Disintegrator Grouting and Epoxy Resin

In Spring 2019, Alphatec Engineering was commissioned by Cargill Deutschland GmbH in Barby, Germany, to rehabilitate the mounting system of a Drytec Disintegrator.

The disintegrator, powered by a 2.2 MW Siemens electric motor installed in 2007, was suffering from increased vibration due to foundation issues.

Features

Project

Regrout, Epoxy Resin Injection , Skid Base and Support Beams Filling with Cementitious Grout

01 The Issue and Remediation Strategy

The mounting system’s vibrations were traced to a deficient foundation. The existing cementitious grout was not connected to the machine frame but rather left the equipment solely supported on steel chocks under the anchor bolts, which exacerbated the vibration problems.

To address this, our specialists proposed a dual-step solution: first, inject epoxy resin to fill voids and cracks, and then regrout with high-performance epoxy grout to restore the foundation’s integrity.

02 The Repair Process

Our team began by removing the outdated cementitious grout, discovering that its lack of contact with the machine frame compromised support.

Hydraulic jacks and Alphapads® were deployed to safely support the machine and facilitate grout removal. To consolidate the foundation, six injection holes were drilled—two vertical holes on each side of the machine and one diagonal hole underneath.

These holes connected the 150 mm thick machine slab with the 1000 mm ground slab, and were prepped by inserting high-tension steel bars, injection copper tubes, and quartz sand.

Following this, our ALPHATEC® 342 epoxy resin was injected under high pressure to fill any discontinuities, creating a monolithic and stable structure.

03 Final Adjustments and Outcome

Once the resin injection stabilized the structure, formwork was installed and sealed using ALPHATEC® 240 Epoxy Putty. The support beams and the underside of the disintegrator were then filled with ALPHATEC® 440 to ensure a seamless bond with the new cementitious grout.

Final measurements, adjustments, levelling, and alignment were performed before pouring the ALPHATEC® 800 High-performance Epoxy Grout. The process filled all cold joints, cracks, and separations in the concrete, and was followed by anchor bolt tightening and thorough site cleanup.

Hardness testing of the epoxy grout confirmed values between 82 and 95 Shore D, indicating excellent performance and durability.

This rehabilitation significantly reduced vibration levels and ensured the reliable operation of the Drytec Disintegrator, securing the production process and overall equipment performance.