Prestressed duct grouting device and using method thereof

Abstract

The invention particularly discloses a prestressed duct grouting device and a using method thereof, anchoring structures are arranged on the two sides of a prestressed duct respectively, and a grouting assembly is arranged at a connecting hole in one side of the prestressed duct and used for grouting the interior of the prestressed duct; the negative pressure assembly is arranged at a connecting hole in the other side of the prestressed duct and used for providing a negative pressure environment for the prestressed duct. The vibration assembly is arranged in the prestressed duct and is used for promoting dense filling of grout through vibration when the grouting assembly is used for grouting; and the traction assembly is arranged outside the prestressed duct, is connected to the vibration assembly through a traction wire and is used for pulling the vibration assembly out of the prestressed duct. The anchoring structures are arranged at the two ends of the prestressed duct for anchoring, the negative pressure assembly is used for keeping the interior of the prestressed duct in a negative pressure state, the grouting assembly is used for grouting to enable grout to flow to the other end along the prestressed duct, the vibration assembly is started to vibrate to eliminate bubbles in the grouting process, and the grouting quality is improved.

Description

TECHNICAL FIELD

[0001] The present application relates to the technical field of prestressed duct grouting equipment, in particular to a prestressed duct grouting device and a use method thereof. BACKGROUND

[0002] In the construction of prestressed concrete structures, the quality of duct grouting directly determines the durability and safety of the structure. The traditional grouting process has three technical bottlenecks: Bubble retention problem: when the slurry flows in the non-horizontal duct, the gas is accumulated at the wave crest due to the action of gravity, even if negative pressure auxiliary grouting is used (such as CN115674428A), negative pressure suction can only remove free gas, and the removal efficiency of micro-bubbles adhering to the prestressed tendon and the corrugated pipe wall is insufficient; Local void defects: conventional mechanical vibration needs to be applied outside the duct (such as CN110700451B), and the vibration energy is attenuated by the concrete, making it difficult to effectively transmit to the deep duct, resulting in local segregation of the slurry to form water capsules; Equipment interference risk: the existing in-duct vibration device (such as CN118979631A) mostly uses a rigid shell, and high-frequency vibration can easily damage the corrosion-resistant layer of the prestressed tendon, and lacks the ability to move synchronously with the slurry.

[0003] According to the above problems, the technical personnel have chosen the following methods to try to solve them: Single negative pressure method: although it can improve the filling degree of the slurry, it is sensitive to the viscosity of the slurry, and high-grade cement slurry is prone to early thickening in a negative pressure environment, which can exacerbate microscopic defects; Static vibration method: fixed position vibration leads to uneven energy distribution, and advanced vibration areas may cause slurry sedimentation, while lagging areas have already solidified bubbles.

[0004] In essence, the existing technology has not been able to solve the core contradiction in the "dynamic densification process of the slurry": the spatial and temporal coordination of the interface disturbance (vibration) required for bubble detachment and the directional driving force (negative pressure) required for gas extraction. SUMMARY

[0005] The purpose of the present application is to provide a prestressed duct grouting device and a use method thereof, which solves the above technical problems.

[0006] To solve the above technical problems, the technical solution adopted by the present application is as follows: a prestressed duct grouting device, comprising a prestressed duct and a prestressed tendon, comprising a grouting assembly, a negative pressure assembly, a vibration assembly, a traction assembly and two anchor structures; The anchor structures are respectively arranged on both sides of the prestressed duct, comprising an anchor pad, a clamping piece and an anchor sleeve plate; the anchor pad is arranged at the end of the prestressed duct, and the upper part is provided with a connecting hole; the prestressed tendon is clamped by the clamping piece after passing through the anchor pad, and the anchor sleeve plate is sleeved outside the anchor pad; The grouting assembly is arranged at the connecting hole on one side of the prestressed duct and is used for grouting in the prestressed duct; The negative pressure assembly is arranged at the connecting hole on the other side of the prestressed duct and is used for providing a negative pressure environment for the prestressed duct; The vibration assembly is arranged in the prestressed duct and is used for vibrating to promote the dense filling of the grout when the grouting assembly grouts; The traction assembly is arranged outside the prestressed duct and is connected to the vibration assembly through a traction line, and is used for driving the vibration assembly to move at a uniform speed after the flow rate of the grout is uniform.

