Grout sleeve mounting device and method of fixing a grout sleeve

Abstract

This invention relates to a grouting sleeve installation device and a method for fixing the grouting sleeve. The grouting sleeve installation device includes a fixing rod, a rebar limiter, fixing bolts, washers, and an inflation device. The fixing rod is fixed to the side mold of a precast concrete component. The top of the fixing rod is equipped with a rebar limiter, and the tail of the fixing rod is equipped with a valve core. The fixing rod is made of rubber and is hollow inside, allowing for inflation and deflation through the valve core. The grouting sleeve installation device of this invention has a simple structure and is easy to operate. It produces precast components with high rebar positioning accuracy and effectively prevents rebar misalignment, significantly improving precast component production efficiency and error tolerance while saving labor.

Description

Technical Field

[0001] This invention relates to the field of building construction technology, and more specifically, to a grouting sleeve installation device and a method for fixing the grouting sleeve. Background Technology

[0002] With national support for green building, the development and planning of prefabricated buildings are being deployed across the country. Prefabricated buildings are characterized by being green and environmentally friendly, having high construction efficiency, and low cost. Prefabricated construction involves transferring on-site construction work to a factory, where prefabricated components are manufactured and transported to the construction site, where they are reliably assembled using methods similar to building blocks.

[0003] Precast concrete components are the most important part of prefabricated buildings. The production efficiency and quality of precast concrete components restrict the construction efficiency and structural safety of prefabricated buildings.

[0004] Grouting sleeves are crucial connectors in precast concrete components. Based on their manufacturing process, grouting sleeves can be categorized into casting and machining processes. To ensure the insertion depth and position of reinforcing bars in precast concrete components, grouting sleeves typically incorporate central limiting plates or rods, guides, or positioning protrusions. These devices increase the difficulty of grouting sleeve production and the smoothness of grouting operations, while also increasing production costs. During precast concrete component production, grouting sleeves are primarily fixed to the formwork using rubber columns or mechanical connections. With rubber columns, insufficient tightness can allow cement slurry to enter and clog the sleeve, while excessive tightness can deform the rubber columns, hindering accurate sleeve positioning. Mechanical fixing allows external forces to easily deform the fixing bolts, affecting their lifespan and the sleeve's positioning accuracy. In order to ensure the compactness of concrete during the production of precast concrete components, vibrators are used to vibrate the concrete in layers during the pouring process to ensure uniform compaction. During the vibration process, the vibrator inevitably comes into contact with the reinforcing bars, which can easily cause the reinforcing bars inserted into the sleeve to slip. This results in the reinforcing bars not being inserted to the required depth as specified in the standard, thus causing the precast concrete components to fail to meet the quality requirements, resulting in serious waste and contradicting the concept of energy conservation and environmental protection in prefabricated buildings. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to provide a grouting sleeve installation device and a grouting sleeve fixing method, which has a simple structure and is easy to operate. It can improve the accuracy of the position of the reinforcing bars in precast concrete components, improve the quality of precast concrete components, ensure the safety of engineering structures, and at the same time improve the production efficiency of precast concrete components.

[0006] The technical solution adopted by the present invention to solve its technical problem is: to construct a grouting sleeve installation device, including a fixing rod, a rebar limiter, a fixing bolt, a washer and an inflation device. The fixing rod is fixed on the side formwork of the precast concrete component. The top of the fixing rod is provided with a rebar limiter and the bottom of the fixing rod is provided with a valve core. The fixing rod is made of rubber and is hollow inside. Inflation and de-inflation are carried out through the valve core.

[0007] According to the above scheme, the end of the fixing rod is provided with an external thread along the axis, and the fixing rod is fixed to the side mold of the precast concrete component by fixing bolts and washers. The fixing bolts are provided with internal threads that match the external threads at the end of the fixing rod.

[0008] According to the above scheme, the fixing rod is provided with fixing protrusions, the number of fixing protrusions is 2 to 15, the width of the fixing protrusions is 5 to 50 mm, and the outer diameter of the fixing protrusions is 22 to 100 mm.

[0009] According to the above scheme, the surface of the rebar limiter is made of rubber, and a recessed limiting piece is provided in the middle of the rebar limiter. The limiting piece is made of a strong magnetic material.

