Closure Load Plug Assembly for Sealing Post-Tension Duct Ends
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Solution Overview
Problem
In post-tensioned concrete construction, existing methods for connecting segments of ducts face challenges with incomplete grouting and leakage due to difficulties in sealing the ends of duct segments, leading to potential air and water intrusion, especially when segments do not correspond with standard lengths.
Innovation Solution
A closure assembly is introduced, comprising a duct coupler assembly with a closure load plug and end cap, which includes a duct coupler assembly that fits against the duct segment, utilizing a duct receiving end with a cylindrical portion and conjunction portion for attachment, along with a gasket to prevent liquid intrusion, and a closure load plug with male threads that screws into a female coupler with threads, forming a seal with the end cap.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If epoxy is applied to seal duct segment ends, then sealing is achieved, but epoxy leaks out into the interface area and grout cannot flow fully through the duct assembly
Solution Approach 1:
The closure load plug is installed at the duct end before grouting to pre-prevent epoxy leakage. This preliminary sealing action ensures that when grout is pumped later, it flows completely through the duct without being blocked by leaked epoxy at the segment interface.
Solution Approach 2:
The invention extracts the sealing function from the epoxy application process and assigns it to a dedicated closure load plug component. This separation allows the epoxy to serve its primary bonding function while the closure plug handles the sealing function, preventing epoxy from interfering with grout flow.
2Ease of operation
If duct segments are joined end-to-end with epoxy sealing, then connection is achieved, but air and water can intrude into the duct interior
Solution Approach 1:
The closure load plug acts as an intermediary component between the duct end and the external environment. It provides a reliable seal that prevents air and water intrusion while allowing the duct segments to be connected end-to-end for ease of assembly.
Solution Approach 2:
The closure load plug incorporates a closure gasket that forms a flexible seal at the duct end. This gasket prevents air and water intrusion while accommodating minor variations in duct end alignment during assembly.
3Ease of manufacture
If standard length duct segments are used, then manufacturing is simplified, but they may not correspond with the length of concrete pours
Solution Approach 1:
The duct system is segmented into standardized modules that can be connected end-to-end using the closure load plug assembly. This segmentation allows flexible configuration to match various concrete pour lengths while maintaining simplified manufacturing of individual standard-length segments.
Solution Approach 2:
The closure load plug assembly serves as a universal connector that works with duct segments of any standard length. This multi-functional component enables both simplified manufacturing of standard segments and adaptability to different concrete pour lengths by simply varying the number of segments used.
Data Source
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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.