Motor and Gearbox Foundation Inspection and Repair on Kiln Drive System

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Project Overview

 

Heidelberg Materials commissioned our team to perform a combined foundation repair and new motor installation on their kiln drive system at the Ketton Cement Works in the UK. The existing foundation had deteriorated over time and required chipping out old grout, installing new anchor bolts, and re-grouting to ensure a solid base for the new motor and existing gearbox.

Key Objectives

  • Restore and strengthen the motor/gearbox foundation
  • Remove and replace any failing anchor bolts
  • Install a new motor and integrate it with the existing gearbox
  • Guarantee accurate alignment and long-term stability

Features

Client
Ketton Cement
Project
Motor and Gearbox Foundation Inspection and Repair on Kiln Drive System
Equipment
Motor Skid Regrout & New Installation
Work period
Spring 2024
Location
United Kingdom

The Challenges

 

  • Simultaneous Repair & Motor Installation
    Foundation work had to coincide with the new motor’s installation in a tight workspace, creating scheduling pressures.
  • Maintaining Gearbox Alignment
    The existing gearbox stayed in place, requiring that its alignment be preserved while old grout was removed and replaced.
  • Anchor Bolt Deficiencies
    Outdated or sub-standard bolts needed upgrading to meet the new motor’s higher load requirements.
  • Logistical Constraints
    Frequent schedule changes and multiple stakeholders demanded close coordination to avoid delays.

 

The Solution

 

The team implemented a systematic approach:

  • Thorough site preparation, removing damaged grout and debris.
  • Upgraded anchor bolts, ensuring a secure, high-load foundation.
  • Real-time alignment checks, preserving gearbox positioning.
  • On-the-spot troubleshooting and efficient material management to avoid delays.

 

The Procedure

 

  1. Mobilisation and Site Preparation
    • Delivered equipment, materials, and tools to site, ensuring safe access in the confined working area around the kiln drive.
  2. Controlled Demolition and Cleaning
    • Chipped out damaged grout around the motor and gearbox plinth.
    • Cleared away debris and made certain that stable concrete and steel surfaces were exposed.
  3. Anchor Bolt Installation
    • Drilled to specified depths for M30 (grade 8.8) bolts, ensuring correct spacing and embedment.
    • Secured bolts with epoxy or mechanical systems to meet the new motor’s load requirements.
  4. Grout Placement
    • Erected formwork to contain high-performance, non-shrink grout.
    • Allowed sufficient curing time, monitored closely in accordance with manufacturer recommendations.
  5. Motor Positioning and Alignment
    • Lowered the new motor onto the skid plate, using AlphaPads for height and angular adjustments.
    • Checked alignment at each stage of torque application to prevent shifts in final positioning.
  6. Torque Testing and Handover
    • Performed incremental tightening up to around 639 Nm on anchor bolts.
    • Confirmed final alignment, documented results, and handed over the installation data to the client.

 

Conclusion

 

This project showcased two concurrent tasks—a foundation repair and a new motor installation—requiring thorough planning, close teamwork, and precise execution in a constrained work area. By carefully coordinating the chipping, anchor-bolt upgrades, and grouting with the Siemens motor installation timeline, we delivered a robust foundation and properly aligned, newly installed motor on schedule.

  • Improved Reliability: A reinforced and re-grouted foundation that meets the load requirements of the new motor.
  • Minimal Downtime: Well-coordinated scheduling with Siemens prevented major disruptions to site operations.
  • Accurate Alignment: Verified through live checks and final torque confirmation, ensuring a stable, efficient kiln drive system.

The Ketton Cement Works now benefits from a reliable, long-term motor and gearbox arrangement that supports its production needs while minimizing the risk of future foundation issues.