Repair of concrete foundations in industry
Chockfast instead of concrete - Fast foundation with the right epoxy resin
Concrete foundations in industrial plants often cause damage to the foundation. Concrete is fundamentally well suited for the creation of foundations and is characterized by a long durability and favorable prices. From our experience, however, old concrete foundations are often significantly better in quality than newer foundations.
Due to the vibration load and e.g. However, oil entry into the concrete foundation causes cracks in the foundations after a few years, the anchor bolts break away due to the constant vibration load and in some cases the different concrete layers of the block separate from each other. This often manifests itself in stronger vibrations of the system. These vibrations are relatively easy to measure, and with regular inspection, the creeping process of foundation damage can be detected by changing the vibration behavior of the machine. It should be noted, however, that not always a faulty foundation of the trigger for vibration problems must be. Thus, e.g. misalignment, defective bearings or components causing greater vibration. In some cases, these problems are also the result of a defective foundation. The first thing to do is to do a thorough research into the causes before unnecessary and expensive measures do not lead to the desired result. In this case, to reduce the vibrations.
You often get a first impression already when looking at the foundation.
If there are clear cracks or parts of the concrete are visibly loose, an oil film is on the concrete, the machine pumps out liquids between the concrete and the housing due to the vibrations or the anchor bolts can no longer be tightened, turned around or even have visible play urgent, a timely repair necessary.
Another step could be a vibration measurement to verify that the system values are in accordance with the applicable guidelines. Due to this vibration measurement, u.U. also alignment errors, bearing problems such as mechanical play, track bearing damage, imbalance, rotor or stator problems with electric motors or irregularities on vane or paddle wheels are detected.
If the investigations prove that the foundation is not in order, the following measures could be a solution:
Drill loose anchor bolts and glue in new anchors to reconnect the machine to the concrete foundation. With good accessibility, the machine usually does not have to be dismantled. Here, a core hole is placed next to the housing, the old anchor severed and a new anchor used. This is then re-shed with suitable materials and can be tightened after about 36 hours with the appropriate torque. Note that the extension of the bolt should be approx. 70%.
For loose concrete parts that support the machine housing, they can be removed by means of a stamper. For large-scale defects, the machine can be supported with hydraulic tools. Again, disassembly of the housing can be dispensed with in many cases. In the subsequent encapsulation with epoxy resins, the curing time in this case is about 36 hours, depending on the ambient temperatures. Due to the shrinkage-free curing of new materials and a very good bond between concrete and steel, the resulting vibrations of the machine can again be introduced into the concrete block as intended.
Another possibility is the injection of epoxy resins in existing cracks or areas in which the concrete layers have separated from each other. In this case, high-pressure packers are set and liquid resins are pressed into the concrete block at approx. 200 bar. This leads to a renewed connection of the problem areas and thereby to an improved vibration behavior of the system. In addition, it is also possible to introduce further ironing agents into the epoxy resins as structural reinforcement. As a final measure, after completion of the work, all concrete surfaces should be provided with a coating to prevent further oil entry into the foundation. The oil leads to a dissolution of the concrete structure, which leads to a reduction of the strength and thereby to further foundation problems.
If you have any questions about the above mentioned work please call us. We are pleased to offer you a tour of its foundations, cause research and the execution of the repair work.