Construction method of high-rise steel pipe concrete column by pressure pouring without vibration

Abstract

This invention relates to the field of building engineering technology, specifically to a non-vibration pressure grouting construction method for tall steel-concrete composite columns. S1: Grouting holes are opened at the bottom of the steel-concrete column, and vent holes are opened at the top. S2: A grouting connection structure is installed, and a grouting connection pipe is welded at an acute angle to the column axis and extends into the column. A check valve is installed on the pipe, and reinforcing ribs are welded between the pipe and the column. S3: Pressure grouting is performed from the compacted concrete until it overflows from the vent holes. S4: After the concrete has settled naturally, secondary grouting is performed until it overflows from the vent holes again. S5: The check valve is closed to prevent backflow. S6: The grouting holes are sealed after the concrete reaches 70% of its design strength. This invention, through a grouting connection structure with a check valve and reinforcing ribs, combined with a secondary grouting process, systematically solves the problems of concrete backflow, insufficient compaction at the top of the column, and easy damage to the connection structure during the initial jacking process of ultra-high-rise buildings. It significantly improves construction quality, safety, and efficiency, and is applicable to the construction of tall steel-concrete composite columns in industrial and civil buildings.

Description

Technical Field

[0001] This invention relates to the field of building engineering technology, specifically to a method for non-vibration pressure grouting construction of tall steel-concrete composite columns. Background Technology

[0002] Concrete-filled steel tube structures are widely used in industrial and civil buildings, especially high-rise buildings and large-span structures, due to their advantages such as high load-bearing capacity, good plasticity and toughness, and convenient construction. The frame columns around industrial buildings such as dry-quenching coke ovens are usually made of tall concrete-filled steel tube columns, which are characterized by their large height, high single pouring height, and strict load-bearing requirements.

[0003] Currently, the main construction methods for concrete inside steel pipes include manual segmental pouring, high-level drop without vibration, and pumping jacking. Among these, the pumping jacking method utilizes the pressure of a concrete pump to force concrete into the pipe from the lower pouring port, using pump pressure to fill the steel pipe from bottom to top. This method eliminates the need for vibration, ensuring the continuity and density of the concrete, and is suitable for the construction of tall steel-concrete composite columns.

[0004] However, in practical engineering applications, the existing pumping jacking construction method still has the following technical problems: First, during the ultra-high single-stage jacking of tall steel-concrete composite columns, the concrete pumping pressure is high. After construction, the concrete is prone to backflow under gravity, leading to voids or incomplete compaction within the column, affecting the structure's load-bearing capacity and durability. Although existing technologies attempt to install check valves or other backflow prevention devices at the pouring inlet, the sealing and reliability of ordinary check valves under ultra-high pressure are difficult to guarantee. Furthermore, the rigidity of the valve structure at the connection with the steel column is insufficient, making the weld prone to tearing due to vibration during pumping, posing a safety hazard.

[0005] Secondly, after the concrete is jacked to the top of the column, due to the concrete's own shrinkage and settling, voids or incomplete compaction can easily occur in the column top area, affecting the joint stress distribution between the steel pipe and the concrete. Existing single-stage jacking techniques cannot guarantee the absolute compactness of the concrete at the column top.

[0006] Third, during the single-stage jacking process of ultra-high-rise buildings, the frictional resistance between the concrete and the inner wall of the steel pipe is relatively large, which can easily lead to excessively high pumping pressure or pumping difficulties, affecting construction efficiency and quality. Summary of the Invention

[0007] To overcome the shortcomings of the prior art, this invention provides a non-vibration pressure grouting construction method for tall steel-concrete composite columns. This method systematically solves the problems of backflow prevention, structural reinforcement, ensuring column top compaction, and lubrication and drag reduction during the ultra-high single-stage jacking process of tall steel-concrete composite columns.

