In mining operations, where equipment faces extreme stresses from harsh environments and heavy loads, epoxy grout is invaluable. Its excellent adherence and mechanical properties ensure that machinery foundations, such as those for ball mills, crushers, and conveyors, remain stable and aligned.
This not only extends the equipment’s lifespan but also minimises maintenance needs, contributing significantly to uninterrupted operations and enhanced safety standards. Epoxy grout’s resistance to environmental factors and its capacity to absorb vibrations make it a cornerstone for maintaining the integrity of critical mining infrastructure.
Ensuring Equipment Stability
The Challenge of Vibrations and Loads
Mining equipment operates under extreme conditions, subjecting foundations to heavy loads and continuous vibrations. Impact shock from heavy machinery such as draglines and rock crushers can significantly shorten equipment lifespan and lead to structural damage. These conditions can lead to foundation degradation, machinery misalignment, and ultimately, operational disruptions.
The Solution: Epoxy Grout
Epoxy grout, known for its high compressive strength and excellent adhesion properties, provides a durable and stable foundation for heavy machinery. Its ability to resist chemical attacks and withstand harsh environmental conditions makes it an ideal choice for mining operations.
A Case Study: Epoxy Grout in Action
The case study centres on a semi-autogenous grinding mill at a mining operation, which faced significant operational challenges due to high vibrations caused by a deteriorating foundation. Alphatec Engineering was tasked with the rehabilitation of the mill’s pinion-bearing pedestal to address these issues and prevent the costly consequences of downtime and lost production.
The root of the problem was identified as the mill’s compromised mounting system, resulting from a combination of poor initial design, suboptimal construction, and wear over time. Notably, the mill, installed in the 1970s, had misaligned motor and pinion shafts and inadequate anchor bolts, both in terms of length and tension, leading to visible movement and further degradation of the foundation.
The solution employed involved a comprehensive approach to repair and reinforce the foundation. This included the removal of the existing base frame, extraction and replacement of damaged anchor bolts, and the application of high-performance epoxy grout, specifically Alphatec® 800, to grout the baseplate and pinion base skid. The process also involved the injection of Alphatec® 342 resin to repair the concrete foundation and the use of Alphatec® 170 for chock grouting new bearing pedestals. The meticulous process of measuring, adjusting, levelling, and aligning the components was critical to ensuring the mill’s optimal function post-repair.
This case underscores the critical importance of a well-designed and maintained foundation in industrial machinery’s operational efficiency. By employing advanced materials like high-performance epoxy grout and undertaking precise rehabilitation procedures, the operation successfully mitigated the risk of vibration-induced damage, ensuring the mill’s longevity and uninterrupted production. The project, completed in Rosia Poieni, Romania, serves as a testament to the benefits of specialised engineering solutions in preserving valuable industrial assets.
Epoxy’s robust composition can ensure over 75 years of added life to infrastructure, highlighting its effectiveness in safeguarding mining operations against common operational challenges.
Operational Efficiency and Cost Savings
Reducing Downtime
The stability provided by epoxy grout foundations directly correlates to reduced machinery downtime. Stable foundations ensure continuous operation, minimising the frequency and duration of maintenance breaks.
Long-Term Cost Benefits
Investing in epoxy grout for machinery foundations can lead to substantial long-term cost savings. By extending the life of equipment and reducing repair needs, mining operations can allocate resources more efficiently.
Conclusion
Epoxy grout offers a strategic advantage in mining operations, ensuring the stability, longevity, and efficiency of critical machinery. Its role in maintaining continuous operation and reducing downtime is invaluable, making it a cornerstone in the operational strategy of mining facilities.
Are you looking to enhance the stability and efficiency of your mining operations? Discover how our epoxy grout solutions can transform your machinery foundations and drive operational excellence. Contact us today to learn more and take the first step towards optimised mining performance.
