Direct Fixation Block Assembly

Abstract

The disclosed solution relates to a block assembly that is configured for direct fixation of railway track elements. The block assembly is configured to be operatively connected to a rail fastener via a plurality of cast-in threaded insert fasteners. The block assembly may be placed on a concrete slab. Further, the block assembly may be partially buried in poured concrete. The block assembly comprises a plurality of indentations that interface with the poured concrete in order to maintain the position of the block assembly. The block assembly comprises a rebar assembly that is contained within the block assembly such that the integrity of the block assembly is increased without introducing problems typically associated with rebar extensions. Further, rebar assembly is configured with an optimized number of bends and welding points in order to increase integrity and reduce manufacturing costs.

Claims

1. A block assembly (301), comprising: a plurality of indentations (308Z) comprising a plurality of edges (309Z), the plurality of indentations (308Z) comprising an indentation (308B), the indentation (308B) comprising a first edge (309BA) and a second edge (309BB), the first edge (309BA) and the second edge (309BB) belonging to the plurality of edges (309Z); a plurality of cast-in threaded insert fasteners (315Z), the plurality of cast-in threaded fasteners (315Z) being disposed partially within the block assembly (301); and a rebar assembly (401), the rebar assembly (401) being disposed entirely within the block assembly (301).

2. The block assembly (301) of claim 1, the block assembly (301) further comprising: a first dorsal surface (329) comprising a second dorsal surface (331) and a plurality of dorsal surfaces (330Z), the second dorsal surface (331) being straight at a first perimeter (341A) of the block assembly (301), the plurality of dorsal surfaces (330Z) being curved at the first perimeter (341A) of the block assembly (301).

3. The block assembly (301) of claim 2, the block assembly (301) further comprising: a first ventral surface (333) comprising a second ventral surface (335) and a plurality of ventral surfaces (334Z), the second ventral surface (335) intersecting the plurality of indentations (308Z) at a second perimeter (341B) of the block assembly (301), the plurality of ventral surfaces (334Z) being curved at the second perimeter (341B) of the block assembly (301).

4. The block assembly (301) of claim 3, wherein the first dorsal surface (329) is smaller than the first ventral surface (333).

5. The block assembly (301) of claim 3, wherein the first perimeter (341A) is shorter than the second perimeter (341B).

6. The block assembly (301) of claim 3, wherein the indentation (308B) intersects at the center of a straight segment of the second perimeter (341B).

7. The block assembly (301) of claim 1, wherein the indentation (308B) is defined by a first distance (310B), a first plurality of distances (312Z), a second distance (324B), a third distance (311B), a first plurality of angles (313Z), and a second plurality of angles (314Z).

8. The block assembly (301) of claim 1, wherein a cast-in threaded insert fastener (315BA) selected from the plurality of cast-in threaded insert fasteners (315Z) comprises a raised cylindrical portion (318BA), a plurality of holes (317Z), a recessed portion (321BA), a shaft (319BA), and a plurality of bell portions (320Z).

9. The block assembly (301) of claim 8, wherein the shaft (319BA) is partially disposed within the rebar assembly (401).

10. The block assembly (301) of claim 8, wherein the raised cylindrical portion (318BA) is configured to fit inside a hole (209BA) of a fastener base (205).

11. The block assembly (301) of claim 1, wherein the rebar assembly (401) comprises: a first rebar segment (405); a first plurality of rebar segments (406Z); a second plurality of rebar segments (407Z); a third plurality of rebar segments (409Z); a fourth plurality of rebar segments (410Z); and a fifth plurality of rebar segments (411Z).

12. The block assembly (301) of claim 1, wherein the block assembly (301) is configured to being operatively connected to a fastener assembly (201), the fastener assembly (201) being configured to operatively connect to a rail (102).

13. The block assembly (301) of claim 12, wherein the fastener assembly (201) comprises a fastener base (205), the block assembly (301) comprising a first dorsal surface (329) configured to support an entire ventral surface the fastener base (205).

