Recyclable valve device and prestressed duct grouting structure

Abstract

The utility model discloses a kind of recyclable valve device and prestressed duct grouting structure, comprising: cross round steel pipe, it is the tubular structure of cross shape, the upper and lower tubular body of cross round steel pipe is hollow structure, the left and right tubular body of cross round steel pipe is opened hole and forms the slurry passage of intercommunication, the left and right two ends of cross round steel pipe are equipped with external thread;Nylon inner core, the diameter of upper portion is greater than the outer diameter of cross round steel pipe, the diameter of lower portion is slightly smaller than the inner diameter of cross round steel pipe upper and lower tubular body, through hole is equipped in the nylon inner core;Sealing ring, it is arranged in nylon inner core lower part and the lower tubular body of cross round steel pipe, for sealing.The utility model solves the problem that current prestressed grouting device damage rate is too high and causes cost increase.

Description

Technical Field

[0001] This utility model relates to the field of concrete prestressing tensioning technology. More specifically, this utility model relates to a reusable valve device and a prestressing duct grouting structure. Background Technology

[0002] Post-tensioning prestressing technology is a construction method that applies prestress to concrete members after they have hardened by threading steel strands, applying tension, anchoring them, and then grouting the ducts. This technology can significantly improve the load-bearing capacity, crack resistance, and durability of structures. Its construction steps include: reserving ducts: providing space for the steel strands and ensuring the tensioning path; concrete pouring and curing: shaping the member and achieving sufficient strength to withstand the tension; threading the strands: threading high-strength steel strands into the ducts in preparation for tensioning; tensioning and anchoring: applying a predetermined tension to bring the member into a pre-stressed state; grouting and sealing: injecting cement grout into the ducts to fix the steel strands and prevent corrosion. This method is widely used in cast-in-place concrete structures such as bridges, floor slabs, and tunnels, and has significant advantages such as flexible construction, strong adaptability, and superior structural performance.

[0003] Grouting is a crucial step in post-tensioned prestressed concrete construction. Its main purposes include: effectively anchoring the steel strands and reliably transferring prestress to the concrete structure; filling pre-reserved ducts to isolate air and moisture, preventing steel corrosion; and enhancing the overall structural integrity, durability, and crack resistance. During post-tensioned prestressed concrete construction, after the prestressing tendons are tensioned, grout is injected into the prestressing duct through pre-reserved grouting holes above the prestressing anchors using a grouting pump until the grout flows continuously and stably from the outlet. At this point, the ball valve at the outlet is tightened. To prevent backflow, the grouting port must continue to be grouted for pressure stabilization. After pressure stabilization, the ball valve at the grouting port is closed. The ball valve can only be removed after the grout has initially set and there is no longer pressure in the duct.

[0004] In current construction, used ball valves often retain residual slurry that is difficult to completely remove even after hammering, cleaning, and soaking. Traditional ball valves consist of a ball core, valve stem, and pipe. Once the residual slurry solidifies, it locks the valve stem, preventing the ball core from rotating. This causes the ball valve's switching mechanism to malfunction, ultimately damaging the ball valve and rendering it unusable. In actual projects, a single prestressed duct typically requires two ball valves to meet grouting requirements, and a beam may contain more than 20 prestressed ducts. This results in a significant number of damaged ball valves, leading to substantial equipment waste and increased construction costs. Summary of the Invention

[0005] The purpose of this invention is to provide a reusable valve device and a prestressed duct grouting structure to solve the problem of high damage rate and increased cost of current prestressed grouting devices.

[0006] The technical solution adopted by this utility model to solve this technical problem is: a reusable valve device for grouting concrete prestressed ducts, comprising: The cross-shaped round steel pipe has a cross-shaped tube structure. The upper and lower tubes of the cross-shaped round steel pipe are hollow. The left and right tubes of the cross-shaped round steel pipe have openings to form a connected slurry channel. Both the left and right ends of the cross-shaped round steel pipe are provided with external threads. The nylon inner core has an upper diameter larger than the outer diameter of the cross-shaped steel tube and a lower diameter slightly smaller than the inner diameter of the upper and lower tubes of the cross-shaped steel tube. A through hole is provided in the nylon inner core. A sealing ring, located at the lower part of the nylon inner core and the lower tube body of the cross-shaped steel tube, is used for sealing.

[0007] The nylon inner core is rotatably installed inside the cross-shaped steel tube. By rotating, the through hole is aligned or misaligned with the slurry channel, thereby opening or closing the slurry channel.

