Proper  industrial equipment installation begins with the foundation. Whether installing pumps, compressors, diesel generators, gas turbines, chillers, cooling towers, or transformers, precision foundation work and alignment are critical to equipment reliability. 

Improper installation accounts for 12-18% of all equipment failures in industrial facilities, with most installation-related failures occurring within the first six months of operation.

Why Foundations Matter for industrial equipment installation

Heavy industrial equipment generates significant forces during operation. Rotating equipment like pumps, compressors, and turbines create vibration that must be properly managed. Without a correctly prepared foundation, even minor vibration leads to misalignment, excessive wear, and premature failure.

The foundation must support the equipment’s weight whilst dampening operational vibration. A large chiller can weigh 25 tonnes or more, whilst transformers can exceed 45 tonnes. These loads require foundations designed specifically for the equipment’s characteristics.

The Critical Role of Epoxy Grouting

Traditional grouting methods using cement-based materials have significant limitations. Cement grout shrinks as it cures, creating voids under equipment baseplates. These voids allow movement and misalignment during operation.

Epoxy grout solves these problems. High-strength epoxy grout provides 100% contact between the equipment baseplate and foundation, eliminates shrinkage and voids, achieves full strength quickly, resists oil, chemicals, and water, and maintains precise equipment positioning.

For precision equipment like pumps and compressors, epoxy grouting is essential. The grout must fill completely under the baseplate whilst maintaining the exact alignment achieved during installation. Epoxy’s flowability ensures complete filling, whilst its high strength prevents any settlement or movement.

Precision Alignment Requirements

Equipment alignment directly determines reliability and service life. Misalignment of just a few thousandths of an inch causes premature bearing failure, excessive vibration, increased energy consumption, and shaft damage.

Professional alignment achieves the precision tolerances required by equipment manufacturers. Typical alignment specifications require accuracy within 0.05mm (0.002 inches). This level of precision is impossible to achieve with manual methods.

Shaft alignment between motors and driven equipment is particularly critical. A misaligned pump might fail in 2-3 years instead of lasting 15-20 years. Proper alignment from the start prevents these costly failures.

Foundation Preparation and Levelling

Before equipment installation, foundations must be properly prepared. The foundation surface must be level within 0.05mm per metre and clean, with no oil, loose material, or contamination. Any deviation from level must be corrected before equipment positioning.

We verify foundation levelness using precision instruments. If corrections are needed, we use epoxy grout to create a perfectly level mounting surface. Once level, the equipment can be positioned and aligned accurately.

Our Industrial Equipment Installation Process

Foundation Assessment We begin by verifying the foundation meets structural requirements for the equipment’s weight and operational forces. We check foundation levelness and identify any preparation needed.

Equipment Positioning Heavy machinery is carefully positioned using specialised rigging equipment. Initial positioning accounts for final grouting thickness and alignment requirements.

Precision Alignment Using precision alignment tools, equipment is positioned to manufacturer specifications. All measurements are verified and documented.

Epoxy Grouting Once alignment is confirmed, we install formwork and pour high-strength epoxy grout. The epoxy completely fills under the baseplate, locking the equipment in precise alignment. Epoxy cures quickly, typically allowing bolt tensioning within 24 hours.

Final Verification After grouting, we re-verify alignment to ensure the equipment remained in position. Anchor bolts are tensioned to specification, and final measurements are documented.

Industrial Equipment Installation We Specialise In

Our foundation and alignment expertise covers all types of heavy rotating and stationary equipment:

• Pumps and Compressors – Critical alignment requirements for reliable operation
• Diesel Generators and Gas Turbines – Precision mounting to control vibration
• Chillers and Cooling Towers – Structural support and alignment of rotating components
• Transformers – Proper positioning and secure mounting

Each equipment type has specific installation requirements. Our experience ensures we meet manufacturer specifications exactly. Contact us today!