14. A kit for deployment of a rail, the kit comprising: a block assembly (301), comprising: a plurality of indentations (308Z) comprising a plurality of edges (309Z), the plurality of indentations (308Z) comprising an indentation (308B), the indentation (308B) comprising a first edge (309BA) and a second edge (309BB), the first edge (309BA) and the second edge (309BB) belonging to the plurality of edges (309Z); a plurality of cast-in threaded insert fasteners (315Z), the plurality of cast-in threaded fasteners (315Z) being disposed partially within the block assembly (301); and a rebar assembly (401), the rebar assembly (401) being disposed entirely within the block assembly (301); and a fastener assembly (201), the fastener assembly (201) being configured to operatively connect the rail (102).

15. The kit of claim 14, wherein the indentation (308B) is defined by a first distance (310B), a first plurality of distances (312Z), a second distance (324B), a third distance (311B), a first plurality of angles (313Z), and a second plurality of angles (314Z).

16. The kit of claim 14, wherein a cast-in threaded insert fastener (315BA) selected from the plurality of cast-in threaded insert fasteners (315Z) comprises a raised cylindrical portion (318BA), a plurality of holes (317Z), a recessed portion (321BA), a shaft (319BA), and a plurality of bell portions (320Z).

17. The kit of claim 14, wherein the block assembly (301) further comprises: a first dorsal surface (329) comprising a second dorsal surface (331) and a plurality of dorsal surfaces (330Z), the second dorsal surface (331) being straight at a first perimeter (341A) of the block assembly (301), the plurality of dorsal surfaces (330Z) being curved at the first perimeter (341A) of the block assembly (301). a first ventral surface (333) comprising a second ventral surface (335) and a plurality of ventral surfaces (334Z), the second ventral surface (335) intersecting the plurality of indentations (308Z) at a second perimeter (341B) of the block assembly (301), the plurality of ventral surfaces (334Z) being curved at the second perimeter (341B) of the block assembly (301).

18. The kit of claim 17, wherein the fastener assembly (201) further comprises: a fastener base (205) configured to being disposed on the first dorsal surface (329), wherein a ventral surface of the fastener base (205) is entirely in contact with the first dorsal surface (329).

19. The kit of claim 17, wherein the first dorsal surface (329) is smaller than the first ventral surface (333) and the first perimeter (341A) is shorter than the second perimeter (341B).

20. A method for installing a block assembly (301) at a concrete slab, the method comprising: placing the block assembly (301) on a surface of the concrete slab, the block assembly (301) comprising: a plurality of indentations (308Z) comprising a plurality of edges (309Z), the plurality of indentations (308Z) comprising an indentation (308B), the indentation (308B) comprising a first edge (309BA) and a second edge (309BB), the first edge (309BA) and the second edge (309BB) belonging to the plurality of edges (309Z); a plurality of cast-in threaded insert fasteners (315Z), the plurality of cast-in threaded fasteners (315Z) being disposed partially within the block assembly (301); and a rebar assembly (401), the rebar assembly (401) being disposed entirely within the block assembly (301); and pouring, around the block assembly (301), a layer of concrete, the layer of concrete being in contact with the plurality of indentations (308Z), the plurality of cast-in threaded insert fasteners (315Z) being accessible above the poured layer of concrete.

Description

BRIEF DESCRIPTION OF DRAWINGS

[0014] The accompanying drawings, which are incorporated herein and constitute part of this specification, illustrate exemplary aspects of the claims, and together with the general description given above and the detailed description given below, serve to explain the features of the claims.

[0015] FIG. 1A is a perspective view of a fixation assembly, as shown from a top perspective.

[0016] FIG. 1B is a perspective view of a fixation assembly, as shown from a bottom perspective.

[0017] FIG. 1C is a planar view of a fixation assembly, as shown from a top perspective.

[0018] FIG. 1D is a planar view of a fixation assembly, as shown from a front perspective.

[0019] FIG. 1E is a planar view of a fixation assembly, as shown from a side perspective.

[0020] FIG. 1F is a planar view of a fixation assembly, as shown from a bottom perspective.

[0021] FIG. 2A is a perspective view of a block assembly, as shown from a top perspective.

[0022] FIG. 2B is a perspective view of a block assembly, as shown from a bottom perspective.

[0023] FIG. 2C is a planar view of a block assembly, as shown from a top perspective.

[0024] FIG. 2D is a planar view of a block assembly, as shown from a front perspective.

[0025] FIG. 2E is a planar view of a block assembly, as shown from a side perspective.

[0026] FIG. 2F is a planar view of a block assembly, as shown from a bottom perspective.