[0007] As a further technical scheme of the above scheme, the grouting assembly comprises a grouting pipe and a grouting device; the grouting device is arranged on one side of the prestressed duct and is connected to the connecting hole of the prestressed duct through the grouting pipe; and a first pressure gauge is further arranged on the grouting pipe.

[0008] As a further technical scheme of the above scheme, a sealing connecting ring is further arranged at the connecting position of the grouting pipe and the connecting hole of the prestressed duct.

[0009] As a further technical scheme of the above scheme, the negative pressure assembly comprises a negative pressure device and a negative pressure pipe; the negative pressure device is arranged on one side of the prestressed duct and is connected to the connecting hole of the prestressed duct through the negative pressure pipe; and a second pressure gauge is arranged on the negative pressure pipe.

[0010] As a further technical scheme of the above scheme, a sealing connecting ring is further arranged at the connecting position of the negative pressure pipe and the connecting hole of the prestressed duct.

[0011] As a further technical scheme of the above scheme, the vibration assembly comprises a vibration main body, a flexible protective layer, an eccentric motor, a Bluetooth receiver, a control module and a battery pack; the vibration main body is in an elliptical shape; the eccentric motor is arranged in the vibration main body and an output shaft of the eccentric motor is arranged along a long axis of the vibration main body; the flexible protective layer covers the vibration main body for protection; the Bluetooth receiver is arranged in the vibration main body and is used for adjusting the vibration frequency; the control module is arranged in the vibration main body and is used for analyzing the instruction signal; and the battery pack is arranged in the vibration main body and is used for providing electric energy.

[0012] As a further technical scheme of the above scheme, a plurality of spiral ribs are arranged in the circumferential direction of the prestressed duct.

[0013] A use method of a prestressed duct grouting device, comprising the following steps: Step S1, a prestressed duct is pre-buried in a concrete structure; a prestressed tendon passes through the prestressed duct from one side and is pulled out from the other side; an anchoring structure is arranged on both sides of the prestressed duct; after the prestressed tendon passes through the anchor gasket and is clamped by the clamping piece, the anchor sleeve plate is sleeved; Step S2, the negative pressure assembly is started to exhaust air, so that the prestressed duct becomes a negative pressure environment; Step S3, start the grouting assembly to inject grout into the prestressed duct, and start the vibration assembly, and the vibration assembly vibrates to destroy the adhesion of bubbles; Step S4, during the vibration of the vibration assembly, the traction assembly pulls the vibration assembly to move along the prestressed duct, and the traction speed matches the grout flow rate; the traction assembly winds the traction line to drive the vibration assembly to move at a constant speed with the grout flow rate.

[0014] Compared with the prior art, the present application has the following advantages and beneficial effects: the present application sets anchor structures at both ends of the prestressed duct, uses a negative pressure assembly to maintain a negative pressure state in the prestressed duct, and uses a grouting assembly to grout so that the grout flows to the other end along the prestressed duct, and at the same time, a vibration assembly is started to vibrate to eliminate bubbles during grouting, thereby improving the grouting quality. BRIEF DESCRIPTION OF DRAWINGS

[0015] Figure 1 is a structural schematic diagram of the present application.

[0016] Figure 2 is a connection schematic diagram of the grouting assembly and the prestressed duct.

[0017] Figure 3 is a connection schematic diagram of the negative pressure assembly and the prestressed duct.

[0018] Figure 4 is a schematic diagram of the internal structure of the vibration assembly.