[0008] A further embodiment of this utility model is: an annular groove is provided on the inner wall of the lower tube of the cross-shaped steel tube, and an annular groove is provided on the outer wall of the lower part of the nylon inner core. A sealing ring is provided in both the annular groove of the nylon inner core and the annular groove of the cross-shaped steel tube, which can form a good upper and lower sealing space inside the cross-shaped steel tube.

[0009] As a further aspect of this utility model, the top and bottom of the nylon inner core are provided with chamfered corners to facilitate installation.

[0010] As a further embodiment of this utility model, the upper sidewall of the nylon inner core is provided with anti-slip texture, and a through hole is provided in the middle of the upper sidewall of the nylon inner core. The anti-slip texture and the through hole facilitate the application of force by tools to twist the inner core.

[0011] As a further embodiment of this utility model, the center of the through hole is at the same height as the center of the opening of the cross-shaped steel pipe, and the diameter of the through hole is slightly smaller than the diameter of the opening. After installation, it can be aligned with the opening of the cross-shaped steel pipe to form a flow channel for the slurry.

[0012] This utility model also provides a prestressed duct grouting structure, including prestressed anchors installed at the grout inlet and grout outlet, and reusable valve devices installed on the prestressed anchors at the grout inlet and grout outlet respectively. One end of the valve device on the grout inlet side is connected to the mud pump / grouting machine, and the other end is connected to the grout inlet of the prestressed anchor. One end of the valve device on the slurry outlet side is connected to the slurry outlet of the prestressed anchor, while the other end is left unattended to observe the slurry flow.

[0013] As a further aspect of this utility model, a slurry receiving container is provided below the valve device on the slurry outlet side to facilitate observation of the slurry outflow.

[0014] This utility model has at least the following beneficial effects: The utility model proposes a reusable valve device and a prestressed duct grouting structure. The device is composed of a nylon inner core and a cross-shaped steel pipe. After the grouting process is completed, this device is easy to disassemble and clean. After cleaning, it can be reused, which significantly reduces the large amount of wear and tear on disposable ball valves, reduces the cost of construction equipment, and has significant economic benefits.

[0015] Improve grouting sealing performance: By setting sealing rings on the cross-shaped steel pipe and the nylon inner core respectively, the structure can reduce installation friction without reducing the sealing effect, effectively preventing grout leakage and air infiltration during grouting, and ensuring the anchoring quality of prestressed tendons and structural durability.

[0016] Easy to operate and control the flow: The nylon inner core is equipped with anti-slip texture and through holes, which can be manually rotated to switch the grout channel 90° to open or close, making grouting control more intuitive and reliable and improving construction efficiency.

[0017] Reusable components reduce costs: The inner core of this device is a precision component made of nylon material, which is low-cost and easy to replace. The nylon inner core and the welded cross-shaped steel tube structure are simple, easy to disassemble and clean, and can be reused after cleaning, significantly reducing the large amount of wear and tear on disposable ball valves, lowering the cost of construction equipment, and resulting in significant economic benefits.

[0018] Adaptable to complex site conditions: This device is suitable for the construction of multi-pipe and large-volume prestressed components. The cross-welded round steel pipe with threads on both sides of the structure makes the installation flexible and the operation steps simple. It is suitable for large-scale rapid deployment and recovery on site, which is conducive to standardized construction management.

[0019] Other advantages, objectives and features of this invention will be partly apparent from the following description, and partly understood by those skilled in the art through study and practice of this invention. Attached Figure Description

[0020] Figure 1 This is an assembly diagram of the reusable valve device of this utility model; Figure 2 This is a three-dimensional view of a nylon core according to an embodiment of the present invention; Figure 3 This is a front view of a nylon inner core according to an embodiment of the present invention; Figure 4 This is a side view of a nylon inner core according to an embodiment of the present invention; Figure 5This is a three-dimensional view of a cross-shaped steel pipe according to an embodiment of this utility model; Figure 6 This is a front view of a cross-shaped steel tube according to an embodiment of this utility model; Figure 7 This is a side view of a cross-shaped steel tube according to an embodiment of this utility model; Figure 8 This is a schematic diagram of the reusable valve device of this utility model in the open state; Figure 9 This is a schematic diagram of the closed state of the reusable valve device of this utility model; Figure 10 This is a schematic diagram of a prestressed duct grouting structure according to an embodiment of the present invention.