[0027] FIG. 2G is a perspective view of a hole, as shown from a top perspective.

[0028] FIG. 3A is a perspective view of a block assembly, as shown from a top perspective.

[0029] FIG. 3B is a perspective view of a block assembly, as shown from a bottom perspective.

[0030] FIG. 3C is a planar view of a block assembly, as shown from a top perspective.

[0031] FIG. 3D is a planar view of a block assembly, as shown from a front perspective.

[0032] FIG. 3E is a planar view of a block assembly, as shown from a side perspective.

[0033] FIG. 3F is a planar view of a block assembly, as shown from a bottom perspective.

[0034] FIG. 3G is a planar view of a hole, as shown from a side perspective.

[0035] FIG. 4A is a perspective view of a block assembly, as shown from a top perspective.

[0036] FIG. 4B is a perspective view of a block assembly, as shown from a top perspective.

[0037] FIG. 4C is a perspective view of a block assembly, as shown from a bottom perspective.

[0038] FIG. 4D is a planar view of a block assembly, as shown from a top perspective.

[0039] FIG. 4E is a planar view of a block assembly, as shown from a bottom perspective.

[0040] FIG. 5A is a perspective view of a block assembly, as shown from a top perspective.

[0041] FIG. 5B is a perspective view of a block assembly, as shown from a bottom perspective.

[0042] FIG. 5C is a planar view of a block assembly, as shown from a top perspective.

[0043] FIG. 5D is a planar view of a block assembly, as shown from a front perspective.

[0044] FIG. 5E is a planar view of a block assembly, as shown from a side perspective.

[0045] FIG. 5F is a planar view of a block assembly, as shown from a bottom perspective.

DETAILED DESCRIPTION

[0046] Various aspects will be described in detail with reference to the accompanying drawings. Wherever possible, the same reference numbers will be used throughout the drawings to refer to the same or like parts. References made to particular examples and implementations are for illustrative purposes, and are not intended to limit the scope of the claims.

[0047] As stated above, monoblock deployments for railway are suboptimal for deployments in which more configuration is required. Typically, monoblocks are custom-made for a deployment. However, this process adds to the cost of deployment and introduces unnecessary delays. Further, any adjustments to a deployment often entails a reworking of the monoblocks and other elements of the track. Therefore, direct fixation blocks may be used to address deficiencies in monoblock-related deployments.

[0048] Differing gauges may be accommodated by a direct fixation block that is spaced according to a desired gauge. For instance, a metro rail may have a narrower gauge than a heavy freight rail. Yet, a direct fixation block may be used for both configurations. Unlike monoblocks, the gauge may be adjusted in the field since each direct fixation block is independent. Another motivation for using direct fixation blocks is to address configurations requiring differing turning radii. For instance, a metro rail may have a tighter turning radius than the turning radius of a heavy freight rail.

[0049] One advantage of direct fixation blocks is the ability to adjust deployments in the field. As stated, custom gauges and turning radii may be required. To the extent those aspects change, the direct fixation blocks generally require no block-specific customization when compared to monoblock-related deployments. Further, monoblock-related deployments often require entirely new monoblocks that would need to be ordered then sent to the field for deployment.

[0050] Nevertheless, direct fixation blocks are not without challenges. When direct fixation blocks are placed on concrete slabs, the blocks are subject to many forces. These forces may damage, displace, and/or disrupt the block (and any attached hardware elements). If the block is so affected, there is a risk that the rail loses support which may lead to a derailment of rolling stock. Such events may cause property damage and even loss of life.

[0051] To secure and protect the block, one or more layers of concrete are poured around the block in order to secure the block to the concrete slab. The poured concrete generally reduces forces from moving and/or dislodging the block from the ground (i.e., the slab). Further, the poured concrete acts to protect the block from weather, mechanical damage, etc. However, existing direct fixation blocks have inadequate configurations to properly secure the block in place.

[0052] Rebar extensions also introduce a risk that the extended rebar may corrode. When the rebar corrodes, the internal rebar may, in turn, begin to corrode as the corrosion spreads throughout the metal.

[0053] In contrast and as stated, the disclosed solution comprises a rebar assembly that is completely contained within the block itself. By having the rebar completely within the block, there are no external elements of the rebar that can corrode. Therefore, exterior corrosion cannot enter the interior of the block by traveling along the rebar extensions.

