A construction device for drilling and grouting piles without breaking the pile head

Abstract

This utility model discloses a non-destructive construction device for bored cast-in-place pile heads, comprising a steel casing, a grouting pump assembly that can move vertically and horizontally, and a sludge removal tank. The outer periphery of the steel casing is provided with a grout discharge port, which is connected to the input end of the grouting pump assembly via a first pipeline. The output end of the grouting pump assembly is connected to the sludge removal tank via a second pipeline. A filter screen is provided inside the sludge removal tank, dividing it into a sewage area and a clean water area. The second pipeline connects to the sewage area. This utility model device enables non-destructive construction of the over-grown portion of the bored cast-in-place pile head.

Description

Technical Field

[0001] This utility model belongs to the field of building construction technology, specifically relating to a device and construction method for eliminating the need to break the pile head of a bored cast-in-place pile. Background Technology

[0002] In the field of engineering construction, cast-in-place piles are a widely used form of pile foundation construction. Because sediment at the bottom of the pile hole and the mud in the hole, in contact with the concrete, can affect the concrete quality, according to relevant specifications, cast-in-place piles typically require an over-pouring height of at least 0.5m to ensure the quality of the pile concrete and reduce the risks of under-pouring and pile breakage. In actual construction, the conventional method involves excavating the site to the designed pile top plus the over-pouring height, then pouring concrete to the over-pouring elevation. This allows the lower-quality concrete, mixed with mud at the bottom, to be pushed up to the over-pouring portion of the pile head. After the pile foundation reaches a certain strength, the over-pouring portion of the pile head is exposed by excavation, and then the pile head is manually chiseled off or a specialized pile head breaking machine is used to cut and break off the excess portion and treat the pile top joint. However, this method is complex and cumbersome, inefficient, and can easily affect the construction progress. Furthermore, it has problems such as difficulty in ensuring construction quality and potential safety hazards to the substructure of the pile. In summary, existing construction technologies for cast-in-place piles and bored piles face significant challenges in ensuring the quality of the pile head concrete and improving construction efficiency, necessitating the development of new technologies to enhance these processes. Summary of the Invention

[0003] The purpose of this utility model is to address the problems existing in the prior art by providing a device and construction method for eliminating the need to break down the pile head of bored cast-in-place piles.

[0004] To achieve the above objectives, the technical solution adopted by this utility model is as follows: A non-destructive construction device for bored pile heads includes a steel casing, a grouting pump assembly that can move vertically and horizontally, and a sludge removal tank. The outer periphery of the steel casing is provided with a grout discharge port, which is connected to the input end of the grouting pump assembly through a first pipeline. The output end of the grouting pump assembly is connected to the sludge removal tank through a second pipeline. The sludge removal tank is equipped with a filter screen, which divides the sludge removal tank into a sewage area and a clean water area. The second pipeline is connected to the sewage area.

[0005] The steel casing grout outlet, grout pump assembly, and sludge removal pool work together to extract the excess concrete, avoiding the need for manual chiseling of pile heads or the use of specialized pile head breaking tools to cut and break the excess concrete pile heads. The grout pump assembly can move vertically and horizontally to adapt to the construction site, and the sludge removal pool can further purify the mud. This utility model reduces the disturbance to the pile structure during pile head breaking, reduces construction costs, eliminates safety hazards, and greatly saves labor costs while ensuring the quality of the pile foundation.

[0006] Preferably, the bottom of the grout outlet is higher than the design elevation of the cast-in-place pile, and a filter screen and a valve are provided at the grout outlet.

[0007] The filter screen can filter out the excess cement slurry above the slurry outlet and extract it. The excess slurry above the design elevation but below the slurry outlet is not removed and serves as a reserved protective layer for the bored pile. This prevents rainwater, dust, and other debris from entering the pile body during the hardening process of the pile foundation concrete, ensuring the quality of the pile foundation concrete. Since the excess slurry above the slurry outlet has not hardened sufficiently due to the extraction of slurry, it can be easily excavated manually using tools after the pile concrete reaches the design strength. Then, the main reinforcement above the excess slurry outlet is removed, and the reserved protective layer above the design elevation but below the slurry outlet is finished. Because the protective layer is relatively thin, it can be easily finished manually, completing the pile foundation construction.

