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Purpose – During the construction process of the China Railway Track System (CRTS) I type filling layer, the nonwoven fabric bags have been used as grouting templates for cement asphalt (CA) emulsified mortar. The porous structure of nonwoven fabrics endowed the templates with breathability and water permeability. The standard requires that the volume expansion rate of CA mortar must be controlled within 1%–3%, which can generate expansion pressure to ensure that the cavities under track slabs are filled fully. However, the expansion pressure caused some of the water to seep out from the periphery of the filling bag, and it would affect the actual mix proportion of CA mortar. The differences in physical and mechanical properties between the CA mortar under track slabs and the CA mortar formed in the laboratory were studied in this paper. The relevant results could provide important methods for the research of filling layer materials for CRTS I type and other types of ballastless tracks in China. Design/methodology/approach – During the inspection of filling layer, the samples of CA mortar from different working conditions and raw materials were taken by uncovering the track slabs and drilling cores. The physical and mechanical properties of CA mortar under the filling layer of the slab were systematically analyzed by testing the electrical flux, compressive strength and density of mortar in different parts of the filling layer. Findings – In this paper, the electric flux, the physical properties and mechanical properties of different parts of CA mortar under the track slab were investigated. The results showed that the density, electric flux and compressive strength of CA mortar were affected by the composition of raw materials for dry powders and different parts of the filling layer. In addition, the electrical flux of CA mortar gradually decreased within 90 days’ age. The electrical flux of samples with the thickness of 54 mm was lower than 500 C. Therefore, the impermeability and durability of CA mortar could be improved by increasing the thickness of filling layer. Besides, the results showed that the compressive strength of CA mortar increased, while the density and electric flux decreased gradually, with the prolongation of hardening time. Originality/value – During 90 days' age, the electrical flux of the CA mortar gradually decreased with the increase of specimen thickness and the electrical flux of the specimens with the thickness of 54 mm was lower than 500 C. The impermeability and durability of the CA mortar could be improved by increasing the thickness of filling layer. The proposed method can provide reference for the further development and improvement of CRTS I and CRTS II type ballastless track in China.

Purpose – The construction of cement asphalt (CA) emulsified mortar can obviously disturb the slab status after the fine adjustment. To decrease or eliminate the influence of CA mortar grouting on track slab geometry status, the effects of grouting funnel, slab pressing method, mortar expansion ratio, seepage ratio and grouting area on China Railway Track System Type (CRTS I) track slab geometry status were discussed in this paper. Design/methodology/approach – Combined with engineering practice, this paper studied the expansion law of filling layer mortar, the liquid level height of the filling funnel, the pressure plate device and the amount of exudation water and systematically analyzed the influence of filling layer mortar construction on the state of track slab. Relevant precautions and countermeasures were put forward. Findings – The results showed that the track slab floating values of four corners were different with the CA mortar grouting and the track slab corner near CA mortar grouting hole had the maximum floating values. The anti-floating effect of “7” shaped slab pressing device was more efficient than fixed-joint angle iron, and the slab floating value could be further decreased by increasing the amount of “7” shaped slab pressing devices. After CA mortar grouting, the track slab floating pattern had a close correlation with the expansion rate and water seepage rate of CA mortar over time and the expansion and water seepage rate of the mortar were faster when the temperature was high. Furthermore, the use of strip CA mortar filling under the rail bearing platform on both sides could effectively reduce the float under the track slab, and it could also save mortar consumption and reduce costs. Originality/value – This study plays an important role in controlling the floating values, CA mortar dosage and the building cost of projects by grouting CA mortar at two flanks of filling space. The research results have guiding significance for the design and construction of China's CRTS I, CRTS II and CRTS III track slab.

Abstract Gap exists in the interface of cement asphalt emulsion mortar and CRTS I track slab universally, which is more severe at four corners than other parts of the track slab. In this work, the temperature and elevation of CRTS I slab track with and without rail were measured continuously to study the influence mechanism of rail on the gap. The results show that the alternating temperature gradient of track slab is the main reason that causes the gap, and laying rail can efficiently decrease the gap size in the slab track without rail. Compared with the slab track without rail, the maximum elevation occurred at the corner, the maximum gap width and the maximum gap depth of the slab track with rail laid were decreased by 0.45 mm (25.7%), 0.75 mm (46.6%) and 9.5 mm (59.4%), respectively; meanwhile, the disqualification ratio at corners was reduced to 5.9%, which is 50% less than that of the track without rail. When elevation mismatch occurs in adjacent track slabs, a gasket should be placed at rail-bearing bed below the track slab in order to avoid the lower slab being dragged up by the higher slab and the further occurrence of new gap.