[0054] External rebar extensions may become damaged and simply break. As stated, corrosion is one factor that damages and/or weakens rebar extensions. When the rebar extension breaks, the block loses integral connection to the poured concretethus leading to unstable block support.

[0055] In contrast, the disclosed solution comprises a rebar assembly that is completely contained within the block itself. As such, the rebar assembly cannot break and lose integral connection with the poured concrete. The block assembly is designed such that the poured concrete retains the block due to the unique characteristics of the disclosed solution (as disclosed below).

[0056] Additionally, rebar extensions are unwieldy to handle by installation personnel. The rebar extensions can be sharp, or at best, coarse and prone to causing injuries. Further, the rebar extensions must be handled with care to avoid any premature damage prior to the pouring of concrete. Even after a block with rebar extensions is placed, the pouring of concrete may lead to damage to the rebar extensions. At best, these factors slow down the installation process. At worse, these issues lead to risk of injuries to installation personnel.

[0057] As stated, the disclosed solution comprises a rebar assembly that is completely contained within the block itself. Since no rebar extends from the disclosed solution, personnel cannot be injured by the rebar. Additionally, personnel can easily handle the blocks without risking damage to the rebar extensions. Therefore, the disclosed solution protects personnel from unnecessary occupational hazards. Additionally, the deployment personnel need not be concerned with prematurely damaging the rebar extensions, since, as stated, the rebar of the disclosed solution is contained within the block completely.

[0058] Still further, rebar extensions introduce interference risks with other elements of the track. For instance, conduit for cables may be deployed in the track prior to pouring concrete. When rebar extensions are placed, the conduit will need to be adjusted such that the conduit and rebar do not interfere. Other trackside elements may include water pipe, heating elements, gas lines, sensors, etc. For metro deployments, many other types of infrastructure may share space with a tunnel used for the metro rail.

[0059] In contrast, the disclosed solution has a rebar assembly that is completely contained within the block itself. As such, the block has no rebar extensions that might interfere with other track elements such as conduit, other rebar, other support, sensors, etc. Even with last-minute additions to track infrastructure, the disclosed solution entirely avoids rebar-based interference with any additions to the track infrastructure. As such, design personnel are free to add elements to the track without concern of interfering with rebar extensions (since the disclosed solution lacks rebar extensions).

[0060] Rebar extensions are not the only means of securing the block in position to avoid forces. The shape of the block may be configured such that the poured concrete more securely holds the block in position. However, existing shapes of direct fixation blocks are suboptimal.

[0061] Existing direct fixation blocks are typically configured in a rectangular shape such that the surfaces of the block are perpendicular to the ground and/or rail fasteners. However, rectangular shapes may be prone to chipping at the corners. For instance, installation personnel may inadvertently strike the corners, thus breaking the corner away.

[0062] In contrast, the disclosed solution has a substantially round perimeter at the base. As such, installation personnel cannot easily damage the block prior to and/or during installation. An additional benefit is that installation personnel have a reduced risk of injury since the block assembly has fewer sharp corners.

[0063] Turning to the shape of existing block assemblies, existing direct fixation blocks that are rectangular are inadequate to resist vertical forces. When the block is pulled by the rail, the block may simply slide up and out of the poured concrete since the perimeter of the block is aligned with the force.

[0064] In contrast, the disclosed solution comprises a configuration wherein the dorsal surface is smaller than the ventral surface area. Stated differently, the disclosed solution has a shape that is more trapezoidal than existing, rectangular blocks. As such, the base (having a larger ventral surface area) is larger than the top (having a smaller dorsal area)thus, the disclosed solution is trapped within the poured concrete. Further, the non-coplanar surface of the disclosed solution firmly holds the block assembly within the poured concrete slab/substratethe block assembly strongly reacts to the poured concrete slab/substrate. As such, the disclosed solution is more difficult to dislodge by forcesespecially vertical/pulling forces.

[0065] Another issue with existing direct fixation blocks is the risk of rotational forces moving the block within the poured concrete. Many existing solutions have perimetric surfaces that are smooth. As such, when a force rotates the block, the surface of the block simply slides within the poured concrete and thus becomes dislodged. In the extreme, the block may damage the poured concrete slab/substrate with the rotational force.