[0021] Among them, 1-cross-shaped steel pipe, 2-nylon inner core, 3-sealing ring, 4-flow channel, 5-opening, 6-through hole, 7-annular groove, 8-chamfered structure, 9-anti-slip texture, 10-valve device, 11-grouting machine, 12-grout receiving container, 13-prestressed duct, 14-through hole, 15-external thread. Detailed Implementation

[0022] The present invention will now be described in detail and completely with reference to the accompanying drawings. Those skilled in the art will be able to implement the present invention based on these descriptions. Before describing the present invention with reference to the accompanying drawings, it should be particularly noted that the technical solutions and features provided in the various parts of the present invention, including the following description, can be combined with each other without conflict.

[0023] Furthermore, the embodiments of the present invention described below are generally only a part of the embodiments of the present invention, and not all of the embodiments. Therefore, all other embodiments obtained by those skilled in the art based on the embodiments of the present invention without inventive effort should fall within the protection scope of the present invention.

[0024] The present invention will be further described in detail below with reference to the accompanying drawings and embodiments, and the specific implementation process is as follows: like Figures 1-10As shown, this utility model provides a reusable valve device for grouting prestressed concrete ducts 13, comprising: a cross-shaped round steel pipe 1, a nylon inner core 2, and a sealing ring 3. The cross-shaped round steel pipe 1 is the main structural component, formed by welding a vertical hollow round pipe to two horizontal grout channel steel pipes, creating a cross-shaped structure. The two horizontal steel pipes have external threads 15 for connecting to external pipelines or anchors. The openings 5 ​​of the two horizontal grout channel steel pipes communicate with the inner cavity of the vertical hollow round pipe, together forming the grout flow channel 4. The nylon inner core 2 is the valve core actuating component. Its upper part is a larger diameter operating part, with a diameter greater than the inner diameter of the vertical hollow round pipe of the cross-shaped round steel pipe 1, which can serve as a limiting element; the lower part is a smaller diameter valve core part, with a diameter slightly smaller than the inner diameter of the vertical hollow round pipe, to ensure smooth insertion and rotation. In this embodiment, the inner diameter of the upper and lower tubes of the cross-shaped steel tube 1 is approximately 1 mm larger than the lower diameter of the nylon inner core 2 to ensure assembly clearance. The valve core portion of the nylon inner core 2 has a horizontal through hole 6. A sealing ring 3 is installed at the lower part of the nylon inner core 2 and the lower part of the hollow tube of the cross-shaped steel tube 1 for sealing. The nylon inner core 2 is rotatably installed inside the cross-shaped steel tube 1; by rotating, the through hole 6 is aligned or misaligned with the slurry channel to open or close the slurry channel.

[0025] The valve device 10 operates as follows: During assembly, the valve core of the nylon inner core 2 is screwed into the vertical hollow cylindrical tube of the cross-shaped steel tube 1 from the upper opening. When the valve needs to be opened, the nylon inner core 2 is rotated so that the axis of its through hole 6 is aligned with the axis of the slurry channel steel tube welded horizontally on the cross-shaped steel tube 1. At this time, the slurry flow can pass through the horizontal slurry channel steel tube on one side, the through hole 6 of the nylon inner core 2, and the horizontal slurry channel steel tube on the other side in sequence, achieving smooth flow, and the valve is in the open state. When the valve needs to be closed, the nylon inner core 2 is rotated ninety degrees so that the axis of its through hole 6 is perpendicularly misaligned with the axis of the slurry channel steel tube. At this time, the solid part of the nylon inner core 2 completely blocks the channel, the slurry flow cannot pass through, and the valve is in the closed state. Through the rotational movement of the above-mentioned mechanical structure, the opening and closing control of the flow channel is achieved.

[0026] The ultimate goal of this embodiment is to provide a grouting valve device 10 that is simple in structure and easy to operate. It achieves opening and closing through a 90-degree rotation of the nylon inner core 2, making operation intuitive and reliable. The cross-shaped welded steel pipe structure ensures the mechanical strength and smoothness of the channel.

