Design and Development of Grouting Machine

Abstract

Grouting is a process in post-tensioning structures like bridges, elevated slabs (parking structures and residential or commercial buildings), residential foundations, walls, and columns etc. Grouting process is the most critical aspect of the post-tensioning procedure carried out in the construction industry. In the present scenario, most of the organization providing post-tensioning services in India use the portable separate grout mixer and grout pump. Both of these equipment have a separate operator to handle. Due to lower pressure and flow rate at discharge the equipment is not capable enough to pump the fluid to the required height. So, the whole machinery needs to be elevated to a certain height to complete the task which is costly and requires more man-hours.

The thesis includes the design and development of the grouting machine. Presently, the grouting machine consists of a grout mixer, grout pump and base frame or supporting structure. Grout mixer is designed based on fluid characteristics and its properties and volume capacity. Agitator motor selection and gear-box selection has been done on the basis of torque calculation that is required to drive the impeller shaft. The efficient and longer service life pump has been selected for transferring the grout to a required height. Combined conceptual design of grout mixer and the pump is done as a one-machine structure. Design and modelling have been performed using CAD software and the same has been analyzed with the help of CAE software.