[0066] In contrast, the disclosed solution has a plurality of indentations that is disposed on the perimetric surface of the block. The plurality of indentations causes the block to maintain the installed position because the poured concrete and plurality of indentions resist one another. The plurality of indentations is particularly well-suited to resist rotational forces. Therefore, the integrity of the poured concrete slab/substrate is maintained.

[0067] Turning to internal rebar assemblies, existing direct fixation blocks comprise rebar assemblies that are suboptimal. Rebar assemblies are intended to increase the integrity of the block. However, many rebar assemblies are configured with an excessive number of bends and/or welding points. As such, the rebar assembly may be prone to failure. Additionally, the rebar assembly is more difficult to manufacture, thus introducing additional costs.

[0068] In contrast, the disclosed solution comprises a rebar assembly that is configured to have an optimized number of bends and/or welding points, in one aspect. As such, the disclosed solution has a high level of integrity while not introducing excessive manufacturing costs.

[0069] FIG. 1A is a perspective view of a fixation assembly 101, as shown from a top perspective. A plurality of axes is shown viz. a first axis 103X, a second axis 103Y, and a third axis 103Z. The axis 103X is perpendicular to the direction of rolling stock traveling along a rail 102. The axis 103Y is parallel to the direction of travel of rolling stock moving along the rail 102. The axis 103Z is vertical, as formed by the normal vector of the axes 103X, 103Y.

[0070] The fixation assembly 101 comprises a fastener assembly 201 and a block assembly 301. The rail 102 is fastened via the fastener assembly 201 to the block assembly 301. The fastener assembly 201 comprises a fastener base 205, a plurality of clips 206Z, a plurality of bolts 203Z, and a plurality of lock washers 204Z. The fastener base 205 is generally configured to align and support the rail 102 such that the plurality of clips 206Z may fasten the rail 102. The plurality of clips 206Z comprises a first clip 206A and a second clip 206B, each of which can be placed in contact with the base of the rail 102.

[0071] The plurality of bolts 203Z comprises a first bolt 203AA, a second bolt 203AB, a third bolt 203BA, and a fourth bolt 203BB. The plurality of bolts 203Z is generally configured to operatively connect the fastener base 205 to the block assembly 301. The plurality of bolts 203Z is operatively connected to the plurality of lock washers 204Z, which prevent the plurality of bolts 203Z from loosening. The plurality of lock washers 204Z comprises a first lock washer 204AA, a second lock washer 204AB, a third lock washer 204BA, and a fourth lock washer 204BB.

[0072] One of skill in the art will appreciate that the bell shape of the block assembly 301 provides stability when the block assembly 301 is placed on a concrete slab. Specifically, more surface area (at the ventral surface of the block assembly 301) is in contact with the slab. Likewise, more mass is disposed closer to the surface, namely at a slab. One of skill in the art will note that the dorsal surface area of the block assembly 301 is smaller than the ventral surface area of the block assembly 301.

[0073] The block assembly 301 comprises a plurality of indentations 308Z. The plurality of indentations 308Z comprises a first indentation 308A and a second indentation 308B. The plurality of indentations 308Z is generally configured to interface with poured concrete to further retain the block assembly 301 in position. Further, the plurality of indentations 308Z provide a keyed interface into poured concrete to facilitate a mechanical lock with the surrounding material. The bell shape of the block assembly 301 provides resistance from the block assembly 301 being pulled out of the poured concrete. The plurality of indentations 308Z restrain the block assembly 301 from vertical forces and provide stability from rotating forces that cause the block assembly 301 to lift and/or rotate within the poured concrete (which is generally undesirable). Further, the plurality of indentations 308Z provide more surface area for the poured concrete to adhere to.

[0074] One of skill in the art will appreciate that the block assembly 301 and the fastener assembly 201 may be sold as a kit due to the relationship between the two assemblies 201, 301. For instance, a railway operator or installer may be desired accelerated deployment of the railway and require that the two assemblies 201, 301 be preinstalled with one another. As such, the operator/installer may simply remove the assemblies 201, 301 from the kit and place the combined assembly onto the concrete slab. One of skill in the art will appreciate that fine tuning may be required such as checking torque values, adjusting rail clips, etc. However, the combined kit offers the advantage of rapid deployment of the railway.