[0010] According to the above scheme, the diameter of the limiting piece is 10~50mm, and the depth of the recess is 2~20mm.

[0011] According to the above scheme, the valve core is connected to the inflation device. The present invention also provides a method for fixing a full grouting sleeve using the aforementioned grouting sleeve installation device, comprising the following steps: S1. Pass the threaded end of the bottom of the fixing rod through the sleeve positioning hole of the precast concrete component side mold, fix the fixing rod to the precast concrete component side mold with fixing bolts and washers, and then use the inflation device to inflate through the bottom valve core, and control the pressure at 1.0~2.0 bar. S2. Install the grouting sleeve on the fixed rod, adjust the position of the grouting sleeve so that the shear groove of the grouting sleeve corresponds to the fixed protrusion on the fixed rod, and then use the air inflation device to inflate through the valve core at the bottom, controlling the pressure at 2.4~2.8 bar. S3. Insert the reinforcing bar into the precast end of the grouting sleeve and adjust the position of the reinforcing bar so that the bottom of the reinforcing bar is in full contact with the limiting plate of the reinforcing bar limiter.

[0012] The present invention also provides a method for fixing a semi-grouting sleeve using the aforementioned grouting sleeve installation device, comprising the following steps: S1. Pass the threaded end of the bottom of the fixing rod through the sleeve positioning hole of the precast concrete component side mold, fix the fixing rod to the precast concrete component side mold with fixing bolts and washers, and then use the inflation device to inflate through the bottom valve core, and control the pressure at 1.0~2.0 bar. S2. Install the grouting sleeve on the fixed rod, adjust the position of the grouting sleeve so that the shear groove of the grouting sleeve corresponds to the fixed protrusion on the fixed rod, and then use the air inflation device to inflate through the valve core at the bottom, controlling the pressure at 2.4~2.8 bar.

[0013] The grouting sleeve installation device and grouting sleeve fixing method of the present invention have the following beneficial effects: (1) The grouting sleeve installation device of the present invention has a simple structure and is easy to operate. It can ensure the insertion depth of the reinforcing bars in the precast concrete components and the complete alignment of the reinforcing bars. The strong magnetic limiting plate can effectively prevent the reinforcing bars from slipping and ensure the insertion depth of the reinforcing bars: Current technologies typically use locators, limiters, and precast end rubber plugs to position and control the insertion depth of reinforcing bars. However, these existing technologies struggle to ensure bar alignment and are prone to displacement during concrete vibration. Displacement leads to insufficient insertion depth, severely impacting structural safety. Furthermore, bar misalignment can block the grout outlet of the grouting sleeve, hindering grouting flow and causing incomplete grouting, affecting joint pull-out performance and posing a significant safety hazard. This invention addresses this issue by controlling the length of the fixing rod to ensure precise bar insertion depth. A strong magnetic limiter guarantees bar alignment and prevents displacement, thus ensuring structural safety.

[0014] (2) The grouting sleeve installation device of the present invention can effectively ensure the position and depth of the reinforcing bars, and can save the production components such as the full grouting sleeve limiting baffle or baffle, guide or positioning protrusion, thereby reducing production costs while improving production efficiency and the smoothness of the grouting construction process: Currently, to ensure the proper placement of reinforcing bars, casting processes use sleeves equipped with locators and limiters, while machining processes involve drilling a hole in the center of the sleeve to install a positioning screw. This invention patent can reduce the need for locators, limiters, and positioning screws, saving materials while improving safety.

[0015] (3) The grouting sleeve installation device of the present invention has a one-to-one correspondence between the size of the fixed protrusion and the size of the shear groove of the grouting sleeve, and the internal pressure of the fixed rod can be controlled by the air inflation device, thereby achieving precise control of the tightness of the grouting sleeve installation and ensuring the sealing and accuracy of the grouting sleeve installation.