[0008] Preferably, the slurry pump assembly includes a slurry pumping box, a base plate, a lifting rod assembly, and universal locking wheels. The slurry pumping box is connected to the first pipeline and the second pipeline and is disposed on the base plate. The lifting rod assembly is disposed at the four corners of the base plate to control the up and down movement of the base plate. The universal locking wheels are disposed below the base plate. A push rod is also installed on the base plate.

[0009] The lifting rod assembly and universal locking wheels enable the slurry pump assembly to move up and down and horizontally. In addition, a push rod is installed on the base plate, which can be manually pushed to move the slurry pump assembly.

[0010] Preferably, the slurry tank is equipped with a slurry pump and a battery mounted on the base plate, the slurry pump is connected to the battery, and the first pipeline and the second pipeline are connected to the slurry pump.

[0011] The slurry pump is installed inside the slurry tank and is also connected to a battery, so that the slurry pump can be used either by plugging in electricity or by directly using the battery connected to the slurry tank. At the same time, the outer shell of the slurry tank can provide good protection for the slurry pump and the battery.

[0012] Preferably, the lifting rod assembly includes a threaded rod with external threads, the threaded rod passing through the base plate, the threaded rod being threadedly connected to a slider with internal threads at the through position, the outer side of the slider being fixed to the base plate, and the bottom of the threaded rod being rotatably connected to a support plate under the base plate.

[0013] The lifting rod assembly moves along a threaded rod via a slider, driving the base plate to achieve the lifting stroke. When the slurry pump assembly needs to move horizontally, the base plate begins to descend, the universal locking wheels connected to the base plate begin to touch the ground, the support plate begins to lift off the ground, and the push rod is pushed to achieve the horizontal movement of the slurry pump assembly. Conversely, when the slurry pump assembly does not need to move horizontally, the base plate begins to rise, the universal locking wheels lift off the ground and retract, and the support plate touches the ground.

[0014] Preferably, the upper side of the lifting rod assembly is provided with a gear drive box, the gear drive box includes a housing, a motor is provided inside the housing, the output end of the motor is connected to a rotating rod, one end of the rotating rod extends out of the housing, the portion of the rotating rod located inside the housing is provided with a first bevel gear, the first bevel gear is meshed with a second bevel gear, and the second bevel gear is connected to the threaded rod.

[0015] The base plate can be moved up and down by manually adjusting the rotating rod and controlling the gear drive box. Alternatively, it can be moved up and down by a motor. The height of the base plate can be adjusted according to the uneven and complex terrain of the construction site. The appropriate method should be selected based on the working conditions.

[0016] Preferably, the clean water zone is located above the wastewater zone, with an inlet connected to the second pipeline on one side of the wastewater zone, a hydraulic shear frame and a mud pusher connected to the hydraulic shear frame on the other side of the wastewater zone, and a drain outlet on one side of the clean water zone.

[0017] The hydraulic shear frame pushes the mud pusher forward, pushing the sludge in the sewage area out from one side. The filter screen can isolate the bottom sludge in the sewage area, and the filtered water can be extracted through the drain of the clean water area for reuse.

[0018] Preferably, a liftable gate is provided on one side of the sewage area, the gate is provided with the water inlet, and the bottom of the gate is provided with a scraper with an inclined slope.

[0019] When dredging the sewage area of ​​the sludge removal tank, the hydraulic telescopic rod pulls the gate upwards into the gate slot. At this time, the hydraulic shear frame on the other side of the sludge removal tank pushes the pusher plate forward, pushing the sludge in the sewage area out from the other side. After the sludge in the sewage area is completely removed, the pusher plate is not retracted immediately. It is retracted only after the scraper at the bottom of the gate has scraped off all the sludge from the surface of the pusher plate. This prevents the pusher plate from being corroded by sludge for a long time and extends its service life. In addition, the scraper at the bottom of the gate is set with an inclined slope, which can also slow down the water flow and prevent the bottom sludge from floating up due to water flow impact.