[0008] To achieve the above objectives, the present invention employs the following technical solution: A method for vibration-free pressure grouting construction of tall steel-concrete composite columns includes the following steps: S1: Grouting holes and venting holes are opened. Grouting holes are opened on the lower side wall of the steel-concrete composite column, and venting holes are opened on its top. S2: Install the grouting connection structure, weld the grouting connection pipe at the grouting hole, the grouting connection pipe forms an acute angle with the axis of the steel-concrete composite column, and extends into the interior of the steel-concrete composite column; install a check valve on the grouting connection pipe; and weld reinforcing ribs between the grouting connection pipe and the steel-concrete composite column; S3: Pressure grouting, connect the delivery pipe of the concrete delivery pump to the grouting connection pipe, and use the concrete delivery pump to pressure grout self-compacting concrete into the steel pipe concrete column until the concrete overflows from the vent hole, then stop pumping. S4: Secondary grouting. After waiting for the concrete to settle naturally for a preset time, start the concrete delivery pump again for secondary pressure injection until the concrete overflows from the vent hole again. S5: Close the stop valve to seal the grouting connection pipe and prevent concrete backflow.

[0009] Furthermore, in S1, the angle between the axis of the grouting hole and the axis of the steel-concrete composite column is 45°.

[0010] Furthermore, in S2, the length of the grouting connection pipe extending into the steel-concrete composite column is 20~30mm.

[0011] Furthermore, in S2, the wall thickness of the grouting connection pipe is not less than the wall thickness of the conveying pipe of the concrete conveying pump, and the exposed length of the grouting connection pipe is 0.4~0.6m.

[0012] Furthermore, in S2, the flow stop valve is installed on the grouting connection pipe at a position 600-800mm away from the outer wall of the steel-concrete composite column.

[0013] Furthermore, in S3, the self-compacting concrete poured is C40 self-compacting concrete with a slump of 20-24 cm, an initial setting time of not less than 14 h, and a final setting time of not more than 18 h.

[0014] Furthermore, in S3, the pumping pressure of the concrete conveying pump is not less than 16 MPa, and the vertical conveying height is not less than 70 m.

[0015] Furthermore, while S3 is being performed, a lubrication step is also included: injecting lubricant into the pipe through the vent hole at the top of the steel-concrete column to reduce the frictional resistance during the concrete pressure grouting process.

[0016] Furthermore, in S4, the natural settling time is 5-6 minutes.

[0017] Furthermore, it also includes a sealing step: after the concrete inside the pipe reaches 70% of the design strength, the grouting hole and the vent hole are repaired and sealed by welding.

[0018] Compared with the prior art, the beneficial effects of the present invention are: 1. By setting up a grouting connection structure with a flow-stop valve and cooperating with a secondary grouting process, the problems of concrete backflow and column top compaction during the ultra-high single jacking process of tall steel-concrete composite columns are systematically solved, significantly improving the construction quality and structural bearing capacity of steel-concrete composite columns.

[0019] This invention incorporates a check valve on the grouting connection pipe, which closes immediately after pressure grouting. This effectively cuts off the concrete backflow channel, preventing the concrete in the column from flowing back under gravity after pumping stops, thus avoiding voids or looseness defects caused by concrete backflow. Furthermore, after the first pressure grouting and the concrete overflowing from the vent, the process doesn't end immediately. Instead, it waits for the concrete to settle naturally for a preset time (preferably 5-6 minutes) before performing a second grouting. Concrete undergoes a certain degree of settling shrinkage before initial setting, especially noticeable at the top of ultra-high columns. The second grouting refills any voids that may appear at the top after settling, ensuring tight contact between the concrete and the column top sealing plate. This fundamentally solves the technical problem of easy voiding and insufficient compaction at the column top in traditional single-lifting processes. The backflow prevention function of the check valve and the compaction function of the secondary grouting work together to ensure the continuity and compactness of the concrete in the entire steel pipe column (especially the critical middle and upper parts and top), thereby ensuring the synergistic performance of the steel pipe and concrete and significantly improving the structural bearing capacity and durability.

[0020] 2. The reinforcing ribs between the grouting connection pipe and the steel-concrete composite column significantly enhance the rigidity and vibration resistance of the grouting connection structure, thereby improving the safety and reliability of the construction process.

