Factors Influencing Sleeve Grouting Quality for Prefabricated Building: An Interpretive Structural Modeling Approach

Abstract

The defect in quality caused by the noncompactness of sleeve grouting has become the main obstacle restricting the further implementation of the prefabricated building in China. Studies have been conducted to explore the influencing factors of inadequate grouting; however, few studies attempt to investigate the complex interrelationship and lack of systematic cognition among these factors. To fill this gap, this study conducted a comprehensive literature review to collect the influencing factors of sleeve grouting and verified the reliability of these factors using the combined methods of brainstorming and semistructured expert discussion. A total of 18 key factors were identified and determined. The structural interpretation model (SIM) and Matrice d’Impacts Croisés Multiplication Appliquée à un Classement (MICMAC) approaches were then used to analyze, depict, and explain the internal relationships between the factors. The results indicate that all factors were classified into six levels, among which poor responsibility of supervisors and weather conditions are the most basic factors, while grouting speed and a loose-sealing rubber plug are the most important factors. Finally, a three-level control strategy was proposed to improve the compactness quality of sleeve grouting. The research findings provide valuable guidelines for managers to eliminate the grouting quality defect and to further the development of prefabricated buildings in China.

This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.

1. Introduction

In recent years, prefabricated buildings have been widely adopted in China due to their preferable characteristics in the construction stage compared to the traditional cast-in-place construction [1–4], which is mainly assembled on-site using prefabricated components that are connected using the vertical sleeve method [5–8]. The specific grouting process flow for prefabricated node connections is as follows: the reinforcement of the butt joint is conducted in the sleeve; then, the rapidly hardening nonshrinkage grouting material is injected to ensure the reinforcement connection of the upper and lower components. However, quality defects for sleeve grouting commonly exist in practical construction engineering that has directly impacted the bearing and deformation capacity of the components [9–11], thereby compromising the whole prefabricated building [12]. Zhao et al. [13] observed that the bearing capacity can be reduced by up to 30% when a defect in grouting quality occurs [14]. Therefore, the construction of a prefabricated building using sleeve grouting as the main component connection method must follow specific requirements to ensure the connection quality performance [15–17], not only to improve the connection technology [18–20], but also to control the influencing factors of the whole grouting construction process.

China issued the national industry standard, named technical specification for grout sleeve splicing of rebars (No. JGJ 355-2015), requiring that sleeve grouting should be compact, which further emphasizes the importance of process quality control for sleeve grouting. In the proposed research, a practical experiment was conducted to determine the current state of grouting quality [21, 22], and three demonstration prefabricated construction projects were selected as the experimental targets located in Tangshan, Beijing, and Haimen. These three cities, located in the north, central, and south of China, were selected for demonstrating the promotion of prefabricated buildings. Taking into account the regional differences, the level of grouting quality of the prefabricated building can be roughly reflected by the experimental results. A kind of redesigned sensor is embedded in the sleeve to collect grouting compactness data [23]. The average algorithm of a normal distribution is applied to calculate the overall quality level, and at least 30 sensors are required to be estimated in each targeted building to ensure the results’ accuracy [24]. In each project, the researchers selected at least three buildings for testing. To reduce the error caused by the construction height, experiments were carried out on the lowest floor, the highest floor, and the middle floor of each building. Notably, it was found that the quality problem regarding the insufficient compactness of sleeve grouting is serious (shown in Figure 1). The experiment followed a two-step process. First, when the grouting workers completed the sealing of the grouting mouth, the condition of the sleeve grouting was tested immediately. It was found that the qualification rates of the three sample projects were 93.1% (P11), 93.10% (P21), and 89.66% (P31), respectively. Then, the grouting compactness of the three projects was tested again 30 minutes later, which is the maximum time interval for supplementary grouting before the initial setting of grouting materials specified according to the standards. And it was found that the qualification rates decreased to 48.28% (P12), 58.62% (P22), and 62.07% (P32). The average qualification rate was 56.32%, which is significantly lower than the national compulsory requirements. Thus, it is urgent to determine the causes of grouting quality defects to improve the prefabricated building quality [16, 25].

