The Problem

Existing Condition of Cement Mill and ID Fan Foundations

The Cement Plant was confronted with significant operational challenges stemming from the misalignment and increased vibration of two cement mill drive systems. These issues were traced back to the foundations of the electric motor equipment connected to gearboxes, indicating a deeper structural problem. 

The ID Fan foundation also presented structural concerns, undermining the plant’s overall efficiency and safety. Initial inspections underscored the urgent need for a comprehensive solution, recommending a strategic approach to regrouting in order to stabilise the equipment and foundation interface.

The Challenges

The deteriorated condition of the foundations posed several challenges, notably the presence of multiple cold joints and extensive voids and cracks throughout the concrete structure. Such defects not only compromised the operational efficiency of the cement mill and ID Fan but also posed significant safety hazards, threatening the continuity of plant operations and the well-being of onsite personnel.

The Solution

Regrouting with Epoxy Grout

In response to these challenges, a decision was made to employ high-strength, chemical-resistant epoxy grout for the regrouting process. This choice was predicated on the material’s superior compressive strength and enhanced longevity compared to traditional cementitious grouts.

Epoxy grouts are known for their robust performance in demanding industrial environments, offering resistance to chemical attack and providing a durable bond that significantly extends the service life of the foundations.

Customised Approach

Alphatec Engineering, leveraging its vast experience and specialised regrouting techniques, devised a customised solution tailored to the unique structural challenges faced by the Cement Plant. This approach combined advanced materials with precision engineering to ensure a successful outcome.

The Procedure

Preparation and Planning

The regrouting project commenced with an exhaustive planning phase, encompassing comprehensive safety briefings, meticulous visual inspections of the affected areas, and a detailed review of the necessary tools and materials. This preparatory stage was crucial in creating a solid start for the subsequent execution phase.

Execution

The execution phase unfolded systematically, beginning with core drilling to facilitate the injection of the epoxy grout and followed by chipping away the deteriorated concrete to prepare the surfaces for the new grout. Precise alignment of the equipment was ensured before the construction of formwork and the careful pouring of the epoxy grout, adhering strictly to best practices to achieve optimal results.

Quality Assurance and Control

Throughout the project, rigorous quality assurance and control measures were in place to monitor the progress and ensure adherence to the highest standards. These included regular monitoring of the work, various alignment checks, and compliance with industry best practices to guarantee the effectiveness of the regrouting work.

Conclusion

Operational Improvements

Post-regrouting, the Cement Plant experienced significant operational improvements, including a marked reduction in vibration levels, enhanced alignment stability, and an extension in the equipment’s operational life. These improvements have contributed to a more efficient and safe plant operation.

Strategic Benefits

The project delivered substantial strategic benefits, including improved plant safety, reduced maintenance costs, and increased production efficiency. These benefits not only enhance the plant’s operational capabilities but also contribute to its long-term sustainability and profitability.

Future Recommendations

In conclusion, it is recommended that continuous monitoring and maintenance be undertaken to ensure the longevity of the regrouted foundations. Additionally, potential areas for further improvement within the plant should be identified and addressed to continuously enhance operational efficiency.