[0021] This invention involves welding reinforcing ribs between the grouting connection pipe and the steel-concrete composite column, forming a triangular support structure for the grouting connection pipe. During high-pressure, high-flow-rate concrete pumping, the grouting connection pipe is subjected to intense pulse vibrations. Without reinforcement, these vibrations can easily lead to fatigue cracking of the weld between the connection pipe and the steel column, causing safety accidents such as grout leakage, sudden pressure drops, or even pipe detachment. This invention, by incorporating reinforcing ribs, effectively transfers the dynamic load borne by the grouting connection pipe to the more rigid steel column body, dispersing stress concentration at the weld, significantly enhancing the overall rigidity and fatigue resistance of the connection structure, and ensuring the continuity and safety of construction under ultra-high pumping pressure.

[0022] 3. By optimizing the setting angle and extension length of the grouting connection pipe, the flow state of concrete in the steel pipe column was improved, the pumping resistance was reduced, and the uniform filling of concrete was facilitated.

[0023] This invention sets the grouting connection pipe and the axis of the steel-concrete composite column at an acute angle (preferably 45°), and extends the grouting connection pipe into the steel column by a certain length (preferably 20-30mm). The 45° angled setting ensures that the concrete entering the steel column has both horizontal and vertical velocity components, avoiding energy loss and turbulence caused by vertical impact on the pipe wall, allowing the concrete to spiral upwards more smoothly along the pipe wall. The 20-30mm extension of the connection pipe into the pipe forms a small "check valve," guiding the concrete flow during pumping and, after pumping stops and the check valve closes, assisting the check valve in preventing backflow. This structural optimization improves the concrete injection and filling effect from a fluid dynamics perspective, reduces pumping pressure requirements, and facilitates uniform and dense filling of concrete within tall columns.

[0024] 4. By simultaneously lubricating the pipe wall during the pressure injection process, the frictional resistance between the concrete and the inner wall of the steel pipe is effectively reduced, the pumping difficulty is reduced, the construction efficiency is improved, and the homogeneity of the concrete is protected.

[0025] This invention involves injecting a lubricant (preferably cement slurry with the same mix proportions as the concrete) into the steel-concrete composite column through a vent at the top of the column while simultaneously applying pressure. Within the tall steel-concrete composite column, the frictional resistance between the concrete and the pipe wall during the upward lifting process is a significant component of the pumping resistance. By pre-forming a lubricating layer on the concrete guide surface or pipe wall, the coefficient of friction can be significantly reduced, pumping pressure decreased, and concrete flow smoother, avoiding pumping difficulties or pipe blockage caused by excessive resistance. Simultaneously, the presence of the lubricating layer also reduces the risk of aggregate segregation and frictional damage at the pipe wall, contributing to maintaining the homogeneity of the concrete.

[0026] 5. By properly sealing the grouting holes and vent holes in the later stages, the integrity and durability of the steel-concrete composite column were ensured.

[0027] This invention involves welding and sealing the grouting holes and vent holes after the concrete has reached 70% of its design strength. This timing ensures that the concrete has sufficient strength to withstand the heat of welding during the sealing operation, while avoiding internal defects caused by concrete shrinkage if sealed too early. The circular plates cut during the drilling process are numbered and matched to their corresponding parts, ensuring consistency between the sealing material and the original steel pipe. This achieves complete closure of the steel pipe column, preventing the intrusion of external corrosive media and guaranteeing the long-term durability of the structure.

[0028] In summary, this invention optimizes the entire process of grouting connection structure, flow-stopping device, secondary grouting process, lubrication measures, and post-sealing, forming a complete method for vibration-free pressure grouting construction of tall steel-concrete composite columns. This method effectively solves the technical problems existing in the prior art, such as concrete backflow, incomplete column top compaction, easy damage to connection structure, and high pumping resistance, significantly improving construction quality, safety, and efficiency, and possessing outstanding substantive features and significant progress. Attached Figure Description

[0029] Figure 1 This is a process flow diagram of the present invention.