[0019] The explanations of the various reference numerals in the drawings are as follows: prestressed duct-1; prestressed tendon-2; grouting assembly-3; grouting pipe-31; grouting device-32; first pressure gauge-33; negative pressure assembly-4; negative pressure device-41; negative pressure pipe-42; second pressure gauge-43; vibration assembly-5; vibration main body-51; flexible protective layer-52; eccentric motor-53; Bluetooth receiver-54; control module-55; battery pack-56; traction assembly-6; traction line-61; anchor structure-7; anchor pad-71; clamping piece-72; anchor sleeve plate-73; connection hole-74; sealing connection ring-8; spiral rib-9. DETAILED DESCRIPTION

[0020] The technical solutions of the present invention will be clearly and completely described below with reference to the accompanying drawings in the embodiments of the present invention, so as to provide a better understanding of the concept of the present invention, the technical problem solved, the technical features constituting the technical solution, and the technical effects brought about.

[0021] like Figures 1-4 As shown, a prestressed duct grouting device includes a prestressed duct 1 and a prestressed tendon 2, and includes a grouting assembly 3, a negative pressure assembly 4, a vibration assembly 5, a traction assembly 6 and two anchoring structures 7. Anchoring structures 7 are respectively set on both sides of the prestressed duct 1, including anchor plate 71, wedge 72 and anchor sleeve plate 73; anchor plate 71 is set at the end of the prestressed duct 1, and a connecting hole 74 is provided at the top; the prestressed tendon 2 passes through the anchor plate 71 and is clamped by the wedge 72, and the anchor sleeve plate 73 is sleeved on the outside of the anchor plate 71. The grouting assembly 3 is located at the connection hole 74 on one side of the prestressed duct 1 and is used to grout the prestressed duct 1. The negative pressure component 4 is located at the connection hole 74 on the other side of the prestressed duct 1, and is used to provide a negative pressure environment for the prestressed duct 1. Vibration component 5 is installed inside the prestressed duct 1 and is used to vibrate during grouting by grouting component 3 to promote dense filling of grout. The traction component 6 is set outside the prestressed duct 1 and is connected to the vibration component 5 through the traction line 61, which is used to drive the vibration component 5 to move backward at a uniform speed with the slurry flow rate.

[0022] In use of the device, firstly, prestressed duct 1 is embedded in the concrete structure, prestressed duct 1 adopts corrugated pipe material, prestressed tendon 2 and traction line 61 are arranged inside prestressed duct 1, anchor structure 7 is arranged at both ends of prestressed duct 1, anchor structure 7 is the combination of anchor pad 71, clamping piece 72 and anchor sleeve plate 73, anchor pad 71 is arranged closely to the cross section of the concrete structure in use, the center of anchor pad 71 penetrates prestressed tendon 2, anchor sleeve plate 73 is sleeved outside anchor pad 71, the front end of anchor sleeve plate 73 is pressed tightly to the edge area of anchor pad 71, the rear end of anchor sleeve plate 73 accommodates wedge-shaped clamping piece 72, clamping piece 72 is locked prestressed tendon 2 through taper surface engagement structure, and clamping piece 72 cooperates with the taper hole in anchor sleeve plate 73 to form a sealed barrier; negative pressure assembly 4 is started to exhaust air in prestressed duct 1, the connecting hole 74 connected with negative pressure assembly 4 is used as an air outlet, so that a negative pressure environment is formed in prestressed duct 1, grouting assembly 3 is started to grout in prestressed duct 1, because prestressed duct 1 is in a negative pressure state, the connecting hole 74 connected with grouting assembly 3 is used as a grouting hole, and the slurry flows along prestressed duct 1 to the side where negative pressure assembly 4 is arranged, vibration assembly 5 is started to vibrate the slurry in the flowing process to destroy the adhesion of air bubbles; at the same time, traction assembly 6 pulls vibration assembly 5 to move, so that vibration assembly 5 moves at a uniform speed with the flow rate of the slurry, and when the slurry seeps out from the connecting hole 74 at one end of negative pressure assembly 4, negative pressure assembly 4 is closed and vibration assembly 5 is pulled out.

[0023] When prestressed duct 1 is arranged in a non-horizontal manner, one end at the lower position is arranged as one end of grouting assembly 3, and one end at the higher position is arranged as one end of negative pressure assembly 4, so that the grouting hole is arranged at the lower position, and the slurry is smoothly injected from the bottom of prestressed duct 1, thereby ensuring the stability of the grouting pressure.

