Foundation assessment and core drilling
A comprehensive evaluation of the damaged foundation was performed to identify cold joints, voids, and cracks. Core drilling was then conducted to enable the precise injection of high-performance epoxy grout.

Epoxy regrouting
By replacing old, weakened grout with high-strength, chemical-resistant epoxy grout, we stabilized the foundation. This material was specifically chosen for its superior compressive strength and durability under demanding industrial conditions.

Equipment allignment and stabilisation
Prior to grout application, both the motor and gearbox, as well as the ID Fan, were accurately aligned. This ensured that any pre-existing misalignment and excessive vibration issues were effectively mitigated.

Structural degradation
The foundation exhibited multiple cold joints, extensive voids, and cracks, which compromised the operational safety and efficiency of the cement mill drive systems and the ID Fan.

Equipment misalignment and vibration
Misalignment and increased vibration levels were impacting performance, necessitating a comprehensive solution that addressed both structural reinforcement and precise realignment of heavy machinery.

Rigorous quality demands
Given the critical nature of the installation, the project required strict quality assurance, including continuous monitoring, frequent alignment checks, and adherence to best engineering practices throughout all phases.

Preparation and planning
Initiated with detailed safety briefings, visual inspections, and a thorough review of the necessary tools and materials, setting the stage for a well-organized execution phase.

Execution phase

Core drilling and concrete removal:
Core drilling allowed for controlled removal of deteriorated concrete, clearing the way for high-performance epoxy injection.

Precise alignment:
Equipment alignment was carefully verified before constructing formwork and placing the new epoxy grout, ensuring optimal stabilization.

Epoxy grout application:
A customised formulation of epoxy grout was poured into the prepared cavities, allowed to cure, and then subjected to rigorous quality checks.

Quality Assurance and Control

Throughout the project, continuous monitoring and regular alignment checks helped maintain adherence to the highest standards of quality, ensuring that the regrouting process met all operational safety and performance benchmarks.

Enhanced operational efficiency
Post-regrouting, the plant experienced a notable reduction in vibration levels and improved alignment stability. This resulted in increased operational uptime and reduced maintenance costs.

Extended equipment lift
The robust, chemical-resistant epoxy grout significantly extended the service life of the motor, gearbox, and ID Fan foundations, ensuring reliable performance under high-demand conditions.

Improved safety and sustainability
By stabilizing the structural integrity of key equipment foundations, the project contributed to a safer operating environment and supported the long-term sustainability and profitability of the plant.