[0030] Figure 2 This is a schematic diagram of the grouting connection structure of the present invention.

[0031] Figure 3 This is a schematic diagram of the construction of the present invention.

[0032] Figure 4 This is a schematic diagram of the three-dimensional structure of the four steel pipe concrete frame columns surrounding the dry quenching coke oven constructed according to the present invention.

[0033] In the diagram: 1. Steel-concrete composite column; 2. Grouting connection pipe; 3. Check valve; 4. Reinforcing rib. Detailed Implementation

[0034] The embodiments of the present invention are described in detail below. To make the objectives, technical solutions, and advantages of the embodiments of the present invention clearer, the technical solutions of the embodiments of the present invention will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. The following description of at least one exemplary embodiment is merely illustrative and is in no way intended to limit the present invention or its application or use. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention. Example 1

[0035] like Figure 1-4 As shown in the figure, this embodiment provides a non-vibration pressure grouting construction method for tall steel-concrete composite columns, applied to the construction of four steel-concrete composite frame columns around a dry quenching coke oven. The steel columns have specifications of Φ600×10mm, are situated on a concrete platform at an elevation of 9.910m, have a column top elevation of 52.660m, and the concrete pouring height inside the steel pipe is 42.750m. The concrete pouring volume for a single steel column is 11.115m. 3 The concrete used is C40 self-compacting concrete.

[0036] like Figure 1-3 As shown, the construction method in this embodiment includes the following steps: S1: Set grouting holes and venting holes Grouting holes are opened on the lower sidewall of the steel-concrete composite column 1. In this embodiment, the grouting holes are located at an elevation of 9.910m. Figure 2 As shown, the axis of the grouting hole forms a 45° angle with the axis of the steel-concrete composite column 1. Simultaneously, vent holes are made on the top sealing plate of the steel-concrete composite column 1. In this embodiment, four Φ50 vent holes are provided, evenly distributed along the circumferential edge of the sealing plate. The circular plates cut during hole making are numbered and saved for later matching during hole sealing.

[0037] S2: Install grouting connection structure A grouting connection pipe 2 is welded at the grouting hole. In this embodiment, the grouting connection pipe 2 is a Φ120×10mm steel pipe, and its wall thickness is not less than the wall thickness of the conveying pipe of the subsequent concrete conveying pump. The grouting connection pipe 2 forms a 45° angle with the axis of the steel-concrete column 1, and one end of it extends into the interior of the steel-concrete column 1, with an insertion length of 25mm (controlled within the range of 20~30mm). The exposed length of the grouting connection pipe 2 is approximately 0.5m (controlled within the range of 0.4~0.6m), and its end is crimped to facilitate connection with the concrete conveying pipe.

[0038] A check valve 3 is installed on the grouting connection pipe 2. In this embodiment, the check valve 3 is a slide gate valve, consisting of two flanges and a pluggable steel plate. The check valve 3 is installed on the grouting connection pipe 2 at a position approximately 700mm from the outer wall of the steel-concrete column 1 (controlled within the range of 600~800mm). During installation, the check valve 3 is first set to the open state to ensure that the concrete delivery is not affected during subsequent pressure grouting.

[0039] To prevent the weld of the grouting connection pipe 2 from tearing due to vibration during construction, a reinforcing rib 4 is welded between the grouting connection pipe 2 and the steel-concrete composite column 1. In this embodiment, the reinforcing rib 4 is a triangular steel plate, welded to the bottom of the grouting connection pipe 2, and fixedly connected to the outer wall of the grouting connection pipe 2 and the outer wall of the steel-concrete composite column 1 to form a triangular support structure.

[0040] S3: Pressure Injection The delivery pipe of the concrete pump is connected to the end of the grouting connection pipe 2 using a special high-pressure clamp. This embodiment uses an HBT-6016 concrete pump with a pumping capacity of 60m³ / h. 3 The pumping capacity is 16 MPa / h, the maximum pumping pressure is 16 MPa, and the maximum vertical conveying height is 70 m, which meets the requirement of a 42.75 m grouting height for this project.

