New Reciprocating Compressor Grouting

The Procedure

Our approach to new installations of foundations for machinery involves ensuring that the concrete block has the necessary integrity and is designed to effectively dampen vibrations, which is its primary purpose. This is achieved through a thorough analysis of the machinery’s requirements and the foundation’s design, as well as the use of high-quality materials and precise construction techniques. Our goal is to create a foundation that will provide optimal support for the machinery while minimising the risk of vibration-related damage or failure.

Initial Conditions

The foundations were strong, with an estimated volume of 123m3 and a mass of around 300 tonnes. This was considered sufficient for a reciprocating machine up to 3.0 MW, assuming the foundation was a solid block.

The concrete surface was well prepared by others. Jacking screw baseplates, measuring 300 mm square and 15 mm thick, were provided by the skid manufacturer and designed by the engineering company. This was sufficient for the task.

A small amount of ALPHATEC® 110 fast-curing epoxy resin was supplied for the jacking screw baseplates. There were a total of 28 M30 jacking bolts for adjusting the levels of the skids.

Anchor bolt holes, measuring 100 mm in diameter and 1300 mm in depth, had already been drilled into the foundation and seemed well executed. The anchor bolts, manufactured from 25CrMo4 steel, were M39 x 1300 mm. 14 compressor skid anchor bolts and six motor skid bolts were used.

The anchor bolts were wrapped with 4mm of PE foam and secured with PVC tape before mounting the skids on the foundation. The local Alphatec representative performed this task.

Preparation Prior To Pouring

Upon completion of the required HSE training course, our team of epoxy grout specialists were fully equipped to commence their work. Their first task was to grout the anchor bolt. Cone-shaped funnels were used to introduce the grout into the anchor bolt holes.

A total of 200 litres of ALPHATEC® 800 High-performance epoxy grout, was utilised for this purpose. Once the grouting process was completed, the heaters were activated and allowed to run overnight.

To prevent the grout from coming into contact with the jacking screws and the upper portion of the anchor bolts, they were covered with PE foam and PVC tape. The jacking screw baseplates were thoroughly cleaned to remove any oil contamination and compressed air was used to clean the entire surface.

Subsequently, the grout formwork was positioned to contain the poured grout material, reinforced with additional timber doublers, and the entire bottom edge was sealed with ALPHATEC® 240 epoxy putty.

Upon receiving approval from both the mechanical contractor and the owner’s engineers, the skid was declared ready for grouting.

Grouting Process

The grout mixture was poured steadily and evenly into place, making sure it touched all the skid surfaces it was supposed to support. Since some areas of the skid beams were not visible, the grout had to be piled up to ensure it flowed well in those areas.

Once one area was full and confirmed to be in contact with the skid flange, the grout pour moved on to adjacent areas. It took about four hours to pour all the grout, using a total of 1400 litres of grout.

After curing overnight, the grout was inspected and found to be sufficiently hard for the formwork to be removed, with a hardness between 82 to 95 Shore D. Then the jacking screws were removed, and the work area was cleaned up.

Conclusion

At Alphatec Engineering, we take great pride in our ability to provide exceptional services for new machinery installations. Our team of experienced professionals uses high-quality products, such as ALPHATEC® 800 epoxy grout, to ensure that your machinery’s foundation is built to last and perform effectively.

We take a comprehensive approach to every project, considering all aspects of the installation process, from preparing the concrete surface to securing anchor bolts and pouring grout. With our attention to detail and commitment to quality, we ensure that your machinery is properly supported and protected against unwanted vibrations.

Our expertise and dedication to customer satisfaction have made us a trusted name in the industry, and we are confident that we can provide the foundation services you need to get the most out of your machinery. Choose Alphatec Engineering for your next installation project and experience the difference that quality and professionalism can make.