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As machines get older, they can experience a range of problems that can impact their stability and efficiency. One of the main issues that ageing machinery faces is a weakened foundation. Over time, the old foundation of a machine can become unstable due to factors such as wear and tear, changes in the environment, and increased loads. This can lead to a range of problems, from reduced efficiency to safety hazards.

Why is Stability in Machinery so Important?

Stability is crucial for the safe and efficient operation of machinery. An unstable and old foundation can cause the machine to vibrate excessively, which can lead to damage and premature wear and tear, resulting in more frequent maintenance and replacement costs. 

It can also cause parts to become misaligned or come loose, leading to breakdowns and unplanned downtime. Additionally, unstable machinery can be a safety hazard for operators and anyone else in the vicinity. Studies have shown that misalignment in heavy machinery can result in energy losses of up to 10%. 

On the other hand, properly aligned machinery can increase efficiency, reduce maintenance costs, and prolong the lifespan of machinery. For example, a study by the Department of Energy found that properly aligned pumps can reduce energy consumption by up to 7%.

What Problems Can Old Machinery Foundations Have?

Old machinery foundations can experience a range of problems, including 

• cracking
• settling
• shifting

These issues can be caused by a variety of factors, including changes in the soil or environment, exposure to moisture, and wear and tear from the machinery itself. Over time, these problems can lead to a weakened foundation that is unable to support the weight and vibration of the machinery.

What Techniques Can be Used to Stabilise Old Machinery Foundations?

There are several techniques that can be used to stabilise old machinery foundation. One technique for restoring stability to aging machinery is laser alignment. 

Laser alignment involves using a laser beam to measure and correct the alignment of machinery components. By aligning machinery components properly, businesses can improve the stability and performance of their equipment and reduce the risk of breakdowns.

Another technique for restoring stability to ageing machinery is vibration analysis. Vibration analysis involves using specialised equipment to measure the vibration levels of machinery components and identify any potential issues that may be affecting performance or stability. By detecting and addressing these issues early on, businesses can prevent further damage to their machinery and improve its reliability.

As machinery ages, it is not uncommon for the grouting and anchor bolts to wear out or become damaged. In some cases, replacing the grouting and anchor bolts may be necessary to restore stability to the machinery. This process involves removing the existing grouting and anchor bolts, preparing the surfaces, and installing new grouting and anchor bolts. It is important to ensure that the new grouting and anchor bolts are compatible with the machinery and that they are installed correctly to avoid further stability issues. In some cases, additional modifications may also be necessary to ensure the long-term stability of the machinery.

To see this type of work in action, check out the repair of a Sag Mill foundation here.

In addition to these techniques, regular maintenance and inspections are critical for identifying and addressing issues with ageing machinery. By performing routine maintenance and inspections, businesses can catch issues early on and take proactive steps to restore stability and prevent breakdowns.

How Alphatec Engineering Can Help

At Alphatec Engineering, we specialise in providing solutions for ageing machinery and infrastructure. We have years of experience working with a variety of industries, including oil and gas, manufacturing, and mining. Our team of experts can assess the specific needs of your machinery and develop a customised solution to restore stability and efficiency.

Contact us today to learn more about our services and how we can help you revitalise your old foundations.

I’m Giles Goldsbro, the technical director of Alphatec Engineering. Alphatec Engineering has a unique history that started in Japan in 1977. At that time, I had been working with construction epoxies for a few years while I was still at Exxon Chemicals. I realised that there was a thriving epoxy grout business in North America focused on natural gas engine compressors, but there was nothing like that in Asia. 

Giles Goldsbro, Technical Director, Alphatec Engineering

While exploring business opportunities in Asia, we discovered that the epoxy grout market was not yet established. But, we identified diesel engine driven generator sets as a potential alternative with similar challenges. We decided to venture into this market and quickly realised its potential for growth. Our experience in working with diesel engine driven generator sets led us to expand our focus to include other types of reciprocating and rotating machinery, as well as hydrogen compressors, among others.

Today, our expertise lies in pairing machinery with concrete, whether it be a concrete foundation or an industrial structure primarily made of reinforced concrete. This specialisation defines us, and we continue to offer customised products and services to meet the unique needs of each client.