[0041] Start the concrete pump and pressurize and inject C40 self-compacting concrete into the steel-concrete composite column 1. In this embodiment, the technical parameters of the C40 self-compacting concrete are as follows: slump controlled at 22cm (within the range of 20~24cm), initial setting time not less than 14h, final setting time not more than 18h, water-cement ratio less than 0.45, and sand content greater than 40% and less than 50%.

[0042] During pressure grouting, concrete fills the steel pipe from bottom to top under pump pressure. When concrete overflows from the vent at the top of the steel-concrete column 1, it indicates that the steel pipe column is basically filled with concrete, and pumping is stopped at this point.

[0043] Simultaneously with pressure grouting, a lubrication step is performed: lubricant is injected into the concrete-filled steel pipe column 1 through the vent hole at the top of the pipe to reduce frictional resistance during the pressure grouting process. In this embodiment, the lubricant is cement slurry with the same mix proportion as the concrete being grouted, and it is continuously injected until the pressure grouting is completed.

[0044] S4: Secondary Grouting After pumping is stopped, allow the concrete to settle naturally. In this embodiment, the natural settling time is controlled to be 5-6 minutes. Concrete will undergo a certain degree of settling shrinkage before initial setting, especially in the 42.75m super high column, where the settling in the top area is more pronounced.

[0045] After natural settling, the concrete pump is restarted for secondary pressure injection until concrete overflows again from the vent at the top of the steel-concrete composite column 1. This secondary grouting fills any voids that may have appeared at the top after settling, ensuring a tight seal between the concrete and the column top slab.

[0046] S5: Closed check valve After the secondary grouting is completed, immediately close the stop valve 3. In this embodiment, insert the steel plate of the slide valve to seal the grouting connection pipe 2 and prevent concrete backflow.

[0047] S6: Blocking Procedures After the check valve 3 is closed, the concrete pump's delivery pipe is removed. Once the concrete inside the pipe reaches 70% of its design strength, the grouting holes and vent holes are repaired and sealed by welding. For the grouting holes, first cut off the remaining portion of the grouting connection pipe 2, remove excess concrete, then roughen the concrete surface, and finally use the circular plate saved in step S1 to perform the repair welding. The vent holes are also repaired and sealed by welding to achieve complete closure of the steel pipe column. Example 2

[0048] This embodiment is basically the same as Embodiment 1, except for the following adjustments to technical features: In step S1, the angle between the axis of the grouting hole and the axis of the steel-concrete composite column 1 is adjusted to 30°, which can also achieve the technical effect of improving the flow state of concrete.

[0049] In step S2, the length of the grouting connection pipe 2 extending into the steel-concrete composite column 1 is adjusted to 20mm; the check valve 3 is set at a position 600mm away from the outer wall of the steel-concrete composite column 1.

[0050] In step S3, the slump of the self-compacting concrete is controlled at 20cm.

[0051] In step S4, the natural settling time is adjusted to 5 minutes. Example 3

[0052] This embodiment is basically the same as Embodiment 1, except for the following adjustments to technical features: In step S1, the number of vent holes is set to 6, which are evenly arranged around the edge of the sealing plate.

[0053] In step S2, the length of the grouting connection pipe 2 extending into the steel-concrete composite column 1 is adjusted to 30mm; the check valve 3 is set at a position 800mm away from the outer wall of the steel-concrete composite column 1; and the exposed length of the grouting connection pipe 2 is adjusted to 0.6m.

[0054] In step S3, the slump of the self-compacting concrete is controlled at 24cm.

[0055] In step S4, the natural settling time is adjusted to 6 minutes. Example 4

[0056] This embodiment is basically the same as Embodiment 1, except that a lubrication step is not performed simultaneously during the pressure grouting process in step S3. Although the pumping resistance is relatively large, the pressure grouting of tall steel-concrete composite columns can still be completed by adjusting the pumping pressure and concrete mix ratio, making it suitable for working conditions with lower requirements for pumping equipment. Example 5

[0057] This embodiment is basically the same as Embodiment 1, except that in step S6, after the concrete inside the pipe reaches 80% of its design strength, the grouting hole and the vent hole are sealed by welding. Depending on the actual engineering situation, a suitable sealing time can be selected within the range of 70% to 90% of the concrete's design strength.

