During an overhaul of a 2-cylinder piston compressor, it became apparent that the underlying foundation had been severely damaged. EMHA was commissioned to structurally repair the foundation and make it fit for the future. The result is a robust and low-maintenance installation that once again meets the requirements for safe and reliable operation.
Situation
An inspection revealed that the existing foundation was in poor condition. The cement grouting had cracked and disintegrated, the concrete showed signs of cracking and had been damaged by oil penetration in several places. The anchor bolts were also no longer functioning properly, which compromised the stability of the machine installation. The client faced the challenge of not only repairing the damage but also preventing future deterioration. The aim was to create a durable foundation capable of withstanding operational loads and one that would facilitate future maintenance.
Approach
Following a site visit, EMHA recommended a complete re-anchoring and re-grouting of the installation. The existing anchor bolts were removed using diamond drilling and replaced with newly designed anchors, calculated using EMHA’s in-house calculation tool. All concrete sections affected by oil were carefully removed and rebuilt using Chockfast Red epoxy grout, creating a homogeneous and strong foundation.
For the compressor extension supports, EMHA designed specific base plates that simplify dismantling during future maintenance and prevent the need to break open the grout layer locally. Finally, the entire foundation was treated with a high-quality 2K epoxy coating system (AQ-paint), which provides structural protection for the concrete against oil, moisture and other contaminants.
Results
The new foundation provides a stable and reliable base for the compressor installation and eliminates the risks arising from the deteriorated structure. The combination of high-quality grouting, correctly designed anchoring and a protective coating has significantly extended the foundation’s service life.
In addition, the modified design of the sole plates ensures that future maintenance can be carried out more efficiently, without the need for major work on the foundation. The client now has a sustainable, low-maintenance solution that enhances operational reliability and helps prevent unplanned downtime.