[0020] The construction method for pile head breaking using the aforementioned pile head-breaking-free device mainly includes the following steps: (1) Before the pile foundation construction, a grout discharge port is set on the outer periphery of the steel casing, with a built-in filter screen and valve. The valve can be connected to the grout pump assembly through the first pipeline.

[0021] (2) After the pile foundation is positioned, the site is excavated to a depth of at least 50 mm above the design elevation. The steel casing is then buried to ensure that the bottom of the grout outlet is at least 50 mm above the design elevation. Once the preparation is complete, a drilling rig is used to drill holes and the steel cage is lowered.

[0022] (3) After the hole is formed, concrete is poured up to the top of the steel casing. After the pouring is completed, the grout outlet of the steel casing is connected to the grout pump assembly through the first pipeline, and the grout pump assembly is connected to the cleaning tank assembly.

[0023] (4) Open the valve and use the grouting pump to extract the sediment and mud from the pile bottom of the over-filled part above the grout outlet and discharge it into the sludge removal pool.

[0024] (5) After the concrete of the pile body reaches the design strength, the main reinforcement above the over-poured part of the concrete above the grout outlet is removed, and the pile head at the design elevation is finished to complete the pile foundation construction.

[0025] Compared with the prior art, the beneficial effects of this utility model are: I. This utility model features a grout discharge port with a steel casing, a grout pump assembly, and a sludge removal pool to extract the over-filled concrete portion. This avoids the need for manual chiseling of pile heads or the use of specialized pile head breaking tools to cut and break the over-filled pile heads, solving problems such as low construction efficiency, difficulty in ensuring construction quality, and potential safety hazards affecting the lower structure of the pile. It also reduces disturbance to the pile structure during pile head breaking, lowers construction costs while ensuring pile foundation quality, eliminates safety hazards, and greatly saves labor costs.

[0026] 2. A protective thin layer of at least 50mm should be placed below the grout outlet and above the design elevation to prevent rainwater, dust, and other debris from entering the pile body, thus ensuring the quality of the pile body. After the pile body hardens, the protective thin layer can facilitate subsequent manual finishing.

[0027] 3. The lifting rod assembly adjusts the height of the base plate by moving the slider on the threaded rod, thereby controlling the universal locking wheel connected to the lower side of the base plate to touch the ground and lift off the ground. The universal locking wheel with spring component facilitates the movement of the slurry pump assembly in uneven construction site conditions.

[0028] Fourth, the slurry pump can quickly draw the excess sediment and slurry into the sludge removal tank for purification. The design of the sludge removal tank allows for the recycling and reuse of the collected sediment and slurry, which meets the requirements of green energy conservation. Attached Figure Description

[0029] Figure 1 This is a schematic diagram of the overall structure of this utility model; Figure 2 This is a schematic diagram of the steel casing of this utility model; Figure 3 This is a schematic diagram of the slurry pump assembly of this utility model; Figure 4 This is a schematic diagram of the dredging pool in this utility model; Figure 5 This is a side view of the dredging pool in this utility model; Figure 6 This is a schematic diagram of the lifting component in the slurry pump assembly of this utility model; In the diagram: 1. Steel casing; 2. Slurry pump assembly; 3. Dredging tank; 4. Valve; 5. First pipeline; 6. Second pipeline; 31. Base plate; 32. Hand push rod; 33. Lifting support rod; 34. Support plate; 35. Universal locking wheel; 36. Rotating rod; 37. Gear drive box; 38. Slurry tank; 41. Inlet; 42. Outlet; 43. Filter screen; 44. Gate; 45. Scraper; 51. Hydraulic telescopic rod; 52. Mud pusher; 53. Gear; 54. Hydraulic scissor frame; 55. Base; 56. Telescopic rod; 61. First bevel gear; 62. Second bevel gear; 63. Motor; 65. Threaded rod; 66. Sliding block. Detailed Implementation

[0030] The technical solution of this utility model will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only a part of the embodiments of this utility model, and not all of them. Based on the embodiments of this utility model, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this utility model.

[0031] The specific embodiments of this utility model adopt the following technical solutions, which will be further described below with reference to the accompanying drawings.

