We are experts in skid installation.
The Alphatec Engineering group of companies has been solving problems with rotating machinery since 1977 in many markets around the world, including Japan, South Korea, China, Malaysia, Singapore, Indonesia, Australia, India, Saudi Arabia, Kuwait, Hungary, Germany, Spain, France, Switzerland, Italy, Nigeria and Senegal, among others.
Thousands of projects have been successfully completed in more than 57 countries, and the machinery worked on encompasses all types of rotating machinery, from large turbo-generators to diesel engines to compressors to pumps, and all types of metal working machinery – in fact almost any machine which has been placed on a concrete foundation or plinth.
Concrete foundation repairs
It is not widely appreciated that concrete foundations can be a major reason for elevated vibration levels or misalignment, nor that concrete can be effectively restored to its design condition as a very effective vibration damper. Fixing foundations is a real speciality, with very few other companies anywhere in the world who can offer the combination of products and services that Alphatec offers, or with the number of case histories to back up the claims made for effectiveness.
Once the foundation has been repaired, the machine can be properly reconnected to the concrete base. This is done by removing the original grout material, and replacing it with ALPHATEC® 800 epoxy grout, which ensures good adhesion between grout and machine, and between foundation and grout. ALPHATEC epoxy grouts are among the best on the market today, with superior flow, which allows the product to be placed easily in challenging situations, and the best balance of physical properties, which enable it to work in protecting both machine and foundation for the life of the machine.
Rotating machinery support and alignment
When grouting a machine in place, it is very important that the machine be in correct alignment, since the whole idea of epoxy grout is to prevent unwanted movement, once the grout is cured and the anchor bolts tightened down. The alignment should be as close to ideal as possible when it is operating, not when cold. Experience is therefore very important in setting up a machine, and Alphatec Engineering works with the manufacturer and/or end-user to ensure that this experience is incorporated into the project.
We also use a system of hydraulic jacks, which allows for easy and rapid adjustments of even the largest items of machinery (2,000t machines have been successfully aligned), with great accuracy. We use optical alignment tools, laser equipment and good old-fashioned dial gauges to achieve the agreed alignment, and then the machine is grouted.
Anchor bolts for machine grouting
Anchor bolts, or hold-down bolts, complement the work of the grout. Simply put, the grout holds the machine up, while the bolts hold it down. This balance needs to be understood, and anchor bolts inspected properly during the evaluation of the job, and its execution. If bolts are loose in the foundation, they can be reconnected by pressure injection of purpose-designed resins. If the bolts are badly damaged, they can be repaired or replaced, often with more effective materials, embedment depths and stretch lengths than the originals.
Worldwide machinery grouting operations
Alphatec Engineering has operating bases in several key areas, including Europe, Asia and Australasia. Our project engineers are used to working in all sorts of environments and cultures, backed up by good materials, tools and equipment, and support from any of the five main operating bases.
90% of the failures of the bases are due to their instability and this occurs due to improper installation (incorrect flatness) and / or the use of inappropriate materials.
If you have a cracked foundation, separated grout / concrete cap, cold joints, broken chocks, loose sole plates or anchor bolts that you think cannot be fixed, we can help.
Critical dynamic assets are the heart of any industrial production. The installation has a direct impact on machinery, it will determine operating conditions, performance and lifecycle cost. Learn more about Alphatec in this short video.
The replacement of 42 anchor bolts in a diesel engine on a concrete foundation is not an easy job.
This whitepaper presents our repair procedure to restore the grout on footings of a 400 m3 HTF tank who was with a significant failure in the anchoring+insulation system in the sliding saddle.
There are two standard methods of installing anchor bolts in a concrete foundation: direct embedding in concrete or grouting into a reservation made in the concrete block.
Industry in general uses an enormous variety of rotating machinery, the greater number of which are mounted on some type of concrete foundation, or plinth.
'GROUT' is defined by the Concise Oxford Dictionary as 'a thin fluid mortar for filling interstices'.
Process plants around the world depend on millions of rotating machines: compressors, pumps, blowers, fans, presses, generators, mills, mixers, and so on through a long list.
Alphatec Engineering recently participated in the Power-Gen Europe exhibition in Milan. We met many interesting potential customers, as well as a few existing clients, and spent the three days of the exhibition listening and talking about the delights of epoxy grouts for installing rotating machi