[0058] The above description is merely a preferred embodiment of the present invention and is not intended to limit the present invention. Those skilled in the art can make various improvements and modifications without departing from the spirit and principles of the present invention, and these improvements and modifications should also be considered within the scope of protection of the present invention.

Claims

1. A method for vibration-free pressure grouting construction of tall steel-concrete composite columns, characterized in that, Includes the following steps: S1: Grouting holes and venting holes are opened. Grouting holes are opened on the lower side wall of the steel pipe concrete column (1), and venting holes are opened on its top. S2: Install the grouting connection structure, weld the grouting connection pipe (2) at the grouting hole, the grouting connection pipe (2) forms an acute angle with the axis of the steel-concrete composite column (1), and extends into the interior of the steel-concrete composite column (1); install a check valve (3) on the grouting connection pipe (2); and weld a reinforcing rib (4) between the grouting connection pipe (2) and the steel-concrete composite column (1). S3: Pressure grouting, connect the delivery pipe of the concrete delivery pump to the grouting connection pipe (2), and pressure grout self-compacted concrete into the steel pipe concrete column (1) through the concrete delivery pump until the concrete overflows from the vent hole and the pumping is stopped. S4: Secondary grouting. After waiting for the concrete to settle naturally for a preset time, start the concrete delivery pump again for secondary pressure injection until the concrete overflows from the vent hole again. S5: Close the stop valve (3) to seal the grouting connection pipe (2) and prevent concrete backflow.

2. The method for vibration-free pressure grouting construction of tall steel-concrete composite columns according to claim 1, characterized in that, In S1, the angle between the axis of the grouting hole and the axis of the steel-concrete composite column (1) is 45°.

3. The method for vibration-free pressure grouting construction of tall steel-concrete composite columns according to claim 1, characterized in that, In S2, the length of the grouting connection pipe (2) extending into the steel pipe concrete column (1) is 20~30mm.

4. The method for vibration-free pressure grouting construction of tall steel-concrete composite columns according to claim 1, characterized in that, In S2, the wall thickness of the grouting connection pipe (2) is not less than the wall thickness of the conveying pipe of the concrete conveying pump, and the exposed length of the grouting connection pipe (2) is 0.4~0.6m.

5. The method for vibration-free pressure grouting construction of tall steel-concrete composite columns according to claim 1, characterized in that, In S2, the stop valve (3) is installed on the grouting connection pipe (2) at a position 600~800mm away from the outer wall of the steel pipe concrete column (1).

6. The method for vibration-free pressure grouting construction of tall steel-concrete composite columns according to claim 1, characterized in that, In S3, the self-compacting concrete poured is C40 self-compacting concrete with a slump of 20-24cm, an initial setting time of not less than 14h, and a final setting time of not more than 18h.

7. The method for vibration-free pressure grouting construction of tall steel-concrete composite columns according to claim 1, characterized in that, In S3, the pumping pressure of the concrete conveying pump is not less than 16 MPa, and the vertical conveying height is not less than 70 m.

8. The method for vibration-free pressure grouting construction of tall steel-concrete composite columns according to claim 1, characterized in that, While S3 is being performed, a lubrication step is also included: lubricant is injected into the pipe from the vent hole at the top of the steel-concrete column (1) to reduce the frictional resistance during the concrete pressure grouting process.

9. The method for vibration-free pressure grouting construction of tall steel-concrete composite columns according to claim 1, characterized in that, In S4, the natural settling time is 5-6 minutes.

10. The method for vibration-free pressure grouting construction of tall steel-concrete composite columns according to claim 1, characterized in that, It also includes a sealing step: after the concrete inside the pipe reaches 70% of the design strength, the grouting hole and the vent hole are repaired and sealed by welding.

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