I. Product Positioning
This all-in-one grouting equipment is custom-built for post-tension duct grouting work in prestressed construction. It integrates powder feeding, proportion mixing, high-pressure pumping and constant-pressure grouting functions into one single device. After the tensioning of bridge box girders and various prestressed concrete members, this machine fills cement slurry into the corrugated ducts where steel strands are placed. The grout layer provides anti-corrosion protection for strands and forms reliable bonding between steel and concrete, serving as essential core equipment for the final prestressing construction procedure.
II. Main Modules and Actual Functions
Inclined Screw Feeder
Workers load cement and grouting admixtures into the right-end hopper. The inclined screw conveyor automatically transports powder materials into the mixing tank. This structure cuts down manual material pouring work and greatly reduces flying dust on site, improving construction cleanliness and saving labor.
Dual-Layer Mixing Tank
The upper tank adopts high-speed stirring to finish rapid slurry mixing. The lower tank works at a low speed to keep stirring the prepared grout continuously. This design effectively prevents grout sedimentation and layer separation, enabling uninterrupted circulating mixing and continuous grouting operation.
Electric Control Cabinet
The white control cabinet on the left is equipped with a complete PLC control system. It can precisely control on-site parameters including water-binder proportion, mixing time and grouting pressure. Meanwhile, the system automatically records all construction data during operation, facilitating later inspection and data sorting.
Horizontal Screw Grouting Pump
The blue horizontal screw pump is responsible for high-pressure conveying of mixed slurry. It provides stable and continuous grouting pressure to ensure smooth and uniform grout injection into prestressed ducts, avoiding unstable pressure fluctuation during grouting.
Movable Chassis Wheels
The whole machine is fitted with bottom walking wheels, which support flexible moving on bridge decks, beam prefabrication yards and other construction areas, adapting to frequent position adjustment during segmented grouting construction.
III. Core Product Features and On-Site Advantages
Highly Integrated Structure with Automated Operation
This machine combines feeding, proportioning, mixing, storage and grouting functions in one unit. Traditional separate equipment such as independent mixers, manual feeding tools and single grouting pumps are no longer needed. It saves on-site layout space and reduces the number of construction workers required. The equipment supports preset water-cement ratio and automatic water feeding, making the slurry proportion far more stable and accurate than conventional manual mixing methods.
Dual-Stage Mixing Guarantees Slurry Quality
High-speed stirring in the upper tank fully disperses cement and admixtures, eliminating dry powder agglomeration and uneven mixing problems. The lower low-speed circulating stirring keeps the finished grout in a uniform state at all times. It effectively avoids slurry stratification, precipitation and viscosity instability, which commonly occur in manual mixing, ensuring consistent grout quality throughout the whole grouting process.
Stable High-Pressure Grouting Complies with Site Standards
The screw pump outputs pressure steadily with tiny fluctuation. It can maintain the constant pressure required for duct grouting, and is compatible with both conventional pressure grouting and vacuum-assisted grouting processes. Stable pressure helps exhaust air inside the ducts thoroughly, improves duct grout compactness and fullness, and greatly reduces hidden dangers of steel strand corrosion caused by incomplete grouting.
Automatic Data Recording for Quality Acceptance
The electric control system automatically collects and stores key construction data including real-time grouting pressure, working duration and mixing proportion. All data can be exported completely, which meets the data filing, supervision inspection and project acceptance requirements of bridge prestressed grouting works.
Flexible Movement and Good Site Adaptability
Thanks to the wheeled integrated design, the machine can be directly moved to beam-end working positions. It is very suitable for multi-span bridge segmented grouting and batch grouting of prefabricated components. The fully closed feeding structure restricts dust overflow, effectively improving the cleanliness of the prestressing construction area.
IV. Main Application Scenarios
The equipment is widely used for corrugated duct grouting of highway and railway bridge box girders and T-beams. It also applies to prestressed duct grouting for large basement structures and long-span concrete components. In addition, it is the matching equipment specially used for vacuum-assisted grouting processes in various key bridge and municipal engineering projects.
