In the modern highway construction, there are more and more pre-stressed bridges. The quality of pre-cast beam is the key of bridge construction. Because the pre-cast beam’s pre-stressing is not accurate and pipe grouting is not compacted in traditional construction, KATTOR technical team researched and developed the advanced technology of intelligent tensioning and large circle grouting for pre-stress beam, changed artificial factors in traditional construction, such as oral communication during operation, quality check by eyes, manual data record and so on. Through wireless sensing technology, computer 

control, standardized operation in whole construction process, Ensure stability of pre-

stressed beam, improve the safety and durability of beam structure. 

• Continuous circulation of full slurry ensure the air is completely discharged from the pipes
• Control pressure and adjust flow accurately 
• Control water-binder ratio accurately 
• Grouting two holes one time, High speed slurrying, high efficiency 
• Standardized mixing time
• Wireless controlling and monitoring
• High integration system, simple and easy for operation

CGS is composed of slurry-making system, grouting system, measuring and controlling system, cycle loop system. Cycle loop system composed of pre-stress pipe,slurry making machine,grouting pump,

Slurry is circulating continuously to discharge air completely in the pipe, detect pipe blockage in time, then increase pressure to flush pipe hole, ensure compacted grouting.

Equipped with precise sensors in the pipe inlet and outlet, to real-timely monitor and feedback pressure to system mainframe for analysis and judgment, measuring and controlling system adjust pressure

accordingly, ensure grouting process meets indicators of construction technical specification, such as slurry quality, pressure value, pressure holding time, to achieve full and compacted grouting.

According to the stability of pressure difference between slurry inlet and outlet within a 

certain time, system mainframe can judge the fullness and compactness of pipe.

Comparison item

Traditional grouting 

CGS

Discharge air in pipe 

Traditional grouting exhaust air by natural 

slurry flow,vacuum grouting can not 

reach real negative pressure

 because of sealing anchor problem

Continuous circulation of full slurry

 ensure the air is completely discharged 

from the pipes

Pressure value and 

pressure holding time 

Unstable pressure at the slurry outlet, 

and cause uncompacted grouting

Automatically adjust the pressure, 

ensure pressurevalue and holding time

 within the specified requirements

Control method

Manual control of water-adding is not strict, water-binder ratio is not accurate.

Automatic water adding device ensure the accuracy of 

water usage and water-binder ratio.

Test actual pressure 

in pipe

Low position inlet and high position 

outlet,can not stop during grouting 

process, 

operation is difficult

Closed circulation loop solve these 

problems,simple technology, easy 

to operate

Work efficiency

Grouting one hole one time

Grouting two holes one time double 

work efficiency 

Data record 

Manual record, unavoidable error.

Automatic record whole grouting process

Quality management

Difficult to understand the real quality 

conditions and grouting compactness 

quality tracing for better understanding 

of the whole grouting process,

 improve management level

Grouting comparison of a highway box girder(25m)

Grouting comparison of a highway hollow slab