所使用在的温福铁路的霞浦隧道13099m的无砟轨道工程。之前，日工程量定位75双延米，两个作业面，需要87天完成。使用本工法后，日工程量可完成112.5双延米，缩短到53天。先无砟轨道工区施工人员为280人，日开销每人100元，每天需28000元。仅仅工费就降低了元，在加之其他费用，可降低成本元。 ndoverallleadershipresponsibilityforsafety.AdministrativeDeputyiswithinthescopeoftheirrespectiveresponsibilitiesatvariouslevelsofsecurityresponsibility,inchargeofsecurityworkinthecontextofleadership,responsibletotheChief.Fifthopenpitproductionsafetyaccidentinvestigationsystem,performedonaproductionsafetyaccident"fourno"principle.Imposedonproductionsafetyaccidentreportstepbystepreportingthreechannels,namely,UnitChief,administrationandsafetysupervisionsystemcounterparttosuperiorleadership,reportsinatimelymanner.Sixthpitmustimplementthe"whoisinchargeofwho"sincharge"and"hosemustbesafe"principlesinplanning,layout,checkproductionwork,summarizedandevaluatedatthesametime,plans,features,review,summary,ratingsafetywork.Firmlyestablishing"safetyistheeffectiveness,safetyisthecredibility,safetyisthecompetitiveness"awareness,tomakesafetywork.Seventhminingtradeunionorganizationaccordingtolawtheworkerstoparticipateintheworksafetyofdemocraticmanagementanddemocraticsupervision,safeguardworkers"legitimaterightsandinterestsinrespectofsafety.PersonaldeathandaTradeUnionhastherighttoparticipateinthemajoraccidentinvestigations,relyonthemassestodoproductionsafetywork.Eighthpitmustbebasedonrelevantlawsandregulations,industrystandardsandcompanyandGod"sstandards,rulesandregulationsissuedbythecompany,developingrulesandregulationsforcoalproduction,institutionalizationan-13-双块式无砟轨道施工工法11工程实例温福线霞浦隧道全线利用本工法成功的完成了6公里双延米的无砟轨道施工，保证了施工安全、质量和进度，在今后的客运专线的无砟轨道施工中值得普遍推广。'