[0024] As shown in Figure 2 , as a preferred embodiment, grouting assembly 3 includes grouting pipe 31 and grouting device 32, grouting device 32 is arranged at one side of prestressed duct 1 and connected to the connecting hole 74 of prestressed duct 1 through grouting pipe 31, and first pressure gauge 33 is further arranged on grouting pipe 31.

[0025] In this embodiment, grouting device 32 is a prior art, the slurry is grouted from grouting pipe 31 to prestressed duct 1 through grouting device 32, and the pressure of the slurry is monitored by using first pressure gauge 33, thereby facilitating adjustment.

[0026] As shown in Figure 2 , as a preferred embodiment, sealing connecting ring 8 is further arranged at the connection between grouting pipe 31 and the connecting hole 74 of prestressed duct 1. In this embodiment, in order to ensure the sealing state of prestressed duct 1 during grouting, sealing connecting ring 8 is additionally arranged at the connection between grouting pipe 31 and the connecting hole 74 of prestressed duct 1.

[0027] As shown in Figure 3As a preferred embodiment, the negative pressure assembly 4 includes a negative pressure device 41 and a negative pressure pipe 42, as shown. The negative pressure device 41 is arranged at one side of the prestressed duct 1 and connected to the connecting hole 74 of the prestressed duct 1 through the negative pressure pipe 42, and a second pressure gauge 43 is arranged on the negative pressure pipe 42.

[0028] In this embodiment, the negative pressure device 41 is a prior art, which is connected to the connecting hole 74 of the prestressed duct 1 through the negative pressure device 41 and the negative pressure pipe 42 to extract air from the prestressed duct 1 to form a negative pressure state, so that the slurry can flow along the direction of the prestressed duct 1, and the second pressure gauge 43 is also arranged on the negative pressure pipe 42 to facilitate monitoring the state and pressure.

[0029] As shown in Figure 3 As a preferred embodiment, a sealing connecting ring 8 is arranged at the connecting position of the negative pressure pipe 42 and the connecting hole 74 of the prestressed duct 1. In this embodiment, the end flange surface of the sealing connecting ring 8 is fastened to the connecting hole port by bolts, and the tapered threaded interface end is screwed with the negative pressure pipe 42 to increase the stability of the sealing state.

[0030] As shown in Figure 4 As a preferred embodiment, the vibration assembly 5 includes a vibration body 51, a flexible protective layer 52, an eccentric motor 53, a Bluetooth receiver 54, a control module 55, and a battery pack 56. The vibration body 51 is elliptical, the eccentric motor 53 is arranged in the vibration body 51, and the output shaft is arranged along the long axis of the vibration body 51. The flexible protective layer 52 covers the vibration body 51 for protection, the Bluetooth receiver 54 is arranged in the vibration body 51 for controlling the vibration frequency, the control module 55 is arranged in the vibration body 51 for analyzing the instruction signal, and the battery pack 56 is arranged in the vibration body 51 for providing electric energy.

[0031] In this embodiment, the eccentric motor 53 is installed at the long axis of the vibration body 51 at an acute angle, and the flexible protective layer 52 is integrally formed with a gradient energy consumption material. It efficiently transmits radial vibration to promote bubble detachment while significantly attenuating axial vibration to isolate the damage risk of the prestressed tendon 2, and its surface dense structure synchronously resists slurry erosion.

[0032] As shown in Figure 2 and Figure 3 As a preferred embodiment, a plurality of spiral tendons 9 are arranged circumferentially around the prestressed duct 1. In this embodiment, the spiral tendons 9 are wound around the outer periphery to constrain the lateral deformation of the concrete and optimize the stress distribution, and the spiral tendons 9 significantly improve the crack resistance of the anchorage zone.