[0075] FIG. 1B is a perspective view of the fixation assembly 101, as shown from a bottom perspective. The plurality of indentations 308Z comprises a plurality of indentation surfaces 307Z and a plurality of edges 309Z.

[0076] The plurality of indentation surfaces 307Z comprises a first indentation surface 307A and a second indentation surface 307B. The plurality of edges 309Z comprises a first edge 309AA, a second edge 309AB, a third edge 309BA, and a fourth edge 309BB. The first indentation surface 307A is formed by the first edge 309AA and the second edge 309AB. The second indentation surface 307B is formed by the third edge 309BA and the fourth edge 309BB.

[0077] FIG. 1C is a planar view of the fixation assembly 101, as shown from a top perspective. The fastener base 205 comprises a plurality of holes 209Z. The plurality of holes 209Z comprises a first hole 209AA, a second hole 209AB, a third hole 209BA, and a fourth hole 209BB. The plurality of holes 209Z is generally configured to enable the plurality of bolts 203Z to operatively connect the fastener assembly 201 to the block assembly 301 via a plurality of cast-in threaded insert fasteners (not shown) within the block assembly 301.

[0078] The indentation 308B comprises a first distance 310B that measures between the dorsal points of the edges 309BA, 309BB. A plurality of distances 312Z comprises a first distance 312BA and a second distance 312BB. The distance 312BA spans the length of the edge 309BA. The distance 312BB spans the length of the edge 309BB.

[0079] A distance 311B measures between the ventral ends of the edges 309BA, 309BB. A distance 324B measures width of the edges 309BA, 309BB at the ventral face of the block assembly 301.

[0080] FIG. 1D is a planar view of the fixation assembly 101, as shown from a front perspective. The indentation 308B is defined by a first plurality of angles 313Z and a second plurality of angles 314Z.

[0081] The plurality of angles 313Z comprises a first angle 313BA and a second angle 313BB. The first angle 313BA is formed between the edge 309AB and the dorsal surface of the block assembly 301. The second angle 313BB is formed between the edge 309BB and the dorsal surface of the block assembly 301.

[0082] The plurality of angles 314Z comprises a first angle 314BA and a second angle 314BB. The first angle 314BA is formed between the edge 309AB and the ventral surface of the block assembly 301. The second angle 314BB is formed between the edge 309BB and the ventral surface of the block assembly 301. The plurality of angles 314Z comprises a first angle 314BA and a second angle 314BB.

[0083] FIG. 1E is a planar view of the fixation assembly 101, as shown from a side perspective. FIG. 1F is a planar view of the fixation assembly 101, as shown from a bottom perspective.

[0084] FIG. 2A is a perspective view of the block assembly 301, as shown from a top perspective. The block assembly 301 comprises a plurality of cast-in threaded insert fasteners 315Z. The plurality of cast-in threaded insert fasteners 315Z comprises a first cast-in threaded insert fastener 315AA, a second cast-in threaded insert fastener 315AB, a third cast-in threaded insert fastener 315BA, and a fourth cast-in threaded insert fastener 315BB. The plurality of cast-in threaded insert fasteners 315Z is generally configured to accommodate the plurality of bolts 203Z. Further, the plurality of cast-in threaded insert fasteners 315Z is configured to align with the plurality of cast-in threaded insert fasteners 209Z of the fastener base 205.

[0085] FIG. 2B is a perspective view of the block assembly 301, as shown from a bottom perspective. FIG. 2C is a planar view of the block assembly 301, as shown from a top perspective. The plurality of cast-in threaded insert fasteners 315Z comprises a plurality of raised cylindrical portions 318Z. The plurality of raised cylindrical portions 318Z comprises a first raised cylindrical portion 318AA, a second raised cylindrical portion 318AB, a third raised cylindrical portion 318BA, and a fourth raised cylindrical portion 318BB. In one aspect, the plurality of cast-in threaded insert fasteners 315Z may not have the plurality of raised cylindrical portions 318Z.

[0086] FIG. 2D is a planar view of the block assembly 301, as shown from a front perspective. FIG. 2E is a planar view of the block assembly 301, as shown from a side perspective. FIG. 2F is a planar view of the block assembly 301, as shown from a bottom perspective.