[figure omitted; refer to PDF]

At present, several studies have been conducted to explore sleeve grouting defects. The research focus can be roughly divided into two categories. The first category is the technical route. For example, Zheng et al. [26] proved that grouting defects can reduce the seismic performance of the structure. Kuang et al. [27] found that grouting defects lead to a decrease in bearing capacity, rigidity, and ductility of the assembled concrete columns. Li et al. [28] discovered that grouting defects can lead to peeling damage between the reinforcement and the grouting material, or the reinforcement will be pulled out by a scraping plow. These technical problems continue to be studied and explored [29, 30]. The second category is the management route, referring to the defect control analysis conducted by exploring the management measures that have been applied [31]. For example, Xiong et al. [32] analyzed the factors influencing the strength of grouting materials. Jin et al. [33] studied the temperature effect on the performance of grouting material. However, based on the literature, most studies lack a systematic cognition for quality defect control, and few studies attempt to investigate the complex interrelationship among these factors.

The proposed study aims to fill this gap of lacking systematic cognition among quality defect factors and their complex interrelationship. A mixed-method approach is used for data processing and result analysis combined with Interactive Structural Modeling (ISM) and Matrice d’Impacts Croisés Multiplication Appliquée à un Classement (MICMAC). The objectives of this study are threefold: (1) to identify the critical influencing factors of sleeve grouting defects in China’s prefabricated construction industry; (2) to clarify the hierarchical relationship and action path among these factors; and (3) to explore the causes of sleeve grouting defects and propose the quality defect control measures and corresponding management strategies.

2. Research Method

A three-step research method is designed to achieve the research objectives (as shown in Figure 2). First, factors affecting the sleeve grouting compactness are identified by using the literature review and analysis approach. Second, key influencing factors are identified utilizing a screening process. A brainstorming session is conducted to determine the definition of each factor. Then, expert interviews are conducted to screen and supplement the preliminary factors, and a final key factors list is determined. Third, the expert rating approach is followed to ascertain experts’ perceptions about the interrelationships among the factors. The adjacency matrix and the reachability matrix are constructed using the ISM technique, and the hierarchy structure is depicted after checking the transitivity through the power iteration analysis. Finally, these influencing factors are classified into four categories according to each factor’s driving power and dependence power using the MICMAC technique, and the specific reasons, control measures, and management strategies for quality defects are discussed in detail.

[figure omitted; refer to PDF]

By combining the graph with the final reachability matrix, the relationships among 18 factors of the ISM model can be obtained, as illustrated in Figure 7.

[figures omitted; refer to PDF]

4.2.4. MICMAC Analysis

The driving force and dependence force of each factor can be calculated based on the reachability matrix, forming a two-dimensional MICMAC diagram, as illustrated in Figure 8. Four groups are formed, that is, (i) the independent variables with low driving force and dependence, (ii) the dependent variables with low driving force but high dependence, (iii) the driving variables with high driving force but low dependence, and (iv) the related variables with the high driving force and dependence. In general, the strong dependence of a factor indicates that its solution depends on the solution of other factors, while the strong driving force indicates that the solution of the factor can help resolve other factors.

[figure omitted; refer to PDF]

It can be observed that all factors are divided into three categories, including driver variables, autonomous variables, and dependent variables, as shown in Figure 6, and there is no relay factor. (i) F1, F2, F12, F14, F16, F17, and F19 are driving factors; (ii) F5, F9, F13, and F18 are self-influencing factors; (iii) F6, F7, F8, F11, F15, and F20 are dependent factors. The factors belonging to different levels are marked with different colors, as shown in Figure 6. It can also be observed that the distribution of all factors indicates a downward trend from the upper-left corner to the lower-right corner, which is consistent with the ISM model structure diagram. The factors at the bottom of the structure have strong driving power and low dependence, while the factors at the top level have stronger dependence and lower driving power. Different factors have different parameter characteristics, which determine that different corresponding strategies need to be formulated in the process of eliminating quality defects.

5. Discussion

5.1. Results Analysis

To further analyze the influence mechanism of each factor, a combined approach is proposed to analyze the driving and dependence power based on the MICMAC technique and ISM hierarchy. As a result of the proposed study, the relationships between factors can be understood more effectively, and coping strategies can be formulated.

5.1.1. Driver Variables

F1 and F17 have the highest driving power and are located at the bottom of the ISM structural diagram (Figure 5), which means that the two factors are relatively independent and experience no interference from other factors. Attention should be paid to the grouting process. In practical prefabricated construction, supervision is the most critical part of quality control, and weather conditions are often neglected factors. Although detailed construction rules have been developed, third party supervisors often overlook the environmental impact within the scope of quality control. Currently, video technology is required to be applied in some projects to achieve quality control after a quality control issue and to analyze the irregular behavior of workers.

