1.1 This compressor, originally installed in 1978, had been suffering from vibration and misalignment
problems for several years. In an attempt to correct these problems, some partial
regrouting had been carried out, but with cement-based products.
1.2 Alphatec Engineering, together with Pignone Española, offered a complete and comprehensive
repair of the foundation by the pressure injection of epoxy adhesives and high tensile strength steel
reinforcement, removal of the existing grout under both compressor and motor, support of the
compressor in its existing position, re-alignment of the compressor with jacking screws, and
placement of epoxy grout to properly support the compressor base, and motor bedplate.
1.3 When the motor was removed for overhaul, it became apparent that considerable corrosion of the
baseplate had taken place, which exacerbated the alignment problems. Since a complete regrout
of the baseplate was not feasible, the grout was chipped out to about 50 mm from the inside edge,
to allow for seal grouting all round. Corrosion inhibitors were injected to stabilize the position
of the bedplate.
1.4 Corrosion of the rebar in the vicinity of the high tension cabling to the motor was also discovered,
and rectified with a corrosion inhibiting repair system.
1.5 Confirmation of the compressor alignment, and final alignment of the motor to the compressor,
was carried out by Pignone Española.
1.6 The alignment of the compresor should now be close to original specifications, and the epoxy
grout can be expected to maintain the position of the bedplate, and thus the alignment, for 15 to
1.7 Cracks and cold joints in the foundation were repaired by epoxy injection.