[0032] A non-destructive construction device for bored pile heads includes a steel casing 1, a grouting pump assembly 2 that can move vertically and horizontally, and a sludge removal tank 3. The outer periphery of the steel casing 1 is provided with a grout discharge port, which is connected to the input end of the grouting pump assembly 2 through a first pipeline 5. The output end of the grouting pump assembly 2 is connected to the sludge removal tank 3 through a second pipeline 6. The sludge removal tank 3 is provided with a filter screen 43, which divides the sludge removal tank 3 into a sewage area and a clean water area. The second pipeline 6 is connected to the sewage area.

[0033] The steel casing grout outlet, grout pump assembly, and sludge removal pool work together to extract the excess concrete, avoiding the need for manual chiseling of pile heads or the use of specialized pile head breaking tools to cut and break the excess concrete pile heads. The grout pump assembly can move vertically and horizontally to adapt to the construction site, and the sludge removal pool can further purify the mud. This utility model reduces the disturbance to the pile structure during pile head breaking, reduces construction costs, eliminates safety hazards, and greatly saves labor costs while ensuring the quality of the pile foundation.

[0034] Preferably, the bottom of the grout outlet is at least 50mm higher than the design elevation of the cast-in-place pile, and a filter screen and valve 4 are provided at the grout outlet.

[0035] The filter screen can filter out the excess cement slurry above the slurry outlet and extract it. The excess slurry above the design elevation but below the slurry outlet is not removed and serves as a reserved protective layer for the bored pile. This prevents rainwater, dust, and other debris from entering the pile body during the hardening process of the pile foundation concrete, ensuring the quality of the pile foundation concrete. Since the excess slurry above the slurry outlet has not hardened sufficiently due to the extraction of slurry, it can be easily excavated manually using tools after the pile concrete reaches the design strength. Then, the main reinforcement above the excess slurry outlet is removed, and the reserved protective layer above the design elevation but below the slurry outlet is finished. Because the protective layer is relatively thin, it can be easily finished manually, completing the pile foundation construction.

[0036] Preferably, the slurry pump assembly 2 includes a slurry pumping box 38, a base plate 31, a lifting rod assembly, and a universal locking wheel 35. The slurry pumping box 38 is connected to the first pipeline 5 and the second pipeline 6 and is disposed on the base plate 31. The lifting rod assembly is disposed at the four corners of the base plate 31 to control the up and down movement of the base plate 31. The universal locking wheel 35 is disposed below the base plate 31. A push rod 32 is also installed on the base plate 31.

[0037] The lifting rod assembly and the universal locking wheel 35 enable the grout pump assembly 2 to move up and down and horizontally. In addition, a push rod 32 is installed on the base plate 31, which can be manually pushed to move the grout pump assembly 2. The universal locking wheel 35 is equipped with a sliding groove, a support sliding rod, and a shock-absorbing spring. In addition to having the function of stopping at any time, it also allows the grout pump assembly 2 to adapt to the uneven terrain of the construction site and extend its service life.

[0038] Preferably, the slurry pumping tank 38 is equipped with a slurry pump and a storage battery installed on the base plate 31. The slurry pump is connected to the storage battery, and the first pipeline 5 and the second pipeline 6 are connected to the slurry pump.

[0039] The slurry pump is installed inside the slurry tank 38 and is also connected to a battery, so that the slurry pump can be used either by plugging in electricity or by directly using the battery connected to the slurry tank. At the same time, the outer shell of the slurry tank can provide good protection for the slurry pump and the battery.

[0040] Preferably, the lifting rod assembly includes a threaded rod 65 with external threads, the threaded rod 65 passing through the base plate 31, the threaded rod 65 being threadedly connected to a slider 66 with internal threads at the through position, the outer side of the slider 66 being fixed to the base plate 31, and the bottom of the threaded rod 65 being rotatably connected to a support plate 34 under the base plate 31.

