Disintegrator Grouting and Epoxy Resin

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When a disintegrator fails, it can lead to a range of issues depending on its specific function and application. A disintegrator failure can result in costly downtime, repairs, and potentially even product recalls or safety concerns.

The Alphatec Engineering team was brought in to carry out the rehabilitation of the mounting system of a Drytec Disintegrator driven by a 2.2 MW Siemens electric motor, which was manufactured in 2007 and installed the same year.

 

The Problem and Solution

 

The mounting system of a Drytec Disintegrator, powered by a 2.2 MW Siemens electric motor, had been experiencing increasing vibration levels; the root cause was a foundation problem. 

Our team of epoxy grout and concrete repair specialists needed to rehabilitate the mounting system, with the aim of restoring the foundation to its original condition and ensuring the continued smooth operation of the disintegrator. We proposed a solution involving the injection of epoxy resin into the foundation to fill any voids and cracks, followed by regrouting with our high-performance epoxy grout.





Features

Client
Cargill Deutschland GmbH
Final user
Cargill Barby
Project
Regrout, Epoxy Resin Injection , Skid Base and Support Beams Filling with Cementitious Grout
Equipment
Disintegrator
Work period
January 2019
Location
Barby, Germany

The Procedure

 

Our approach to foundation repairs involves restoring the integrity of the concrete block and ensuring that it effectively dampens vibrations, which is its primary purpose. 

 

Deterioration Of The Mounting System

 

The Alphatec Engineering team began by removing the existing cementitious grout. They discovered that the grout did not physically connect to the machine foundation, meaning it did not support the machine at all.

After further investigation, the team found that the machine was only supported on steel chocks under the anchor bolts, which contributed to the machine’s vibration. Although the anchor bolts were in good condition, their plastic sleeves designed to allow for stretching were useless because the machine was sitting on the steel chocks.

Furthermore, the grout under the machine frame did not support the machine because it did not make contact with the machine frame. Although cement grouts possess good free-flow characteristics, they can become problematic due to the “false set” phenomenon where the cement paste starts to harden and stiffen prematurely, creating a thick and solid mass in the mixture.

 

In-situ support of the machine

 

Our team of specialists used Alphapads®, our hydraulic jacks, to support the machine and remove the remaining grout under the machine frame. They carefully positioned the machine to maintain its original position and loosened the anchor bolts to separate it from the existing grout. After removing the deteriorated grout and steel chocks, the team then proceeded to consolidate the foundation using epoxy resin injection.

 

Foundation consolidation with epoxy resin injection

 

Our team drilled six injection holes in total to connect the 150 mm thick machine slab with the 1000 mm thick ground slab. They made two vertical holes on each side of the machine and one diagonal hole under it, each one metre long.

To prepare for the injection of our specially formulated ALPHATEC® 342 epoxy resin, the team inserted high tension steel bars, injection-copper tubes, and quartz sand into the six holes. After pouring the grout, the team carried out the epoxy resin injection to ensure optimal adhesion and structural stability of the machine foundation.

 

Grouting Process

 

Our Alphatec Engineering team began the grouting process by installing formwork to contain the pour of epoxy grout, which was sealed with our ALPHATEC® 240 Epoxy Putty. We filled the support beams and the underneath of the disintegrator with ALPHATEC® 440 to ensure a perfect bonding between the existing surfaces and the cementitious grout that was poured.

Before grouting the machine with our ALPHATEC® 800 High-performance Epoxy Grout, our team performed measurements, adjustments, levelling, and alignment of the components.

To fill any cold joints, separations, cracks, machine-frame, machine-slab, or discontinuities in the concrete, our specialists injected ALPHATEC® 342 injection resin under high pressure into the injection holes. This process resulted in a monolithic structure.

Finally, we removed the formwork and performed a hardness measurement of the epoxy grout, which was between 82 to 95 Shore D. Our team then tightened the anchor bolts and cleaned the area thoroughly.

 

Conclusion

 

Alphatec Engineering was able to restore the foundation of the disintegrator machine to its original condition, ensuring its continued smooth operation. This project showcases our commitment to delivering high-quality solutions that meet our clients’ unique needs and exceed their expectations.

Our epoxy resin-based grouts, reinforced with inert fillers for superior stiffness and heat resistance, are perfect for repairing cracked or damaged foundations and for installing new machinery in compliance with OEM and API RP 686 recommendations.

We specialise in the repair of critical machinery foundations using state-of-the-art techniques and advanced polymer products. By choosing Alphatec Engineering, you can be confident that your machinery will operate smoothly and reliably, maximising your productivity and reducing downtime.