[0027] In another technical solution, an annular groove 7 is provided on the inner wall of the lower tube of the cross-shaped steel tube 1, and an annular groove 7 is provided on the outer wall of the lower part of the nylon inner core 2. Sealing rings 3 are provided in both the annular grooves 7 of the nylon inner core 2 and the annular grooves 7 of the cross-shaped steel tube 1, forming a double sealing structure. Preferably, these two sealing rings 3 are positioned above and below the through hole 6 of the nylon inner core 2. The working process of this sealing structure is as follows: when the nylon inner core 2 is fully screwed into the cross-shaped steel tube 1, the sealing ring 3 located on the lower part of the nylon inner core 2 forms a dynamic sealing pair with the smooth inner wall of the vertical tube of the cross-shaped steel tube 1, responsible for maintaining a seal when the nylon inner core 2 rotates. Meanwhile, the sealing ring 3 located on the cross-shaped steel tube 1 forms a static sealing pair with the outer wall of the lower section of the nylon inner core 2. The working principle of this double sealing ring 3 design is to construct two independent sealing interfaces. The upper dynamic sealing ring 3 primarily addresses the sealing requirements under rotational operation, while the lower static sealing ring 3 serves as a redundant barrier, further enhancing sealing reliability. Together, they ensure that grout cannot leak from the assembly gap between the nylon inner core 2 and the cross-shaped steel pipe 1 when the valve is closed. The layout of the double sealing rings 3 creates an effective sealing space, greatly reducing the risk of leakage due to pressure shocks and equipment wear during grouting. This design reduces the installation friction of the nylon inner core 2 while ensuring the long-term stability of the sealing effect, thereby guaranteeing the grouting quality.

[0028] In another technical solution, the top and bottom edges of the nylon inner core 2 are chamfered or rounded to form a chamfered corner structure 8. This chamfered corner serves as a guide and centering element during the installation of the nylon inner core 2 onto the cross-shaped steel tube 1. The chamfered corner design simplifies the installation process, avoids assembly difficulties or component scratches caused by minor misalignments, and makes on-site operations faster and more efficient.

[0029] In another technical solution, the upper sidewall of the nylon inner core 2 is provided with an anti-slip texture 9, such as knurling. A through hole 14 is provided in the middle of the upper sidewall of the nylon inner core 2, and the axis of the through hole 14 is perpendicular to the axis of the nylon inner core 2. The anti-slip texture 9 increases the friction between the operator's fingers and the nylon inner core 2, making it easier to grip and rotate directly by hand. When residual slurry causes greater rotational resistance, or when more effortless and precise control of the rotation angle is required, the operator can insert a metal rod (such as a hex wrench, screwdriver, or a specially made thin lever) into the through hole 14. At this time, the through hole 14 and the metal rod form a lever system. With the axis of the nylon inner core 2 as the fulcrum, the force applied by the operator to the metal rod will generate a torque much greater than that of direct manual rotation, thereby easily overcoming resistance and completing a 90-degree rotation opening and closing action, ensuring that the valve can be reliably operated under any working condition.

[0030] In another technical solution, the center of the through hole 6 is at the same height as the center of the opening 5 of the cross-shaped steel pipe 1, and the diameter of the through hole 6 is slightly smaller than the diameter of the opening 5. When the centers of the two holes are aligned (i.e., in the valve open state), a tiny stepped contraction and expansion channel is formed due to the slightly smaller diameter of the through hole 6. This design is beneficial for guiding the slurry flow and reducing turbulence and energy loss. More importantly, during the closing process of the rotating nylon inner core 2, when the two holes begin to misalign, the difference in hole diameter allows the solid part of the nylon inner core 2 to cover the channel cross-section more quickly, accelerating the cut-off of flow and reducing the amount of slurry leakage during the closing process. The equal position ensures that the flow channel has the maximum flow area when aligned, guaranteeing grouting efficiency.

[0031] This utility model also provides a grouting structure for prestressed ducts 13, including prestressed anchors installed at the grout inlet and outlet. Each prestressed anchor at the grout inlet and outlet is equipped with a reusable valve device 10. One end of the valve device 10 on the grout inlet side is connected to a mud pump / grouting machine 11, and the other end is connected to the grout inlet of the prestressed anchor. One end of the valve device 10 on the outlet side is connected to the grout outlet of the prestressed anchor, and the other end is left unused for observing grout flow. Specifically, the installation method is as follows: the first set of valve devices 10 is connected to the grout inlet of the prestressed anchor via its external thread 15, and the other port of this valve device 10 is connected to the mud pump / grouting machine 11 via a pipeline. The second set of valve devices 10 is connected to the grout outlet of the prestressed anchor via its external thread 15, and the other port of this valve device 10 remains unused and open.