[0041] The lifting rod assembly moves along the threaded rod 65 via the slider 66, driving the base plate 31 to achieve the lifting stroke. When the slurry pump assembly 2 needs to move horizontally, the base plate 31 begins to descend, the universal locking wheel 35 connected to the base plate 31 begins to touch the ground, the support plate 34 begins to lift off the ground, pushing the push rod 32 to achieve the horizontal movement of the slurry pump assembly 2. Conversely, when the slurry pump assembly 2 does not need to move horizontally, the base plate 31 begins to rise, the universal locking wheel 35 lifts off the ground and retracts, and the support plate 34 touches the ground. The lifting support rod 33 can prevent the base plate 31 from rising excessively.

[0042] Preferably, the upper side of the lifting rod assembly is provided with a gear drive box 37. The gear drive box 37 includes a box body, and a motor 63 is provided inside the box body. The output end of the motor 63 is connected to a rotating rod 36. One end of the rotating rod 36 extends out of the box body. The portion of the rotating rod 36 located inside the box body is provided with a first bevel gear 61. The first bevel gear 61 is meshed with a second bevel gear 62. The second bevel gear 62 is connected to the threaded rod 65.

[0043] The base plate 31 can be moved up and down by manually adjusting the rotating rod 36 and controlling the gear drive box. Alternatively, the base plate 31 can be moved up and down by the motor 63. The appropriate method should be selected according to the working conditions.

[0044] Preferably, the clean water zone is located above the wastewater zone. One side of the wastewater zone is provided with an inlet 41 connected to the second pipeline, and the other side of the wastewater zone is provided with a hydraulic shear frame 54 and a mud pusher 52 connected to the hydraulic shear frame 54. One side of the clean water zone is provided with an outlet 42.

[0045] The hydraulic scissor lift 54 ​​includes an interwoven network formed by multiple X-shaped rods connected to each other. A telescopic rod 56 is connected to the interwoven network. A gear 53 is connected to the left X-shaped rod of the interwoven network. A fixing block is connected to the top of the right X-shaped rod of the interwoven network. The fixing block is hinged to the base 55 on the right side of the sewage area. A movable pulley is connected to the bottom of the right X-shaped rod of the interwoven network. Under the action of the telescopic rod 56, the movable pulley moves on the base 55 to realize the stroke control of the hydraulic scissor lift 54.

[0046] The hydraulic shear frame 54 pushes the mud pusher 52 forward, pushing the sludge in the sewage area out from one side. The filter screen 43 can isolate the bottom sludge in the sewage area, and the filtered water is extracted through the outlet 42 of the clean water area for secondary use.

[0047] Preferably, a liftable gate 44 is provided on one side of the sewage area, the inlet 41 is provided on the gate 44, and a scraper 45 with an inclined slope is provided at the bottom of the gate 44.

[0048] When dredging the sewage area, the hydraulic telescopic rod 51 pulls the gate 44 upward into the gate slot. At this time, the hydraulic shear frame 54 on the other side of the dredging pool pushes the pusher plate 52 forward, pushing the sludge in the sewage area out from the other side. After the sludge in the sewage area is completely cleaned, the pusher plate 52 is not retracted temporarily. After the scraper plate 45 at the bottom of the gate 44 scrapes off all the sludge on the surface of the pusher plate 52, the pusher plate 52 is retracted to avoid prolonged erosion by sludge and extend its service life. In addition, the scraper plate 45 with an inclined slope at the bottom of the gate 44 can slow down the water flow and prevent the bottom sludge from floating up due to water flow impact.

[0049] The present invention employs the above-mentioned device to perform a non-destructive construction method for the pile head of bored cast-in-place piles as follows: Before the pile foundation construction, the construction site is leveled to ensure that the grout outlet on the outer periphery of the steel casing 1 is at least 50mm above the design elevation. A filter screen and valve 4 are installed inside the grout outlet. The valve 4 can be connected to the grout pump assembly through the first pipeline 5. After the steel casing 1 is installed, the pile hole drilling work is carried out according to the construction requirements.

[0050] After the pile hole drilling is completed, concrete is poured up to the top of the steel casing 1. After the pouring is completed, the grout discharge port of the steel casing 1 is connected to the grout pump assembly 2 through the first pipeline 5, and the grout pump assembly 2 is connected to the sludge removal pool 3 through the second pipeline 6. Then, the valve 4 and the grout pump are opened to discharge the excess cement grout into the sludge removal pool 3 through the grout pump assembly 2. The 50mm excess grout reserved in advance is not removed and serves as a reserved protective layer for the bored pile to prevent rainwater, dust and other debris from entering the pile body during the hardening process of the pile foundation concrete, thus ensuring the quality of the pile foundation concrete.