 What Is Alphatec’s Main Activity?

 Alphatec Engineering is a company that specialises in resin and grout installations of machinery foundations, as well as the repair of machinery foundations. 

Our core expertise lies in the use of grout to effectively connect machinery to concrete foundations, whether it be a standard concrete foundation or a reinforced concrete industrial structure. Essentially, we address machinery problems by addressing the foundation they sit on.

Grout is a type of mortar that is specially formulated to provide a secure, stable, and durable connection between the machinery and the concrete. This is crucial because it ensures proper alignment of the machines, which in turn prevents vibration, excessive wear and tear, and other issues that can lead to premature failure of the machinery.

Aside from our grouting services, Alphatec Engineering also offers a range of other products and services. For example, we provide solutions for repairing cracks and other damages in concrete foundations, which can extend the lifespan of the machinery and prevent more severe issues from arising. Additionally, we offer specialised coatings that protect machinery from corrosion and other types of damage.

At Alphatec Engineering, we are dedicated to providing high-quality solutions for machinery foundation challenges, ensuring that our clients’ machinery operates optimally and reliably for long-term performance.

What Does Alphatec Engineering Specialise In?

Alphatec Engineering specialises in offering comprehensive solutions for machinery installation and repair. Our focus is on providing customised products and services that are tailored to meet the unique requirements of each client. With our expertise in this field, we have earned a reputation as a trusted partner for businesses across diverse industries, such as manufacturing, energy, and many others. We pride ourselves on delivering reliable and high-quality solutions that help our clients achieve optimal performance and efficiency for their machinery installations.  

What are Alphatec Engineering’s Star Products? 

In addition to providing solutions for machinery foundations, our product range is designed to provide effective and durable solutions for machinery installation and repair. And we have the expertise to tailor our products to meet the specific requirements and expectations of our clients. With our high-performance grouts and polymer systems, we ensure that machinery foundations are properly supported, repaired, and protected, helping our clients achieve optimal performance and longevity for their machinery installations. Our key products include: 

• ALPHATEC® 800, a high performance, aggregate-filled epoxy grout with superior mechanical and chemical properties. This grout material has been specifically formulated to support heavy machinery on concrete foundations, and when used correctly, will ensure the transfer of static and dynamic loads into the inertia block. 
• ALPHATEC® 110 is a three-component polymer grout system consisting of modified epoxy resin, chemical hardener, and blended aggregate. It is especially formulated for rapid curing. In the last few years, ALPHATEC® 110 has been used successfully in major refineries and petrochemical plants throughout Europe during winter shutdowns. 
• ALPHATEC® 342 is a two-component polymer grout injection system consisting of modified epoxy resin and chemical hardener. It is specially formulated for moisture and oil tolerance, and shows exceptionally good bond to wet, submersed, and oil-soaked concrete. It is widely used for the repair of water-soaked concrete foundations for presses, rolling mills, and rails, as well as for the repair of underwater or immersed structural concrete. It also performs well in the repair of all types of rotating machinery foundations, where oil contamination is inevitable. 

Would Alphatec like to collaborate?

 At Alphatec Engineering, we are committed to supporting the growth of green businesses and advancing sustainable technologies. We recognise the vital role that hydrogen and wind energy play in this effort, and we are actively seeking to expand our capabilities in these areas.

We are proud to provide specialised services and solutions to support the development and maintenance of renewable energy infrastructure. We believe that investing in these technologies is not only good for the environment, but also presents significant economic opportunities for our clients and partners.

Research and development are essential components of our business, and we are committed to staying at the forefront of innovation in our industry. To this end, we are interested in forging partnerships with universities and research institutions to enhance our capabilities and expand our knowledge base. 

In particular, we are seeking to build our research capabilities in areas such as fatigue resistance, where we recognize the need for more advanced testing techniques. By collaborating with academic partners, we hope to not only improve our own products and services, but also contribute to the broader advancement of our industry.

If you would like to find out more, collaborate or see if we have the right service or product for you, reach out here!