[0016] Existing technologies for sleeve installation typically involve inserting a screw into the center of a rubber post or directly securing it with metal threads. Insufficient tightening allows cement slurry from the concrete to enter and clog the sleeve, while excessive tightening can deform the rubber post, preventing accurate sleeve positioning. Mechanical fixing is prone to bolt deformation due to external forces, affecting bolt lifespan and sleeve positioning. This invention's patented design features a highly matched internal structure between the fixing rod and the sleeve, ensuring both a tight seal and accurate installation. The air-filled fixing method minimizes material wear, allowing for long-term, frequent use.

[0017] (4) The grouting sleeve installation device of the present invention is highly practical and easy to operate. The installation and disassembly of the grouting sleeve are completed by simple inflation and deflation: Currently, grouting sleeves are fixed with screws, which require frequent screw removal during installation. Frequent screw removal is labor-intensive and causes significant material waste. Screw wear can lead to insecure installation and inaccurate positioning. This invention only requires tightening the screws once, and after fixing, installation and removal are carried out using an air inflation device, which saves labor and ensures installation accuracy. Attached Figure Description

[0018] The present invention will be further described below with reference to the accompanying drawings and embodiments. In the accompanying drawings: Figure 1 This is a schematic diagram of the grouting sleeve installation device of the present invention; Figure 2 This is a schematic diagram of the installation of the full grouting sleeve; Figure 3 This is a schematic diagram of the installation of a semi-grouting sleeve; Figure 4 This is a schematic diagram of X-ray solid inspection of rebar insertion depth; Figure 5 This is a schematic diagram of X-ray solid inspection of the insertion depth of a rebar (insufficient insertion depth); Reference numerals: 1-valve core, 2-fixing bolt, 3-washer, 4-fixing rod, 5-fixing protrusion, 6-limiting plate, 7-grouting sleeve, 8-rubber plug, 9-reinforcing bar, 10-precast concrete component side mold, 11-mold table, 12-threaded end, 13-inflation device. Detailed Implementation

[0019] To provide a clearer understanding of the technical features, objectives, and effects of the present invention, specific embodiments of the present invention will now be described in detail with reference to the accompanying drawings.

[0020] Unless otherwise defined, the technical or scientific terms used herein shall have the ordinary meaning as understood by one of ordinary skill in the art to which this invention pertains. The terms “first,” “second,” and similar terms used in this patent application specification and claims do not indicate any order, quantity, or importance, but are merely used to distinguish different components. Terms such as “comprising” or “including” mean that the element or object preceding the word encompasses the element or object listed following the word and its equivalents, without excluding other elements or objects. Terms such as “connected” or “linked” are not limited to physical or mechanical connections, but can include electrical connections, whether direct or indirect. Terms such as “upper,” “lower,” “left,” and “right” are used only to indicate relative positional relationships; these relative positional relationships may change accordingly when the absolute position of the described object changes.

[0021] Example 1 like Figure 1 As shown, the grouting sleeve installation device includes a fixing rod 4, a rebar limiter, a fixing bolt 2, a washer 3, and an inflation device 13. The fixing rod 4 has threads at its end, and can be fixed to the precast concrete component side mold 10 by the fixing bolt 2 and the washer 3. A rebar limiter is provided at the top of the fixing rod 4, and a valve core 1 is provided at the tail of the fixing rod 4. After the fixing rod 4 is installed, it can be inflated and deflated by the valve core 1. The fixing rod 4 is made of rubber, the threaded end of the fixing rod 4 is made of metal, and the inside of the fixing rod 4 is hollow. The end of the fixing rod 4 has external threads along the axis, and the fixing bolt 2 has internal threads that match the external threads at the end of the fixing rod 4. The fixing rod 4 has different sizes depending on the model (12~40) of the grouting sleeve 7, and the length of the fixing rod is 8d (d is the diameter of the rebar matching the grouting sleeve) + 20mm. The fixing rod 4 is equipped with fixing protrusions 5, the number of which ranges from 2 to 15 depending on the model of the grouting sleeve 7. The width of the fixing protrusions 5 ranges from 5 to 50 mm, and the outer diameter of the fixing protrusions 5 ranges from 22 to 100 mm. A rebar limiter is installed at the top of the fixing rod 4. The outer material of the rebar limiter is rubber, and a recessed limiting plate 6 is installed in the middle of the rebar limiter. The limiting plate 6 is made of a strong magnetic material, and the diameter of the limiting plate 6 ranges from 10 to 50 mm, and the depth of the recess ranges from 2 to 20 mm, depending on the model of the grouting sleeve 7. A valve core 1 is installed at the bottom of the fixing rod, through which air can be inflated. The inflation device 13 displays the inflation pressure, which is controlled between 2.4 and 2.8 bar.