[0033] A method for using a prestressed duct grouting device, comprising the following steps: Step S1, embed prestressed duct 1 in concrete structure, prestressed tendon 2 passes through prestressed duct 1 from one side, and passes out from the other side, anchor structure 7 is arranged on both sides of prestressed duct 1 and is anchored, prestressed tendon 2 is clamped after passing through anchor pad, using anchor sleeve plate 73 to cover; Step S2, start negative pressure assembly 4 to pump, and make prestressed duct 1 into negative pressure environment; Step S3, start grouting assembly 3 to inject slurry into prestressed duct 1, and simultaneously start vibration assembly 5, vibration assembly 5 vibrates to destroy bubble adhesion; Step S4, in the process of vibration of vibration assembly 5, traction assembly 6 pulls vibration assembly 5 to advance along prestressed duct 1, and the traction speed is matched with the slurry flow rate; traction assembly 6 rolls up traction line 61 to drive vibration assembly 5 to move at a uniform speed along with the slurry flow rate.

[0034] First, prestressed duct 1 and prestressed tendon 2 are arranged in the concrete structure, and are anchored through anchor structure 7; when the grouting operation is started, negative pressure assembly 4 first establishes a duct negative pressure environment, and grouting assembly 3 injects slurry from the connecting hole 74 below the anchor pad 71; two operations are simultaneously performed: vibration assembly 5 is started by wireless instruction, and the radial vibration wave generated by the eccentric motor 53 continuously destroys bubble adhesion; traction assembly 6 rolls up traction line 61 at a rate matching the slurry flow rate, so that vibration assembly 5 moves at a uniform speed along with the slurry flow rate. Negative pressure assembly 4 continuously pumps off the desorbed bubbles through the high-position connecting hole 74, and sealing connecting ring 8 maintains the integrity of the air path sealing. When the slurry overflows from the air outlet hole, negative pressure assembly 4 is closed and vibration assembly 5 is pulled out.

[0035] The application fundamentally solves the problems of bubble retention and voids in duct grouting through the time-space coordination mechanism of vibration and negative pressure: the directional vibration of the vibration assembly directly destroys the bubble interface adhesion, the negative pressure gradient is coupled to form a bubble directional pumping channel, and the slurry densification degree is significantly improved; the operation mode of the vibration assembly moving synchronously with the slurry flow ensures that the vibration energy is dynamically and uniformly released along the whole length of the duct, and local segregation defects are completely eliminated; the flexible protective layer effectively isolates the vibration energy transmission, fully releases the vibration efficiency while fully guaranteeing the integrity of the prestressed tendon corrosion protection system; the double-mechanism cooperation greatly shortens the grouting operation cycle, the negative pressure environment synchronously optimizes the slurry condensation process, and the secondary grouting link necessary in the traditional process is eliminated; the high reusability of the vibration assembly and the low energy consumption of the system significantly reduce the whole life construction cost. The above breakthrough results are due to three core synergies: ① functional synergy: vibration peeling bubble and negative pressure directional pumping form a relay type bubble removal mechanism; ② dynamic synergy: the vibration source moving rate is accurately matched with the slurry flow rate to realize no dead corner densification; ③ structural synergy: flexible protection and sealing traction channel synchronously solve the damage risk and leakage risk, and jointly build an efficient and reliable grouting quality guarantee system.

[0036] The "connection", "fixation" appearing in the description of the present application can be fixed connection, processing molding, welding, or mechanical connection, and the specific meaning of the above terms in the present application is understood according to the specific circumstances.

[0037] In the description of the present application, the terms "center", "upper", "lower", "horizontal", "inner", "outer" and the like indicate the orientation or positional relationship only for the convenience of describing the present application and simplifying the description, and do not indicate or imply that the device or element referred to must have a specific orientation, so it cannot be understood as a limitation on the present application.

[0038] Finally, it should be noted that: the above embodiments are only used to illustrate the technical solutions of the present application, and are not limited thereto; although the present application has been described in detail with reference to the foregoing embodiments, those skilled in the art should understand; it can still modify the technical solutions described in the foregoing embodiments, or make equivalent replacement for part or all of the technical features; and these modifications or replacements do not make the essence of the corresponding technical solutions deviate from the scope of the technical solutions of the embodiments of the present application.

