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[0001] The present invention relates to a rail support mechanism used for railroad mass transit roadway intersections, street running track and more specifically precast concrete structures with a removable rubber boot assembly.
[0002] Existing rail support structures for mass-transit or railroad systems typically utilize timber or cast-in-place construction that is both relatively expensive to construct and difficult to repair. More particularly, where time consuming timber construction is not used, construction is often preformed using cast-in-place methods, which are also time consuming and therefore, expensive. Thus, there exists a need to minimize the time at the construction site. In addition, for cast-in-place systems, current rail replacement techniques typically involve using a jack-hammer to chip away the concrete in the vicinity of the rail that is to be replaced. This technique is both time consuming and expensive, and exposes the rail line, construction crew and any associated railroad or nearby automobile traffic to extended periods of construction repair. Other types of rail support systems have previously utilized rubber on polymer boots on sleeves around the rail. However, these systems are generally positioned within the concrete while curing, and are thus not removable, or require attachment hardware to retain the boot in operable position.
[0003] In addition, to the above problems, there is also a need to provide a rail support apparatus that minimizes noise generated by rail cars traversing the rails. Similarly, there exists a need to reduce and minimize vibrations associated with passing rail cars, and thus to improve the quality of the ride for passengers.
[0004] Finally, there is a significant need for a method of manufacture and construction which can streamline the construction schedule by offering precast concrete rail support structures that are manufactured in a controlled environment, can be easily transported to an installation, and can be quickly repaired. Thus, the present invention addresses these problems and industry needs, as described below.
[0005] In a first aspect of the present invention, an apparatus is provide that is a precast slab that includes at least one shaped trough for receiving a rail and a resilient rail support device. The precast nature of the slab allows the time consuming process of curing the concrete that forms the slab to occur in a controlled manufacturing facility. Precast slabs of customized or standardized dimensions can then be produced at a location remote from the construction site, and subsequently delivered for speedy installation, thereby reducing the time and associated cost of having construction crews located at the construction site.
[0006] It is another aspect of the present invention to provide a combination resilient rail support device, or boot, that holds the rail within the precast slab. Proper retention of the resilient boot and rail is achieved because the slab is made with a shaped trough that includes a recess with a pronounced shoulder for receiving and engaging a predetermined geometric profile on the resilient boot. Noise and vibration dampening is achieved by isolating the metallic rail within the precast slab by surrounding it with the resilient boot. Vertical retention of the resilient boots within the shaped troughs is achieved because the lateral recesses of the shaped troughs feature upper shoulders that prevent vertical dislodgement of the resilient boot and rail from the shaped trough during normal rail car operating conditions. The resilient boot also lends itself to easy future repairs of the rail, because the resilient boot can be removed from the precast slab by withdrawing it using properly sized equipment with the rail intact, thereby eliminating the need to jack-hammer or otherwise remove the rail from the rail support using difficult, time consuming and expensive techniques. Thus, in one aspect of the present invention, an apparatus is provided comprising a substantially concrete slab that includes a least one shaped trough comprising a first lateral recess and having an upper shoulder. The apparatus also includes a resilient boot shaped for insertion into the shaped trough, the resilient boot including a bottom portion and two side support portions, at least one of the side support portions including a lateral projection that inserts into the first lateral recess to impede vertical travel. In addition, the apparatus includes a rail positioned within an interior opening in the resilient boot, wherein the resilient boot supports the rail when the resilient boot and the rail are installed within the shaped trough.
[0007] In another aspect of the invention, a method is provided for manufacturing the precast slab portion of the precast rail support. The method of manufacture includes providing a form with a bock-out that properly forms the shaped troughs of the precast slab. The method includes providing block-outs with proper projections to create lateral recesses in the shaped troughs that will then receive the lateral projections of the resilient boot when the resilient boots and rails are installed in the precast slabs at the construction site. Other steps of the manufacturing process include placing structural reinforcement in the form prior to adding concrete to the form, and properly finishing the surface of the concrete for providing high quality, precast structural slabs for future placement at the construction site, and wherein the slabs are designed to withstand significant compressive loads. Thus, in one aspect of the present invention, a method of manufacturing a precast slab is provided comprising the steps of attaching at least one block-out to a precast form, the at least one block-out corresponding to a shaped trough in the precast slab, wherein the at least one block-out includes at least one recess projection corresponding to a lateral recess in the shaped trough and also includes a shoulder projection corresponding to an upper shoulder in the lateral recess of the shaped trough. Additional steps include applying a not-stick coating to the at least one block-out and an interior region of the precast form, and then adding concrete to the precast form to form the precast slab. Subsequently, additional steps include allowing the concrete to cure and then removing the at least one block-out and the precast form to expose the precast slab.