[0051] After the pile concrete reaches the design strength, the over-grouted part above the grout outlet is not fully hardened due to the extraction of cement grout. Therefore, the over-grouted part of the concrete above the grout outlet can be easily excavated manually using tools. Then, the main reinforcement above the over-grouted part is removed, and the reserved protective layer below the grout outlet above the design elevation is broken and finished to complete the pile foundation construction.

[0052] Although embodiments of the present invention have been shown and described, it will be understood by those skilled in the art that various changes, modifications, substitutions and alterations can be made to these embodiments without departing from the principles and spirit of the present invention, the scope of which is defined by the appended claims and their equivalents.

Claims

1. A construction device for bored cast-in-place pile heads that does not require demolition, characterized in that, The system includes a steel casing (1), a pump assembly (2) that can move vertically and horizontally, and a sludge removal tank (3). The outer periphery of the steel casing (1) is provided with a sludge discharge port, which is connected to the input end of the pump assembly (2) through a first pipeline (5). The output end of the pump assembly (2) is connected to the sludge removal tank (3) through a second pipeline (6). The sludge removal tank (3) is provided with a filter screen (43), which divides the sludge removal tank (3) into a sewage area and a clean water area. The second pipeline (6) is connected to the sewage area.

2. The drilling head-free construction device for bored piles according to claim 1, characterized in that, The bottom of the grout outlet is higher than the design elevation of the cast-in-place pile, and a filter screen and valve (4) are installed at the grout outlet.

3. The drilling head-free construction device for bored piles according to claim 1, characterized in that, The slurry pump assembly (2) includes a slurry tank (38), a base plate (31), a lifting rod assembly, and a universal locking wheel (35). The slurry tank (38) is connected to the first pipeline (5) and the second pipeline (6) and is located on the base plate (31). The lifting rod assembly is located at the four corners of the base plate (31) to control the up and down movement of the base plate (31). The universal locking wheel (35) is located below the base plate (31). A push rod (32) is also installed on the base plate (31).

4. The drilling head-free construction device for bored piles according to claim 3, characterized in that, The slurry tank (38) is equipped with a slurry pump and a storage battery installed on the base plate (31). The slurry pump is connected to the storage battery, and the first pipeline (5) and the second pipeline (6) are connected to the slurry pump.

5. The drilling head-free construction device for bored piles according to claim 3, characterized in that, The lifting rod assembly includes a threaded rod (65) with external threads, which passes through the base plate (31). The threaded rod (65) is threadedly connected to a slider (66) with internal threads at the through position. The outer side of the slider (66) is fixed to the base plate (31). The bottom of the threaded rod (65) is rotatably connected to a support plate (34) under the base plate (31).

6. The drilling head-free construction device for bored piles according to claim 5, characterized in that, The upper side of the lifting rod assembly is provided with a gear drive box (37). The gear drive box (37) includes a box body. A motor (63) is provided inside the box body. The output end of the motor (63) is connected to a rotating rod (36). One end of the rotating rod (36) extends out of the box body. The part of the rotating rod (36) located inside the box body is provided with a first bevel gear (61). The first bevel gear (61) is meshed with a second bevel gear (62). The second bevel gear (62) is connected to the threaded rod (65).

7. The drilling head-free construction device for bored piles according to claim 1, characterized in that, The clean water zone is located above the sewage zone. One side of the sewage zone is provided with an inlet (41) connected to the second pipeline. The other side of the sewage zone is provided with a hydraulic shear frame (54) and a mud pusher (52) connected to the hydraulic shear frame (54). One side of the clean water zone is provided with a drain (42).

8. The drilling head-free construction device for bored piles according to claim 7, characterized in that, A liftable gate (44) is provided on one side of the sewage area. The inlet (41) is provided on the gate (44). A scraper (45) with an inclined slope is provided at the bottom of the gate (44).

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