[0022] like Figure 2As shown, the method for fixing the full grouting sleeve 7 includes the following steps: S1, passing the threaded end of the bottom of the fixing rod 4 through the sleeve positioning hole of the precast concrete component side mold 10, fixing the fixing rod 4 to the precast concrete component side mold 10 by fixing bolts 2 and washers 3, and then using the inflation device 13 to inflate through the bottom valve core 1, with the pressure controlled at 1.0~2.0 bar. S2, installing the grouting sleeve 7 on the fixing rod 4, adjusting the position of the grouting sleeve 7 so that the shear groove of the grouting sleeve 7 corresponds to the fixing protrusion 5 on the fixing rod 4, and then using the inflation device 13 to inflate through the bottom valve core 1, with the pressure controlled at 2.4~2.8 bar. S3, inserting the reinforcing bar 9 from the precast end of the grouting sleeve 7, adjusting the position of the reinforcing bar 9 so that the bottom of the reinforcing bar is in full contact with the reinforcing bar limiter limit plate 6.

[0023] like Figure 3 As shown, the method for fixing the semi-grouting sleeve 7 includes the following steps: S1, passing the threaded end of the bottom of the fixing rod 4 through the sleeve positioning hole of the precast concrete component side mold 10, fixing the fixing rod 4 to the precast concrete component side mold 10 by fixing bolts 2 and washers 3, and then using the inflation device 13 to inflate through the bottom valve core 1, with the pressure controlled at 1.0~2.0 bar. S2, installing the grouting sleeve 7 on the fixing rod 4, adjusting the position of the grouting sleeve 7 so that the shear groove of the grouting sleeve 7 corresponds to the fixing protrusion 5 on the fixing rod 4, and then using the inflation device 13 to inflate through the bottom valve core 1, with the pressure controlled at 2.4~2.8 bar.

[0024] Application Example 1 In a project in Shanghai, a prefabricated concrete shear wall structure system was adopted. The prefabricated components mainly used fully grouted sleeves, and one of the components used the fully grouted sleeve installation device of this invention.

[0025] The installation of the full grouting sleeve mainly includes the following steps: First, the threaded end 12 of the fixing rod 4 is passed through the sleeve positioning hole of the precast concrete component side mold 10, and fixed to the precast concrete component side mold 10 by the gasket 3 and fixing bolt 2. Then, air is injected into the fixing rod 4 through the air valve core 1 using the air inflation device 13 to control the pressure at 1.5 bar. The assembly end of the grouting sleeve 7 is installed on the fixing rod 4, and the position of the grouting sleeve 7 is adjusted so that the shear groove of the grouting sleeve 7 corresponds one-to-one with the position of the fixed position protrusion 5. Then, air is injected through the air valve core 1 to control the pressure at 2.5 bar. The reinforcing bar 9 is inserted from the precast end of the grouting sleeve so that the end of the reinforcing bar 9 is in full contact with the limiting piece 6. After the grouting sleeve 7 and the reinforcing bar 9 are installed, concrete is poured, and then vibrated thoroughly with a vibrator. After the concrete hardens, the air is completely released through the air valve core 1, and then the precast concrete component side mold 10 is removed. The installation of the reinforcing bar 9 is inspected by X-ray. The specific inspection results are shown in [link to X-ray inspection report]. Figure 4 .

[0026] Comparative Example 1 In a Shanghai project, a prefabricated concrete shear wall structure system was adopted. The prefabricated components primarily used fully grouted sleeves, with one component secured using a traditional rubber column. The installation of the fully grouted sleeves mainly included the following steps: First, the sleeve retainer was installed on the bottom side formwork and initially tightened. Then, the grouted sleeve assembly end was installed on the retainer and tightened. Reinforcing bars were inserted from the prefabricated end of the grouted sleeve, and their positions were manually adjusted. After the grouted sleeve and reinforcing bars were installed, concrete was poured, and then thoroughly vibrated with a vibrator. After the concrete hardened, the retainer screws were loosened, and then the side formwork was removed. The installation of the reinforcing bars was inspected using X-rays; specific inspection results can be found in [link to X-ray inspection report]. Figure 5 .

