Ladle Turret Foundation Regrout

Download Success Case

Alphatec Engineering was called upon by a multinational steel company to replace the metallic section of the pedestal supporting their ladle turret and hydraulic system with rotary arms. 

Our team of certified specialists expertly replaced the damaged cement-based grout within the four-day timeframe they were given. The successful completion of this project ensured the continued smooth operation of the ladle turret, maintaining productivity and safety in the steel production process.

This report outlines the details of the rehabilitation work carried out by Alphatec Engineering on the ladle turret foundation.

 

The Problem and Solution

 

A multinational steel company needed to change the metallic section/base frame of the pedestal that supports the ladles and its hydraulic system with rotary arms.

The change required the replacement of the existing, damaged cement-based grout. Alphatec Engineering supplied the correct type of grout for the job. And our certified field crew, experts on handling grout products, completed the work within a four-day period. 




Features

Client
CELSA GROUP
Final user
Celsa, Planta de Castellbisbal
Project
Grout Removal, Anchor Bolt Isolation, Regrout
Equipment
Ladle Turret
Work period
August 2020
Location
Barcelona, Spain

The Procedure

 

Our approach to foundation repair for machinery involves ensuring that the concrete block has the necessary integrity to effectively dampen vibrations, which is its primary purpose. This is achieved through a thorough analysis of the machinery’s requirements and the foundation’s design, as well as the use of high-quality materials and precise construction techniques. Our goal is to ensure a foundation will provide optimal support for the machinery while minimising the risk of vibration-related damage or failure.

 

Rehabilitation of Concrete Foundations

 

This base frame was anchored to a concrete foundation plinth by 59 M64 anchor bolts. These went down about 50 mm into cement-based grout.

First, the base was lifted off by hydraulic jacks, and then completed with the help of a crane. This was to prevent damage to the anchor bolts, in particular the threads.

Removal of the existing grout was done by chipping out a little more than 60-70 mm (on average) of the cement grout. It reached 90-100 mm in some of the inner areas of the hole. In all cases, it is important to reach sound concrete, and meticulously clean the chipped area.

 

Restoring the integrity of the concrete block

 

As the existing layer of cementitious grout was heavily contaminated with oil, this facilitated its detachment from the foundation, in large sections.

The cement grout and the underlying concrete were so badly soaked in oil that virtually no cohesive strength remained. Additionally, the base has been subjected to high forces and considerable tilting torque.

 

Final Steps

 

The following day the new base was lifted and put into position. The alignment of the base was checked and levelled using screw jacks with 0.2 mm overall tolerance.

A coat of ALPHATEC® 400 was applied first on the exposed concrete before pumping the cementitious grout. This was to bond the new cement grout with the old concrete.

A grout pump was used to guarantee the correct supply and avoid any gaps or voids, although the volume was low.

The next day the formwork was removed and the area was cleaned. The material had cured sufficiently to allow for light mechanical work. Anchor bolts were tightened 48 hours after pouring.

 

Conclusion

 

At Alphatec Engineering, we understand the importance of having a strong and reliable foundation for your machinery. Our team of experts meticulously prepared the concrete surfaces, secured the anchor bolts, and poured the grout with precision to ensure maximum stability and protection against unwanted vibrations.

Our commitment to using high-quality products and attention to detail sets us apart from the competition. We prioritise the long-term performance and durability of your machinery, ensuring that your investment is protected. When you choose Alphatec Engineering, you can trust that you’re receiving the best foundation services in the industry.