Fiberizer - Regrout and Foundation Repair

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In the paper industry, fiberizers are essential machines that play a crucial role in the production process. These powerful machines are designed to break down raw materials into fibrous components, forming the backbone of paper production. However, to ensure the smooth operation and longevity of fiberizers, the stability and integrity of their foundations are of paramount importance.

Fiberizers, also known as defibrators, are precision machines that use rotating discs or beaters to mechanically disintegrate raw materials such as wood chips or recycled paper. The resulting pulp serves as the basis for creating high-quality paper products. The performance and efficiency of fiberizers heavily rely on the strength and stability of their foundations.

A robust foundation provides the necessary support to absorb the vibrations, shock loads, and mechanical forces generated during the intense operation of fiberizers. It ensures proper alignment, reduces vibrations, minimises the risk of structural damage, and contributes to the overall efficiency of the machine.



Features

Client
Essity Prudhoe
Final user
Essity Prudhoe
Project
Regrout and Foundation Repair
Equipment
Fiberizer
Work period
June 2023
Location
Newcastle, United Kingdom

The significance of a well-designed and well-maintained foundation for fiberizers cannot be underestimated. An unstable foundation can lead to a range of issues, including increased vibrations, misalignment of components, accelerated wear and tear, elevated maintenance requirements, decreased productivity, and safety hazards for operators.

To address these challenges and optimise fiberizer performance, paper manufacturers must prioritise foundation stability. By employing best practices in foundation design, construction, and maintenance, organisations can ensure the longevity, reliability, and efficiency of their fiberizer operations.

 

The Problem and Solution

 

Problem: Essity Prudhoe faced issues with the foundation of their fiberizer, as the cement grout had detached due to improper installation and lack of surface preparation. This resulted in excessive vibrations and compromised foundation integrity.

Solution: Alphatec Engineering was contacted on an emergency basis and efficiently mobilised to the site within two weeks. They proposed a solution to address the foundation issues to ensure long-term stability.

 

The Procedure

 

Upon arrival at the site, the team from Alphatec Engineering assessed the existing foundation and identified the issues related to the detached cement grout. To rectify the problem, they followed a systematic procedure:

Removal of Cement Grout: The team carefully removed the approximately 50mm detached cement grout from the foundation. This process involved using specialised tools to ensure thorough removal without causing any damage to the foundation or surrounding components.

Foundation Preparation: After the cement grout removal, the foundation required proper preparation to create an ideal surface for the installation of the new grouting material. The team meticulously performed surface scabbling and prepared the foundation by removing any debris, contaminants, or irregularities.

Alphatec 800 Epoxy Grout: Alphatec Engineering selected Alphatec 800 epoxy grout as the replacement material for the foundation. This high-quality epoxy grout offers excellent bonding properties and superior durability. The team mixed the epoxy grout according to the manufacturer’s instructions, ensuring accurate ratios for optimal performance.

Reinstallation of the Fiberizer: With the foundation prepared and the epoxy grout ready, the team reinstalled the fiberizer using precise positioning techniques. They ensured proper alignment and securely anchored the machinery to the foundation, taking into consideration the operational requirements and load distribution.

Curing and Quality Assurance: After the installation, the epoxy grout required a curing period to achieve its full strength. The team closely monitored the curing process, ensuring the appropriate curing time and environmental conditions were maintained. This step was crucial for establishing a strong and reliable bond between the foundation and the machinery.

Testing and Verification: Once the epoxy grout had fully cured, Alphatec Engineering conducted rigorous testing and verification procedures to ensure the stability and integrity of the foundation. This involved assessing vibration levels, alignment, and functionality to confirm that the fiberizer was operating within permissible limits and that the foundation was stable.

 

Conclusion

 

Through a systematic and meticulous procedure, Alphatec Engineering successfully addressed the foundation issues of Essity Prudhoe’s fiberizer throught its successful foundation regrout and repair. The thorough removal of the detached cement grout, proper foundation preparation, and use of Alphatec 800 epoxy grout ensured a stable and durable foundation for the machinery. 

The team’s expertise, attention to detail, and adherence to industry best practices played a significant role in restoring the fibrizer’s functionality.