For the factors F2, F12, F14, F16, and F19, the total driving force index reached 70, accounting for 48.61% of the total, and the coverage rate of factors affected reached 77.78%. More attention should be paid to achieving maximum quality improvement benefits with less resource consumption. For example, for F2, it is necessary to increase the professional training of workers and strengthen the management of workers’ turnover; for F16, the advanced auxiliary technology can be used for grouting quality control defects, such as the simulation for guiding the construction of BIM technology, the grouting compactness measurement of sensing technology, the detection application of hollow defects in the sleeve using ultrasonic technology, and so on.

5.1.2. Autonomous Variables

The factors for autonomous variables are mainly concentrated in the fourth layer of the ISM and have low driving or dependence power and large dispersion. The mental state of workers (F18) should be taken as a key factor in improving quality and efficiency. Studies have shown that the output of workers who have been working several hours (such as 5 hours) in a row is lower than when they have been given regular breaks. The fatigue level monitoring and health management of workers have been widely applied in the machinery production and craft industry and can be used as references in the prefabricated building construction industry for grouting workers. A reasonable construction plan and more attention to the mental state of workers are important to ensure the quality of grouting operation.

F5 and F9 have lower driving and dependence power. The inadequate protection measures (F5) and quality problems of raw grouting materials (F9) belong to the front end of the influence chain and are relatively independent; furthermore, these factors can be avoided by adopting some quality inspection measures in advance.

F13 is a specialized transitional factor that changes from passive influence to active influence, while other factors at the same level belong to dependent variables. The unstandardized grouting process mainly refers to the failure to strictly follow the published construction method when grouting, such as plugging the channel ahead of time, not plugging the channel in time, not checking the grout density, etc. The stronger attribute of dependence than driving power indicates a greater influence from other factors, such as the mental state of workers (F18), poor responsibility of supervisors (F1), construction technology with insufficient accuracy (F14), and lack of experience of workers (F2).

5.1.3. Dependent Variables

F6, F8, F11, F7, and F10 derive from different ISM hierarchy; they are dependent variables but have relatively high driving forces, indicating that their quality problems are dependent upon the resolution of other underlying factors, for example, ash not cleared in time (F7) and need to strengthen protection measures (F5), increase worker experience (F2), enhance the sense of responsibility of quality supervision (F1), and so on. Also, the second-level factors (F6, F8, and F11) and third-level factors (F7 and F10) have an internal connection; for example, inadequate fluidity of grouting material (F11) is related to ash clearing in the component base and grouting port (F7) and the complete standing exhaust of slurry before grouting construction (F10). Therefore, taking these factors into account can not only test whether the quality control of the lower-level factors is effective but also effectively control the upper-level factors.

F15 and F20 are the strongest dependent variables located in the first layer of the ISM hierarchy, where the single dependent power is 18 and driving power is 2. In the sleeve grouting construction process, the rubber plug that blocks the grouting channel is often removed for some nonstandard operations, and as a result, the grouting material flows out of the channel. Besides, if the grouting speed (F20) is too rapid, a series of quality defects can be caused, such as empty drum, noncompactness, rubber plug loose (F15), among others. In the current construction industry, the effective control of grouting speed (F20) and preventing the rubber plug from falling off (F15) have become the two most critical technical issues. The characterization of highly dependent power indicates that the resolution of the technical issues largely depends on the control of the underlying factors, such as improving the mechanical performance of grouting (F12), applying auxiliary information technology to quality defects at the early warning signs (F16), eliminating adverse effects of the working environment (F19), strengthening the construction process management (F1, F5, F7, F9, F10, etc.), and so on.

5.2. Recommendations

Based on the analysis of the results of this research, the mechanism and implication of each key factor have been clarified. Furthermore, to improve the quality of sleeve grouting construction, a three-level quality control strategy is proposed for the relevant enterprises and technical personnel.