[0008] In yet a separate aspect of the present invention, a method of installing at the construction site is provided by preparing a subgrade to receive the precast slabs. The precast slabs are then lowered onto the prepared subgrade, and the resilient boots with the rail contained therein are lubricated and forced downward into the shaped troughs of the precast slab. Upon forcing the lubricated resilient boot and rails downward, the side projections of the resilient boot engage the lateral shoulders of the shaped troughs to hold the resilient boots in place without the need for accessory hardware. Thus, in one aspect of the present invention, a method for installing a precast rail system is provided, comprising the steps of preparing a subgrade to receive the precast rail support apparatus, followed by placing a precast slab of the precast support apparatus onto the prepared subgrade, wherein the precast slab includes at least one shaped trough extending along a longitudinal orientation of the precast slab, and wherein the shaped trough has a lateral recess that further includes an upper shoulder. Additional steps include positioning a resilient boot around a rail and then installing the resilient boot and rail into the shaped trough, wherein the resilient boot has a lateral projection to engage the lateral recess of the shaped trough under the upper shoulder, and wherein the resilient boot is impeded from being disengaged from the precast slab.
[0009] Additional advantages of the present invention will become readily apparent from the following discussion, particularly when taken together with the accompanying drawings.
[0010]
[0011]
[0012]
[0013]
[0014] While the present invention will be described more fully hereinafter with reference to the accompanying drawings, in which particular embodiments and methods of implantation are shown, it is to be understood at the outset that persons skilled in the art may modify the invention herein described while achieving the functions and results of this invention. Accordingly, the description which follows is to be understood as illustrative and exemplary of specific structures, aspects and features within the broad scope of the present invention and not as limiting of such broad scope.
[0015] In general, the present invention is a precast structural slab that is subsequently fitted with a resilient boot supporting a railroad track or mass-transit line. The combined slab/rail system is installed at road intersections, street running track and thus is heavily traveled. Referring now to
[0016] Referring now to
[0017] Still referring to
[0018] In a separate aspect of the invention, the side support portions
[0019] Without limiting the scope of this disclosure, in one preferred embodiment the two rail assembly shown in
[0020] In a separate aspect of the present invention, a method of manufacturing the precast slab
[0021] The interior surfaces of the precast forms including the exterior block-out surfaces are then oiled or otherwise receive a non-stick coating. Preferably, the forms are stood on edge during oiling to prevent the buildup of oil during its application. In addition, if necessary, the forms are also optionally cleaned prior to oiling to dislodge previously adhered concrete. This optional cleaning step is preferably performed while the form is placed in an upright position. After oiling, the form is placed in a horizontal position if not already in such an orientation, and the reinforcing materials, such as a rebar cage, carbon fiber, etc., is placed into position. In addition, lifting devices are preferably positioned such that they are cast into the precast slab
[0022] Preferably, the surface of the concrete is then smoothed in the form using a device such as a screed or a straight edge. In addition, as the concrete goes into its initial set, the surface may optionally be troweled smooth, with burrs and high spots eliminated. In addition, it is also optional to slightly round what will be the bottom edges. Further optional steps include conducting quality assurance and/or quality control to check for items such as proper dimensioning of the forms prior to adding the concrete to the forms, as well checking proper finishing and flatness to the concrete surface prior to letting the concrete fully cure. After the concrete is allowed to cure, the form is turned over and all bolts and any accessories are removed from the forms as necessary. Hook cables or lifting means are then attached to the lifting devices, and the precast slab
[0023] In yet a separate aspect of the present invention, a method of installing the precast rail support
[0024] The present invention lends itself to easy repair of the rail
[0025] To provide clarity to the drawings, the following is a list of the components and associated numbering as found in the drawings:
# Component 10 Precast rail support 12 Precast slab 14 Rail 16 Shaped trough 18 Resilient boot 20 Lateral recess 22 Upper shoulder 24 Interior opening 26 Bottom portion 28 Side support portions 29 Lateral projection 30 Void spaces
[0026] While various embodiments of the present invention have been described in detail, it is apparent that modifications and adaptations of those embodiments will occur to those skilled in the art. However, it is to be expressly understood that such modifications and adaptations are within the spirit and scope of the present invention, as set forth in the following claims.