Existing Condition of Cement Mill and ID Fan Foundations
The Cement Plant was confronted with significant operational challenges stemming from the misalignment and increased vibration of two cement mill drive systems. These issues were traced back to the foundations of the electric motor equipment connected to gearboxes, indicating a deeper structural problem.

The ID Fan foundation also presented structural concerns, undermining the plant’s overall efficiency and safety. Initial inspections underscored the urgent need for a comprehensive solution, recommending a strategic approach to regrouting in order to stabilise the equipment and foundation interface.

The deteriorated condition of the foundations posed several challenges, notably the presence of multiple cold joints and extensive voids and cracks throughout the concrete structure. Such defects not only compromised the operational efficiency of the cement mill and ID Fan but also posed significant safety hazards, threatening the continuity of plant operations and the well-being of onsite personnel.

Regrouting with Epoxy Grout
In response to these challenges, a decision was made to employ high-strength, chemical-resistant epoxy grout for the regrouting process. This choice was predicated on the material’s superior compressive strength and enhanced longevity compared to traditional cementitious grouts.

Epoxy grouts are known for their robust performance in demanding industrial environments, offering resistance to chemical attack and providing a durable bond that significantly extends the service life of the foundations.

Customised Approach
Alphatec Engineering, leveraging its vast experience and specialised regrouting techniques, devised a customised solution tailored to the unique structural challenges faced by the Cement Plant. This approach combined advanced materials with precision engineering to ensure a successful outcome.

The deteriorated condition of the foundations posed several challenges, notably the presence of multiple cold joints and extensive voids and cracks throughout the concrete structure. Such defects not only compromised the operational efficiency of the cement mill and ID Fan but also posed significant safety hazards, threatening the continuity of plant operations and the well-being of onsite personnel.

Operational Improvements
Post-regrouting, the Cement Plant experienced significant operational improvements, including a marked reduction in vibration levels, enhanced alignment stability, and an extension in the equipment’s operational life. These improvements have contributed to a more efficient and safe plant operation.

Strategic Benefits
The project delivered substantial strategic benefits, including improved plant safety, reduced maintenance costs, and increased production efficiency. These benefits not only enhance the plant’s operational capabilities but also contribute to its long-term sustainability and profitability.

Future Recommendations
In conclusion, it is recommended that continuous monitoring and maintenance be undertaken to ensure the longevity of the regrouted foundations. Additionally, potential areas for further improvement within the plant should be identified and addressed to continuously enhance operational efficiency.