Project background
A New South Wales gold producer engaged ESI Alphatec to conduct machinery foundation repair and regrouting for its gyratory crusher, Metso 54X75.
This critical process equipment had endured significant wear and tear, and required repair, regrouting and realignment.
Challenges
The primary crusher was mounted to reinforced concrete foundation using four stud bolts, steel packing and an epoxy grout, with visual motion between the lower shell main frame and the grout foundation.
Our team addressed these issues by:
- Raising the crusher off plinth
- Conducting ultra high pressure (UHP) demolition & scabbling
- Installing new foundation bolts
- Grouting the foundation
- Removing the formwork
- Installing new tensional foundation bolts
Our solution
ESI Alphatec’s repair design aimed to recreate the intimate connection between the crusher main frame and concrete foundation.
Once intimate contact is re-established, vibration and dynamic forces generated during crushing operations are disbursed and dampened by the concrete foundation mass.
When this connection is broken, these forces are isolated within the machine itself, causing substantial increase in the wear of rotating parts and cracking to the mainframe or internal components, ultimately resulting in unreliable critical process equipment, and requiring long lead components to be replaced.
To facilitate the repair and regrouting work, the team elevated the crusher using purpose-designed lifting frame in the dump pocket above, removed the hold-down bolts, and removed the grout and part of the reinforced concrete foundation to a sound base using hydrodemolition.
Our team then installed and set K-screws to strategic locations under the crusher frame, lowered the crusher onto K-screws, and levelled and aligned the crusher using a horizontal jacking frame.
They then poured new epoxy foundation cap, installed new ESI Alphatec-designed hold-down bolts, with their arrangement and tension via bolt set to requirements.
Outcome
With our team having levelled and aligned the main frame, poured new Epoxy grout, installed and tension-set new hold-down bolts, and repainted the equipment, the client now has a renewed, fully operable crusher, helping ensure its reliable, safe and efficient operation.
Products used
The ESI Alphatec products sourced, supplied and used were:
- Chockfast® Red
- KS-Jackscrews
- Hold down bolts
For more information about our machinery grouting and repair services or any of our products and services, email info@esi-techgroup.com.