[0087] FIG. 2G is a perspective view of the cast-in threaded insert fastener 315BA, as shown from a top perspective. The cast-in threaded insert fastener 315BA comprises a plurality of holes 317Z. The plurality of holes 317Z comprises a first hole 317BAAA, a second hole 317BAAB, a third hole 317BABA, and a fourth hole 317BABB. The plurality of holes 317Z is generally configured to enable the removal of a nylon plastic insert from the cast-in threaded insert fastener 315BA. This removal process may be accomplished via specialized tool.

[0088] FIG. 3A is a perspective view of the block assembly 301, as shown from a top perspective. The block assembly 301 comprises a rebar assembly 401. The rebar assembly 401 is generally configured to provide strength to the block assembly 301 as well as maintain the integrity of the concrete of the block assembly 301. Further, the rebar assembly 401 is generally configured to work with the geometry of the block assembly 301 to counteract bending forces caused by passing rolling stock. The shown configuration is configured such that reinforcement welding is minimized without compromising the integrity of the rebar assembly 401 (and the block assembly 301).

[0089] The rebar assembly comprises a rebar segment 405, a first plurality of rebar segments 406Z, a second plurality of rebar segments 407Z, a third plurality of rebar segments 409Z, a fourth plurality of rebar segments 410Z, and a fifth plurality of rebar segments 411Z. The plurality of rebar segments 406Z comprises a first rebar segment 406A and a second rebar segment 406B. The plurality of rebar segments 407Z comprises a first rebar segment 407A and a second rebar segment 407B. The plurality of rebar segments 409Z comprises a first rebar segment 409A and a second rebar segment 409B. The plurality of rebar segments 410Z comprises a first rebar segment 410A and a second rebar segment 410B. The plurality of rebar segments 411Z comprises a first rebar segment 411A and a second rebar segment 411B.

[0090] FIG. 3B is a perspective view of the block assembly 301, as shown from a bottom perspective. FIG. 3C is a planar view of the block assembly 301, as shown from a top perspective. FIG. 3D is a planar view of the block assembly 301, as shown from a front perspective. FIG. 3E is a planar view of the block assembly 301, as shown from a side perspective. FIG. 3F is a planar view of the block assembly 301, as shown from a bottom perspective.

[0091] FIG. 3G is a planar view of the cast-in threaded insert fastener 315BA, as shown from a side perspective. The cast-in threaded insert fastener 315B comprises a recessed portion 321BA, a plurality of bell portions 320Z, and a shaft 319BA. The plurality of bell portions 320Z comprises a first bell portion 320BAA and a second bell portion 320BAB. The bell portion 320BAB is configured to retain the cast-in threaded insert fastener 315BA inside the block assembly 301, wherein the conical shape creates a shear cone that prevents axial pullout.

[0092] FIG. 4A is a perspective view of a block assembly 302, as shown from a top perspective. The instant view depicts an alternative embodiment (namely the block assembly 302) of the disclosed solution wherein the plurality of cast-in threaded insert fasteners 315Z comprises fewer cast-in threaded fasteners and is so identified as a plurality of cast-in threaded insert fasteners 316Z. As shown, the cast-in threaded fasteners 316AA, 316BB are disposed in the same position as that shown in FIG. 2A through FIG. 2F, abovewith respect to the cast-in threaded fasteners 315AA, 315BB. Further, the cast-in threaded fasteners 315AB, 315BA have been omitted in respect to FIG. 2A through FIG. 2F, above.

[0093] The block assembly 302 is configured to accommodate an alternative fastener assembly that comprises two holes. For example, the alternative fastener assembly would have a first hole and a second hole. With reference to the fastener assembly 201, the first hole would be similar to the hole 209AA, and the second hole would be similar to the hole 209BB. Further, the holes 209AB, 209BA would be omitted.

[0094] To be clear, the fastener assembly 201 may be used with the alternative embodiment shown in the instant view as the block assembly 302. However, the holes 209AB, 209BA would not have the lock washers 204AB, 204BA and the bolts 203AB, 203BA installed. Therefore, the alternative embodiment shown has the advantage of being more elegant while accommodating a rail fastener assembly with two or four holes.

