Closure Load Plug Assembly for Sealed Post-Tension Duct Grouting
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Solution Overview
Problem
In post-tensioned concrete construction, existing methods for connecting segments of ducts often result in incomplete grouting due to epoxy leakage and air/water intrusion, especially when segments of standard lengths do not match the concrete pour requirements, leading to structural integrity issues.
Innovation Solution
A closure assembly comprising a duct coupler assembly with a closure load plug and end cap, which includes a duct coupler with a cylindrical portion and conjunction portion for secure attachment, and a gasket to prevent liquid intrusion, allowing for effective sealing and extension of ducts to match varying concrete pour lengths.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If duct segments are joined using epoxy and conventional sealing methods, then duct connection is achieved, but epoxy leaks out and grouting becomes incomplete
Solution Approach 1:
The closure load plug is installed at the duct end before grouting to pre-establish a seal that prevents epoxy leakage and ensures complete grouting. This preliminary sealing action eliminates the harmful effect of epoxy leaking out during the connection process.
Solution Approach 2:
The closure load plug acts as an intermediary component between the duct end and the grouting process. It provides a sealed interface that allows grout to be pumped through the entire duct assembly without epoxy interference, ensuring complete grouting.
2Adaptability or versatility
If standard length duct segments are used, then manufacturing is simplified, but they do not match non-standard concrete pour lengths
Solution Approach 1:
The duct system is divided into standard-length segments that can be connected using the closure load plug assembly. This segmentation allows flexible configuration to match various concrete pour lengths while maintaining the benefits of standardized manufacturing for each segment.
Solution Approach 2:
The closure load plug assembly provides a dynamic connection solution that can accommodate varying total lengths by combining different numbers of standard segments. This enables the duct system to adapt to non-standard concrete pour requirements while retaining standardized segment manufacturing.
3Reliability
If grout is pumped through duct interior to seal against air and water, then sealing is achieved, but epoxy leakage prevents complete grouting
Solution Approach 1:
The closure load plug is installed before grouting to pre-establish a sealed environment in the duct interior. This preliminary sealing prevents air and water intrusion while allowing complete grout penetration, eliminating the problem of epoxy blocking the grouting process.
Solution Approach 2:
The closure load plug serves as an intermediary sealing mechanism that enables effective grout pumping through the duct interior. It creates a sealed pathway that prevents air and water intrusion while allowing complete grout flow, resolving the conflict between sealing effectiveness and grout penetration.
Data Source
AI summary
A closure assembly includes a section of duct, a duct coupler assembly, a closure load plug, and an end cap. The duct coupler assembly is fit against the section of duct. The closure load plug is mechanically connected to the duct coupler assembly. The end cap is mechanically connected to the closure load plug.