(1) The first level of the control strategy is mainly aimed at the fifth- and sixth-level factors. These factors will not directly lead to grouting defects but will affect other factors. Suggestions are made as follows: (i) the supervisory personnel should be required to improve their sense of responsibility by adopting some regulatory measures. (ii) The impact of weather conditions on construction quality should be emphasized to avoid forced construction in poor conditions in an attempt to accelerate the construction progress. (iii) The environmental conditions will damage any components that are stacked or stored in an exposed area; thus it is necessary to strengthen the protection measures of these components. (iv) In terms of construction capacity improvement, the construction equipment and technology should be continuously updated to improve the construction accuracy, efficiency, and quality, for example, the improved sleeve grouting technology for grouting speed and maintaining a stable pressure in the sleeve to reduce hollowing. (v) The workers should receive training to reach a certain level of professional skills before working on a real construction project; such training should include mastering the operational procedures, being familiar with machine performance, understanding the working environment, and so on.

(2) The second level of the control strategy is aimed at the fourth-level factors. It can be concluded from Figure 5 that these factors are directly related to other factors at other levels, which are the most basic quality defect control elements for sleeve grouting construction. Specific guidelines are recommended as follows: (i) establish a strict raw material quality inspection system and improve the inspection process, such as image and video data acquisition. (ii) It is necessary to improve the mobilization process of prefabricated components, arrange the component storage yard in an organized manner, and take protective measures for components that are stored in the open-air environment. (iii) To maintain the mental state of workers, it is necessary to formulate reasonable working hours with break time to maintain worker efficiency and wellbeing.

(3) The third-level control strategy mainly focuses on the prefabricated building component installation and grouting operation. According to the grouting process, several key quality control points need to be known: (i) check the component grouting channel and remove any debris to maintain an unobstructed slurry path; (ii) after the slurry is prepared according to the specified mix proportion, check the fluidity of the grouting material to ensure that the bubbles are completely discharged after letting it stand for the required amount of time; (iii) the sleeve and reinforcement shall be installed accurately to ensure that the verticality, anchorage length, and other parameters meet the quality requirements; (iv) check that the grouting joint is sealed tightly and meets the quality requirements of setting time required for grouting; (v) the grouting speed should be strictly controlled to avoid quality defects such as hollowing (too slow) and blocking (too fast); (vi) the outlet should be sealed firmly with wooden or rubber plugs immediately, thereby avoiding the grouting noncompactness due to slurry leakage caused by plug malfunction.

6. Conclusion

In recent years, the Chinese government has promoted the transformation of the construction industry to uphold a high level of quality and low level of pollution. From this foundation, prefabricated building construction and its key node connection technology have been developed. However, in practical application, the problem of sleeve grouting defects has been difficult to resolve. The quality influencing factors are complex and its action mechanism is unclear and lacks systematic identification and strategy analysis. This study identified 18 key factors of sleeve grouting noncompactness by applying a combined approach of literature review, brainstorming, and expert interview. The ISM method was then applied to structure the factors into a hierarchy of six distinct levels, and the MICMAC tool was used to classify the factor attributes, including seven variables, four autonomous variables, and seven independent variables. The results reveal the internal relationship among the factors affecting the quality of sleeve grouting, based on which a three-level strategy is recommended to facilitate the sleeve grouting process in China’s prefabricated building construction industry.

Some unique research highlights of this study include the following: (i) the single-factor sleeve grouting quality analysis is extended to the factor system and the internal relationship analysis of its factors; (ii) from the perspective of assigning importance to human and external environments, the factors related to the mental state of workers, working environment, and weather conditions are included in the factor system, and the corresponding strategic suggestions are made; (iii) each factor is analyzed from the aspects of structure position, driving force, and dependent force. Besides, the research method and results of this study are not limited to China’s construction industry. First, sleeve connection technology is widely used in other countries, such as Singapore and Japan, and grouting quality problems are common. Second, although different problems may be caused by different construction techniques and management methods in different regions, the methods and perspectives of this study could provide a useful reference for other economies to investigate the sleeve grouting quality barriers. Finally, more information technology needs to be applied and updated in the area of quality supervision to improve the quality of the construction process and construction products.

This study has limitations that should not be overlooked. First, the identified key factors are concerned with on-site construction, and the impact of other stages is not taken into account, such as the design defects. Second, the field investigation mainly focuses on the demonstration project, thereby lacking the application analysis of sleeve grouting technology in conventional prefabricated building projects. Third, due to the limitation of the ISM method, there is a lack of comprehensive analysis of all sleeve grouting quality factors.

Acknowledgments

This research was supported by the National Key R & D Program of China (grant nos. 2016YFC0701810 and 2016YFC0701800). The authors would like to especially thank the experts, scholars, and engineering construction personnel who participated in the research.

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