Epoxy Concrete Repair Method: How to Repair Equipment Foundations

Concrete Foundations Under Machinery Equipment

Industrial equipment such as pumps, compressors, or solid-handling machinery, like crushers in mines, usually experience vibration and heat, which can cause deterioration of their concrete bases.

Other contributors to concrete foundation failure also include load-bearing fatigue, chemical spills, and overloaded operational demands.  Environmental factors such as water ingress and poor drainage can also weaken the concrete surface, while poor installation practices may lead to premature deterioration. Addressing these issues and failures is crucial for maintaining stability in industrial operations. Consequently, epoxy concrete repairs have become a superior choice for efficiently restoring equipment foundations and concrete bases.

Epoxy Concrete Repair for Unlevelled Equipment on Concrete Foundations

Epoxy-based concrete repair materials provide high-performance repair and protective systems for buildings and structures that require durability and mechanical strength. These epoxy concrete repair systems are beneficial for industrial facilities thanks to their abilities to:

• Enhance corrosion resistance
• Reduce the risk of water ingress
• Mitigate damage from chemical exposure

In addition, the epoxy concrete repair materials are easy to apply and require less time than traditional cementitious materials, while still delivering long-term structural integrity.

Epoxy concrete repair systems are therefore effective for restoring unlevelled equipment caused by concrete deterioration. They are suitable for concrete foundations of industrial machinery that handles high-temperature media, chemicals, or heavy loads, such as pumps, compressors, turbines, generators, and manufacturing equipment.

Belzona Concrete Repair for Concrete Foundations of Unlevelled Equipment

Belzona’s concrete repair systems are based on a range of epoxy resins and selected aggregates. The appropriate product selection depends on the operational environment. This blog demonstrates how to use Belzona 4111 (Magma-Quartz) to restore unlevelled equipment on concrete bases.

Belzona 4111 (Magma-Quartz) is an epoxy concrete repair and rebuilding system that utilizes Belzona 4151 (Magma-Quartz Resin) and graded quartz aggregate for repairing and resurfacing concrete subjected to mechanical and chemical damage, as well as for grouting and bonding. The consistency of the final mix of Belzona 4111 (Magma-Quartz) can be adjusted to meet the specific needs of the repair. For optimal adhesion to concrete surfaces, the application of Belzona 4111 (Magma-Quartz) must be applied over Belzona 4911 (Magma TX Conditioner).

When tested in accordance with ASTM C157, Belzona 4111 (Magma-Quartz) exhibits no measurable shrinkage during the curing process. It is resistant to a wide range of chemicals, including alkalis, hydrocarbons, detergent solutions, mineral and lubricating oils, salts, and many other chemical types.

Step-by-Step Guide How to Repair Concrete Foundations of Industrial Machinery

Step 1 – Surface Preparation Prior to Application of Epoxy Concrete Repair System

Start the repair by removing all loose material from the concrete base beneath the machinery. Use a brush or vacuum to ensure the area is clean and free of debris.

Step 2 – Prepare Conditioner for the Repair Area

Combine Belzona 4911 (Magma TX Conditioner) Base and Solidifier. For small-batch mixing, use a ratio of two parts Base to one part Solidifier by volume. After mixing, apply the conditioner directly to the clean and dry concrete surface.

Step 3 – Condition the Damaged Concrete

Apply the mixed Belzona 4911 (Magma TX Conditioner) to the concrete surface beneath the machinery. Belzona 4911 (Magma TX Conditioner) must then be overcoated within the overcoating window specified in the Instruction for Use. This conditioner is essential for achieving proper adhesion of the Belzona epoxy concrete repair materials.

Step 4 – Mix Belzona 4151 (Magma-Quartz Resin) Base and Solidifier

Combine Belzona 4151 (Magma-Quartz Resin) Base and Solidifier. The base to solidifier mixing ratio is 2:1 by volume or 2.3:1 by weight. Belzona recommends strictly following the manufacturer’s Instruction for Use to ensure optimum results.

Step 5 – Introduce Belzona 4111 (Magma-Quartz) Aggregate into the Mixing

Once the Belzona 4151 (Magma-Quartz Resin) has been thoroughly mixed, gradually add Belzona 4111 (Magma-Quartz) Aggregate to the mixture of Belzona 4151 (Magma-Quartz Resin) while continuing to monitor and the consistency as the mixing progresses. Continue blending the aggregate with the resin until the desired consistency is reached. For large batches or full unit mixes, a forced action mechanical mixer may be used to facilitate the process.

Step 6 – Apply the Product to the Deteriorated Concrete Foundations Under Machinery

Apply and gradually pack the fully mixed Belzona 4111 (Magma-Quartz) into the deteriorated concrete foundation beneath the equipment. Use a steel float to press down and compress the product in order to remove any entrapped air. After completion of the application, allow the product to fully cure before returning the equipment to service.

Frequently Asked Questions

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