[0027] from Figure 4 and Figure 5 It is evident that in Example 1, the present invention patent is used, the reinforcing bars are fully aligned and the reinforcing bar depth is sufficiently long. In Comparative Example 1, the reinforcing bars are aligned, but the insertion depth does not meet the standard requirements (8 times the diameter of the reinforcing bar). The precast components produced do not meet the standards and need to be scrapped, resulting in a great waste.

[0028] The embodiments of the present invention have been described above with reference to the accompanying drawings. However, the present invention is not limited to the specific embodiments described above. The specific embodiments described above are merely illustrative and not restrictive. Those skilled in the art can make many other forms under the guidance of the present invention without departing from the spirit and scope of the claims. All of these forms are within the protection scope of the present invention.

Claims

1. A grouting sleeve installation device, characterized in that, It includes a fixing rod, a rebar limiter, fixing bolts, washers, and an inflation device. The grouting sleeve is installed on the fixing rod, which is fixed to the side formwork of the precast concrete component. The top of the fixing rod is equipped with a rebar limiter, and the bottom of the fixing rod is equipped with a valve core. The fixing rod is made of rubber and is hollow inside, and is inflated and deflated through the valve core.

2. The grouting sleeve installation device according to claim 1, characterized in that, The end of the fixing rod is provided with an external thread along the axis. The fixing rod is fixed to the side mold of the precast concrete component by fixing bolts and washers. The fixing bolts are provided with internal threads that match the external threads at the end of the fixing rod.

3. The grouting sleeve installation device according to claim 1, characterized in that, The fixing rod is provided with fixing protrusions, the number of fixing protrusions is 2 to 15, the width of the fixing protrusions is 5 to 50 mm, and the outer diameter of the fixing protrusions is 22 to 100 mm.

4. The grouting sleeve installation device according to claim 1, characterized in that, The surface of the rebar limiter is made of rubber, and a recessed limiting piece is provided in the middle of the rebar limiter. The limiting piece is made of a strong magnetic material.

5. The grouting sleeve installation device according to claim 4, characterized in that, The diameter of the limiting piece is 10~50mm, and the depth of the recess is 2~20mm.

6. The grouting sleeve installation device according to claim 1, characterized in that, The valve core is connected to the inflation device.

7. A method for fixing a full grouting sleeve using the grouting sleeve installation device according to any one of claims 1-6, characterized in that, Includes the following steps: S1. Pass the threaded end of the bottom of the fixing rod through the sleeve positioning hole of the precast concrete component side mold, fix the fixing rod to the precast concrete component side mold with fixing bolts and washers, and then use the inflation device to inflate through the bottom valve core, and control the pressure at 1.0~2.0 bar. S2. Install the grouting sleeve on the fixed rod, adjust the position of the grouting sleeve so that the shear groove of the grouting sleeve corresponds to the fixed protrusion on the fixed rod, and then use the air inflation device to inflate through the valve core at the bottom, controlling the pressure at 2.4~2.8 bar. S3. Insert the reinforcing bar into the precast end of the grouting sleeve and adjust the position of the reinforcing bar so that the bottom of the reinforcing bar is in full contact with the limiting plate of the reinforcing bar limiter.

8. A method for fixing a semi-grouting sleeve using the grouting sleeve installation device according to any one of claims 1-6, characterized in that, Includes the following steps: S1. Pass the threaded end of the bottom of the fixing rod through the sleeve positioning hole of the precast concrete component side mold, fix the fixing rod to the precast concrete component side mold with fixing bolts and washers, and then use the inflation device to inflate through the bottom valve core, and control the pressure at 1.0~2.0 bar. S2. Install the grouting sleeve on the fixed rod, adjust the position of the grouting sleeve so that the shear groove of the grouting sleeve corresponds to the fixed protrusion on the fixed rod, and then use the air inflation device to inflate through the valve core at the bottom, controlling the pressure at 2.4~2.8 bar.

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