Oxygen Compressor Foundation Investigation and Repair

When bearing clearances measure below specification, component replacement seems the obvious solution. But at this industrial gas facility in Greece, comprehensive foundation diagnostics revealed that structural defects, not mechanical wear were forcing the compressor out of alignment.

This case study demonstrates how proper root cause investigation provided a more effective and economical solution than treating symptoms.

Features

Client

Industrial Gas Plant

Project

Foundation assessment, core drilling, epoxy injection, precision regrout, and alignment stabilisation

Equipment

BURCKHARDT 4D250B Oxygen Compressor

Work period

Winter 2025

Location

Greece

01 The Problem

Initial assessments suggested mechanical wear, but Alphatec’s investigation revealed a more complex underlying cause.

Comprehensive diagnostic measurements uncovered severe foundation deficiencies:

Soft foot conditions at all four bed plate corners ranging from 0.04mm to 0.17mm, exceeding Burckhardt’s maximum tolerance of 0.05mm
Multiple cold joints throughout the foundation structure indicating defective multi-layer construction
Extensive voids, cracks, and porous corners compromising structural integrity
Historical clearance data confirming the issue had persisted throughout the equipment’s operational life

The critical diagnostic insight came when measurements were taken with the bed plate loosened. Bearing clearances improved significantly, confirming that the foundation was forcing the equipment into a stressed position. The root cause was foundation-induced stress, not mechanical wear.

02 The Solution

Alphatec’s diagnostic-led approach integrated three technologies to provide complete structural and alignment restoration:

Deep structural repair – Core drilling to 1m depth across identified cold joints, followed by pressure injection of Alphatec®342 epoxy resin to stabilise stress cracks and bond concrete layers throughout the foundation structure
3D laser measurement system – Established precise reference points before dismantling, creating an exact positioning map for reinstallation to within 0.001 inch tolerances
Hydraulic alignment technology – Alphapad support systems provided micro-adjustment capability during the grouting process, eliminating traditional shimming tolerances and associated alignment uncertainties
Precision foundation regrout – Alphatec®800 high-performance epoxy grout installation with comprehensive surface preparation and controlled curing to 80 D-Shore hardness specifications

04 Results and Benefits

This project demonstrates Alphatec’s diagnostic-led methodology for complex foundation failures. Rather than addressing surface symptoms, comprehensive investigation identified root causes, multi-layer construction defects and cold joints that required deep structural repair before surface grouting could provide lasting results.

The investigation revealed that bearing clearance issues stemmed from foundation-induced stress rather than mechanical wear. This shifted the repair strategy from component replacement to structural correction providing a more effective and economical solution that addressed the actual problem. Grout achieved 85-90 Shore D hardness across the foundation surface, confirming proper cure and structural integrity.

The completed foundation repair eliminated the forced alignment condition, allowing the compressor to operate with proper bearing clearances and load distribution.