Fiberizer - Foundation Regrout and Repair

Alphatec Engineering was urgently called to Essity Prudhoe in Newcastle, United Kingdom, to address significant foundation issues affecting a critical paper fiberizer. In the paper industry, fiberizers—or defibrators—play an essential role in breaking down raw materials into the fibrous pulp required for paper production.

For such precision machinery, a solid and stable foundation is paramount to ensure efficient operation and long-term performance.

Features

Client

Essity Prudhoe

Project

Regrout and Foundation Repair

Equipment

Fiberizer

Work period

June 2023

Location

Newcastle, United Kingdom

01 The Challenge and Strategy

The fibreizer’s foundation had become compromised due to improperly installed cement grout and inadequate surface preparation. This failure led to detachment of approximately 50 mm of the grout, resulting in excessive vibrations and a weakened overall foundation integrity.

Recognising the urgency, Alphatec Engineering mobilised within two weeks and proposed a comprehensive repair strategy designed to restore the original stability of the equipment.

02 The Repair Process

Upon arrival at the site, the team conducted a detailed assessment of the foundation. The first step involved the careful removal of the detached cement grout using specialised tools to prevent any collateral damage. Following this, the foundation surface was thoroughly scabbled and cleaned, eliminating debris, contaminants, and any irregularities that could affect the bond of new materials.

Alphatec Engineering then prepared a new mixture of Alphatec® 800 epoxy grout, renowned for its excellent adhesion and durability. The epoxy was mixed precisely according to the manufacturer’s guidelines and applied to the prepared foundation. With meticulous attention to alignment and load distribution, the fibreizer was reinstalled and securely anchored to the newly grouted base.

Once in place, the grout was allowed to cure under controlled environmental conditions, ensuring it reached full strength and provided a reliable bond between the foundation and machinery.

03 Conclusion

After the curing period, rigorous testing was carried out to verify the installation’s success. Vibration levels, alignment accuracy, and overall functionality were assessed to confirm that the fibreizer was operating within permissible limits and that the foundation was stable.

This comprehensive remediation not only restored operational integrity to the fibreizer but also enhanced the system’s long-term performance and safety.