Claims

1. A prestressed duct grouting device, comprising a prestressed duct (1) and prestressed tendons (2), characterized in that: It includes a grouting assembly (3), a negative pressure assembly (4), a vibration assembly (5), a traction assembly (6), and two anchoring structures (7). Anchoring structures (7) are respectively set on both sides of the prestressed duct (1), including anchor plate (71), wedge (72) and anchor sleeve plate (73); the anchor plate (71) is set at the end of the prestressed duct (1), and a connecting hole (74) is provided at the top; the prestressed tendon (2) passes through the anchor plate (71) and is clamped by the wedge (72), and the anchor sleeve plate (73) is sleeved on the outside of the anchor plate (71); The grouting assembly (3) is set at the connecting hole (74) on one side of the prestressed duct (1) for grouting inside the prestressed duct (1); The negative pressure component (4) is set at the connection hole (74) on the other side of the prestressed duct (1) to provide a negative pressure environment for the prestressed duct (1); The vibration component (5) is installed inside the prestressed duct (1) and is used to vibrate the grouting component (3) during grouting to promote the dense filling of the grout. The traction component (6) is set outside the prestressed duct (1) and connected to the vibration component (5) via the traction line (61) to drive the vibration component (5) to move backward at a constant speed with the slurry flow rate.

2. The prestressed duct grouting device as described in claim 1, characterized in that: The grouting assembly (3) includes a grouting pipe (31) and a grouting device (32); the grouting device (32) is set on one side of the prestressed duct (1) and is connected to the connection hole (74) of the prestressed duct (1) through the grouting pipe (31). A first pressure gauge (33) is also provided on the grouting pipe (31).

3. The prestressed duct grouting device as described in claim 2, characterized in that: A sealing ring (8) is also provided at the connection between the grouting pipe (31) and the connection hole (74) of the prestressed duct (1).

4. The prestressed duct grouting device as described in claim 1, characterized in that: The negative pressure assembly (4) includes a negative pressure device (41) and a negative pressure pipe (42); the negative pressure device (41) is located on one side of the prestressed channel (1) and is connected to the connection hole (74) of the prestressed channel (1) through the negative pressure pipe (42); a second pressure gauge (43) is provided on the negative pressure pipe (42).

5. A prestressed duct grouting device as described in claim 4, characterized in that: A sealing ring (8) is also provided at the connection between the negative pressure pipe (42) and the connection hole (74) of the prestressed duct (1).

6. The prestressed duct grouting device as described in claim 1, characterized in that: The vibration assembly (5) includes a vibration body (51), a flexible protective layer (52), an eccentric motor (53), a Bluetooth receiver (54), a control module (55), and a battery pack (56). The vibration body (51) is elliptical in shape, and the eccentric motor (53) is located inside the vibration body (51), with its output shaft arranged along the long axis of the vibration body (51). The flexible protective layer (52) covers the vibration body (51) for protection, and the Bluetooth receiver (54) is located inside the vibration body (51) for regulating the vibration frequency. The control module (55) is located inside the vibration body (51) for parsing command signals. The battery pack (56) is located inside the vibration body (51) for providing electrical energy.

7. The prestressed duct grouting device as described in claim 1, characterized in that: The prestressed duct (1) is provided with multiple spiral ribs (9) in the circumferential direction.

8. The method of using the prestressed duct grouting device as described in claim 1, characterized in that: Includes the following steps: Step S1: Pre-embed prestressed ducts (1) in the concrete structure. Prestressed tendons (2) pass through the prestressed ducts (1) on one side and exit from the other side. Anchoring structures (7) are set on both sides of the prestressed ducts (1) for anchoring. After the prestressed tendons (2) pass through the anchor pads and are clamped by the clamping plates (72), they are covered by the anchor sleeve plates (73). Step S2: Start the negative pressure component (4) to extract air and turn the prestressed duct (1) into a negative pressure environment; Step S3: Start the grouting assembly (3) to inject grout into the prestressed duct (1), and at the same time start the vibration assembly (5) to vibrate and break the air bubbles adhering to the duct. In step S4, during the vibration of the vibration component (5), the traction component (6) pulls the vibration component (5) forward along the prestressed duct (1), and the traction speed matches the slurry flow rate; the traction component (6) winds up the traction line (61) and drives the vibration component (5) to move backward at a uniform speed with the slurry flow rate.

Images