Gas Storage Compressor Foundation Grouting

Alphatec Engineering was engaged to carry out the foundation grouting and alignment of a gas engine compressor system for a large gas storage facility.

The objective was to ensure proper load transfer, long-term vibration resistance, and secure anchor bolt installation using high-performance epoxy grout. This project forms part of Alphatec’s ongoing commitment to improving machinery foundation reliability in critical energy infrastructure.

Features

Client

Gas Storage Operator

Project

Foundation preparation, anchor bolt core drilling, epoxy grouting, alignment, and stabilisation of gas engine compressor units using Alphatec® 800 and Alphatec® 240 epoxy system

Equipment

Gas engine compressor unit
Coupled motor and gearbox skid
Custom skid-mounted steel base

Work period

Spring 2025

Location

Central Europe

01 Identified Challenges

The compressor units were mounted on skid bases with limited space for traditional levelling methods, requiring shim pack placement and custom pre-alignment techniques.

Core-drilled anchor bolt pockets had to be precisely cleaned and prepared to ensure maximum bond strength. Additionally, ambient temperature constraints required careful material pre-conditioning and protection of the work area to maintain optimal grout curing performance.

02 The Execution

Alphatec supplied and installed precision-cut M39 anchor bolts with engineered stretch length to comply with API RP 686 guidelines.

The epoxy grouting operation used Alphatec® 800, a heavy-duty, flowable epoxy designed for compressor skid foundations. All shim packs were removed after leveling, and formwork was installed before final grout placement. The entire foundation repair and grouting operation was completed in six days, minimising disruption to site operations.

04 Results and Benefits

The result was a vibration-stable compressor foundation with properly tensioned anchor bolts and excellent grout coverage.

The use of specialist epoxy grouting methods and certified installation practices ensured lasting structural integrity. This project reinforces Alphatec Engineering’s role as a trusted provider of foundation repair services for rotating equipment in energy and gas infrastructure.