[0032] The working process of this grouting structure is as follows: At the start of the grouting operation, two operators rotate the nylon inner core 2 of the valve device 10 on both sides of the grout inlet and outlet to the open position. The mud pump is started, and the grout flows sequentially through: mud pump → grout inlet valve device 10 → prestressed anchor inlet → prestressed duct 13 → prestressed anchor outlet → outlet valve device 10 → finally flowing out stably from the empty outlet. The operator observes at the outlet and gives a signal when the grout flows out continuously and stably without bubbles. The operator on the outlet side then rotates the nylon inner core 2 of the valve device 10 next to him ninety degrees to the closed position, cutting off the flow channel. After the grout outlet is sealed, continue to pressurize the grout in the pipe for several minutes to prevent backflow of grout and ensure that the grout fills the tiny gaps in the prestressed duct 13. After the grouting is completed, close the valve device 10 at the grout inlet. At this point, the grouting process is complete. After the grout has initially set, the two sets of valve devices 10 can be disassembled and cleaned for reuse.

[0033] The ultimate goal of this implementation is to construct a highly efficient, reliable, and low-cost prestressed grouting system. By installing recirculating valves at two key locations, the grouting process can be visualized and reliably controlled. This structure solves the problem of single-use traditional ball valves, forming a complete technical solution from device to system, significantly reducing construction material and maintenance costs.

[0034] In another technical solution, a grout receiving container 12, such as a bucket or basin, is provided below the valve device 10 on the grout outlet side. The container operates based on a simple collection principle. In the initial stage of grouting, a mixture that may contain air bubbles or water flows out of the channel first; the channel is only considered full when pure grout flows out. The fluid flowing out of the empty outlet flows directly into the receiving container below, preventing grout from flowing around and contaminating the work surface, damaging the appearance of the concrete structure, or wasting materials. Operators can clearly observe the grout flow status (whether it is continuous and stable) from the liquid level in the container, thus accurately determining when to close the valve.

[0035] Although the embodiments of this utility model have been disclosed above, they are not limited to the applications listed in the specification and embodiments. They can be applied to various fields suitable for this utility model. For those skilled in the art, other modifications can be easily made. Therefore, without departing from the general concept defined by the claims and their equivalents, this utility model is not limited to the specific details and embodiments shown and described herein.

Claims

1. A reusable valve device for grouting prestressed concrete ducts, characterized in that, include: The cross-shaped round steel pipe has a cross-shaped tube structure. The upper and lower tubes of the cross-shaped round steel pipe are hollow. The left and right tubes of the cross-shaped round steel pipe have openings to form a connected slurry channel. Both the left and right ends of the cross-shaped round steel pipe are provided with external threads. The nylon inner core has an upper diameter larger than the outer diameter of the cross-shaped steel tube and a lower diameter slightly smaller than the inner diameter of the upper and lower tubes of the cross-shaped steel tube. A through hole is provided in the nylon inner core. A sealing ring, which is located at the lower part of the nylon inner core and the lower tube body of the cross-shaped steel tube, is used for sealing; The nylon inner core is rotatably installed inside the cross-shaped steel tube. By rotating, the through hole is aligned or misaligned with the slurry channel, thereby opening or closing the slurry channel.

2. The reusable valve device as described in claim 1, characterized in that, The lower inner wall of the cross-shaped steel tube is provided with an annular groove, and the lower outer wall of the nylon inner core is provided with an annular groove. Both the annular groove of the nylon inner core and the annular groove of the cross-shaped steel tube are provided with sealing rings.

3. The reusable valve device as described in claim 1, characterized in that, The nylon inner core has chamfered corners at the top and bottom.

4. The reusable valve device as described in claim 1, characterized in that, The upper sidewall of the nylon inner core is provided with anti-slip texture, and a through hole is provided in the middle of the upper sidewall of the nylon inner core.

5. The reusable valve device as described in claim 1, characterized in that, The center of the through hole is at the same height as the center of the opening of the cross-shaped steel pipe, and the diameter of the through hole is slightly smaller than the diameter of the opening.

6. A prestressed duct grouting structure, comprising prestressed anchors installed at the grout inlet and grout outlet, characterized in that, The prestressed anchorages located at the grout inlet and grout outlet are respectively equipped with reusable valve devices as described in any one of claims 1 to 5; One end of the valve device on the grout inlet side is connected to the mud pump / grouting machine, and the other end is connected to the grout inlet of the prestressed anchor. One end of the valve device on the slurry outlet side is connected to the slurry outlet of the prestressed anchor, while the other end is left unattended to observe the slurry flow.

7. The prestressed duct grouting structure as described in claim 6, characterized in that, A slurry receiving container is located below the valve device on the slurry outlet side.

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