[0095] FIG. 4B is a perspective view of the block assembly 302, as shown from a top perspective. The rebar assembly 401 is shown in more detail. FIG. 4C is a perspective view of the block assembly 302, as shown from a bottom perspective. Again, the rebar assembly 401 is shown in more detail. FIG. 4D is a planar view of the block assembly 302, as shown from a top perspective. Yet again, the rebar assembly 401 is shown in more detail. FIG. 4E is a planar view of the block assembly 302, as shown from a bottom perspective. Lastly, the rebar assembly 401 is shown in more detail.

[0096] FIG. 5A is a perspective view of the block assembly 301, as shown from a top perspective. As stated herein, the block assembly 301 comprises a dorsal surface 329 that is smaller than a ventral surface 333 (not shown in the instant view). The dorsal surface 329 comprises a plurality of dorsal surface 326Z and a dorsal surface 331. The plurality of dorsal surfaces 330Z comprises a first dorsal surface 330A and a second dorsal surface 330B. The plurality of dorsal surfaces 330Z are curved at a perimeter 341A of the block assembly 301. The dorsal surface 331 is straight at the perimeter of the block assembly 301. To emphasize that the dorsal surface 329 is smaller than the ventral surface 333, a plurality of distances 326Z is shown. The plurality of distances 326Z comprises a first distance 326A and a second distance 326B.

[0097] FIG. 5B is a perspective view of the block assembly 301, as shown from a bottom perspective. The instant view depicts the ventral surface 333 in fuller detail. As with FIG. 5A above, the dorsal surface 329 is smaller than the ventral surface 333. Again, the distance 326A emphasizes this relationship between the dorsal surface 329 and the ventral surface 333.

[0098] As shown, the ventral surface 333 comprises a plurality of ventral surfaces 334Z and a ventral surface 335. The plurality of ventral surfaces 334Z comprises a first ventral surface 334A and a second ventral surfaces 335B. The plurality of ventral surface 334Z are curved at a perimeter 341B of the block assembly 301.

[0099] In contrast to the dorsal surface 331, the ventral surface 335 is not continuously straight at the perimeter 341B of the block assembly 301. The plurality of indentations 308Z is shown as intersecting with the ventral surface 335, as shown by the plurality of distances 311Z, respectively. As stated herein, the plurality of indentations 308Z provides for stabler positioning within the poured concrete without the need for rebar extensions.

[0100] FIG. 5C is a planar view of the block assembly 301, as shown from a top perspective. The instant view depicts the plurality of indentation surfaces 307Z extending from the dorsal surface 331 to the ventral surface 335. One of skill in the art will appreciate that the dorsal surface 329 has no indentation such that the fastener base 205 (at a ventral surface) may be disposed on the block assembly 301 with adequate support. This advantage enables any standard rail fastener to be attached to the block assembly 301 without interference (or lack of support) caused by the plurality of indentations 308Z.

[0101] FIG. 5D is a planar view of the block assembly 301, as shown from a front perspective. FIG. 5E is a planar view of the block assembly 301, as shown from a side perspective.

[0102] FIG. 5F is a planar view of the block assembly 301, as shown from a bottom perspective. The instant view more clearly shows the plurality of indentations 308Z cutting into the perimeter 341B of the block assembly at the plurality of distances 311Z. One advantage of the block assembly 301 is that the plurality of indentations 308Z is tapered from the dorsal surface 329 to the ventral surface 333 in order to increase the surface area of the ventral surface 333. As such, the block assembly 301 has the capability of being adequately supported on the concrete slab prior to the pouring of concrete. Such support at the ventral surface 333 enables stability during installation as well as during operation.

[0103] The foregoing method descriptions and diagrams/figures are provided merely as illustrative examples and are not intended to require or imply that the operations of various aspects must be performed in the order presented. As will be appreciated by one of skill in the art, the order of operations in the aspects described herein may be performed in any order. Words such as thereafter, then, next, etc. are not intended to limit the order of the operations; such words are used to guide the reader through the description of the methods and systems described herein. Further, any reference to claim elements in the singular, for example, using the articles a, an, or the is not to be construed as limiting the element to the singular.

[0104] The preceding description of the disclosed aspects is provided to enable any person skilled in the art to make, implement, or use the claims. Various modifications to these aspects will be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other aspects without departing from the scope of the claims. Thus, the present disclosure is not intended to be limited to the aspects illustrated herein but is to be accorded the widest scope consistent with the claims disclosed herein.