Click here to view a visual guide to the repair process.
Here we can see the machinery being lifted off the grout bed and foundation.
The grout bed was concave and therefore the bottom of the skid was not in complete contact with the grout. This was probably due to improper grouting techniques - - most likely not using a header box or not being aware of the pot life or working time of the grout material.
Mechanical wickets comprised of #4 rebar were epoxed to the foundation throughout. These will function as a mechanical anchor to help anchor the epoxy to the foundation and prevent edge curling at the perimeters. After the wickets are installed, the entire area is abrasive blasted and cleaned.
Here we see the skid back on the foundation. Note the expansion joint here - - expansion joints are installed to control cracking in the epoxy grout and are generally placed every 4 to 6 feet. Here we are using redwood stripes that have been embedded in silicone and have a backer rod on the top to prevent a bond with the skid plate base. Another advantage of using expansion joints is that you can break up a large area and pour once cell at a time, carefully ensuring that your grout is in complete contact with the base. Too large of a pour can cause excessive cracking.
Here we can see the grout flowing from one side of the machine to the other.

Skid Mounted Equipment Industrial Foundation Repair

Project Highlights 
  • Replacement Epoxy Grout was installed.
  • Machinery was returned to optimal working order.
Project Description 

A piece of industrial equipment was found to have excessive vibration immediately after grouting. Repair Process protocols were followed in order to arrive a solution to keep all mechanicals in proper working order, reduce mechanical wear, and enhance service life of the machine. Faulty installation resulted in no grout bond between the middle of the base of the machinery and the concrete foundation. The void caused a "trampoline" effect, leading to excessive vibration. Excessive vibration can significantly shorten the service life of machinery, leading to mechanical failure, and premature maintenance needs.

Technical Summary 

Cause/Effect:

  • Excessive vibration immediately after grouting

Repair Required?

  • All mechanisms in proper working order

Repair Analysis:

  • Equipment subject to damage with continued operation

Repair Strategy:

  • Remove machinery
  • Remove grout
  • Remove 1” of concrete block to achieve proper surface profile
  • Install “wickets” to mechanically anchor grout bed
  • Install expansion joints
  • Install epoxy grout bed