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Alphatec Engineering

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ABOUT
The Alphatec Group was established in 1977 and our main business has been contracting; regrouting industrial machinery for which cement-based grouts have failed, and replacing them with permanent polymer grouts, properly designed to perform as the interface between machine and foundation. We also repair machinery foundations, restoring the concrete integrity and its ability to damp out vibrations and formulate and manufacture quality polymer products for use by other professionals.
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Alphatec Engineering - About

SectorOil & Gas
Specialty
Upstream

The Alphatec Group was established in 1977 and our main business has been contracting; regrouting industrial machinery for which cement-based grouts have failed, and replacing them with permanent polymer grouts, properly designed to perform as the interface between machine and foundation. We also repair machinery foundations, restoring the concrete integrity and its ability to damp out vibrations and formulate and manufacture quality polymer products for use by other professionals.

Alphatec began as a partnership between two individuals interested in solving machinery foundation problems, and has grown to a group of companies in 10 countries, with more than 4000 contracts completed in 40 countries.

After a few years in the contracting business it became apparent that we needed better evaluation and quality control of the growing number of polymer products that we were buying from outside suppliers, and this led to the establishment of chemical and physical research laboratories, and an active product development programme.

Alphatec group companies now manufacture a wide range of polymer products under the “Alphatec” brand, including grouts & adhesives, floorings & linings, coatings & sealants, for industrial concrete and steel protection. The partnership between our contracting, research, and manufacturing divisions, together with the equipment manufacturer, and the end user, is particularly effective in developing solutions to otherwise intractable problems.

Partnerships to count on

The idea of “partnership” lies at the very heart of the Alphatec Group corporate philosophy. Each employee is a partner in the success of the company, and each project undertaken is a two -, three – or four – way partnership in attacking and arresting the deterioration of the plant’s facilities.

We have an on-going policy of providing our customers with the best products available in the marketplace at any particular time. We also search out unusual technologies – the ALPHAPAD system of hydraulically adjustable sole pads is one example – to solve specific application problems. Our alignment equipment for setting up a machine before grouting, is first-class, as are the techniques employed to ensure that the machine is in alignment when running, rather than when stationary. Where the product or technology does not presently exist, the Alphatec Group is uniquely positioned to develop the products, tools, and techniques necessary to meet customer demand.

Reliable solutions

The integrity of the products we sell, the work we undertake, and the people carrying out that work, is the key to our success over the last twenty-five years. We look forward to continuing this successful partnership during the coming years.

We firmly believe that the era of polymergrouts has arrived. When these materials were first introduced, replacement of failed cement-based grouts and adhesive bonding repairs of cracked foundations were the main applications. Cement grouts continue to be used for the installation of many types of machinery, mainly due to their low initial cost. Increasingly, the overwhelming advantages of polymer grouts for new machinery installation are becoming recognized.

The polymer grouts offered by the Alphatec Group are already extensively tried and proven in many industries around the world – these are not experimental products. There is a growing awareness of the importance of foundations and grout on the long-term performance of rotating machinery.

Many machinery manufacturers are recommending the use of polymer grouts,and a growing number of engineering companies and plant owners & operators are actively specifying their use for the installation of all rotating machinery.

Many of our polymer products are based on the polyether family of resins; mainly epoxies and vinyl esters. The first epoxies were introduced in the 1940s, and revolutionized the way engineers looked at ‘plastics’. The physical properties and stability of the epoxy compound were truly amazing. Since that time – over 50 years ago – there have been many advances in the way the basic resins are used in formulating useful products. It is still possible to buy a liquid resin from one supplier, a recommended chemical hardener from another, and call it a ‘formulated’ product, but its properties will be very limited.

Today’s formulator has an almost endless supply of additives & modifiers available, and the original limitations of the epoxy compound – such as low heat resistance – can be greatly improved. Alphatec 130, our high temperature service polymer grout, which will withstand direct contact temperatures of 150º C, is one example of a properly formulated product. Our impermeable vinyl ester linings for steel and concrete are outstanding for their acid resistance. (Contact us for individual Product Data Sheets for specific products, and information on the entire product range).

Contact

Europe | Middle East | Africa

Alphatec Engineering (Europe) Ltd,
Avda 9 de Octubre 2,
Pol Ind Torrubero,
46136 Museros,
Valencia,
SPAIN
Tel: +34-961-451-599
Fax: +34-961-464-985
Email: giles.goldsbro@alphatec-engineering.com
Attn: Giles Goldsbro

Alphatec Engineering (Europe) Ltd,
1-2 Marino Mart,
Fairview,
Dublin 3,
IRELAND
Tel: +353 1 853 5842
email: finbar.osullivan@alphatec-engineering.com
Attn: Finbar O’Sullivan

South East Asia | China | Central & South Asia

Asia Alphatec Engineering Sdn Bhd,
Lot 4459 Taman Muhibbah,
71000 Port Dickson,
Negeri Sembilan,
MALAYSIA
Tel: +60-6-647-9333
Fax: +60-6-647-6333
Email: lee.hock.meng@alphatec-engineering.com
Attn: Lee Hock Meng

United Kingdom | Ireland

DND Construction Supplies
28 Waterfield Gardens
Crawley, West Sussex
RH11 6BT
UNITED KINGDOM
Tel: +44 1293 441 181
Mobile: +44 776 737 0479
UK Representative
Email: Dndcs@aol.com

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Resin Injections

Newly installed equipment that has lost adhesion between its metal parts and the concrete foundation; skid-mounted machines required to be filled with mortar or concrete, creating many voids and gaps and faulty adhesion between the skid and the foundation; adjacent concrete slabs with undesired relative movement; stress related cracks, cold joints… Alphatec developed the AT300 Epoxy resins family and the injection procedure up to 350 bars, to directly address all this scenarios achieving best results, assuring steel-concrete adhesion and the monolithic behaviour for the system.

Alphatec grouting resinsAT 800: high performance,water tolerant, aggregate-filled epoxy grout with superior mechanical and chemical properties.AT 800w: winter version.AT 440: modified epoxy resin-based adhesive which is used to bond new concrete to old.AT 170: two-component epoxy chock grout system, approved by Lloyds Register of ShippingAT 110: high performance, aggregate- filled, fast curing epoxy grout.Alphatec injection…

Regrouting

In case of existing machinery showing instability and vibration problems because of oil-degraded grout, anchor bolt failure or grout separation, the best procedure is to substitute the existing grout without removing the equipment, reducing down time and expenses. The specially designed hydraulic jack system marketed under the ALPHAPAD® trademark, enables us to work with the equipment in situ, and align it with utmost precision. The importance Of A Sound Foundation. AT800 is the best non-shrinking, thermal and shock resistant grout material to transfer all vibrations generated within the machine to the foundation where it will be properly damped

Product Sales

The benefits of using epoxy grouts are most easily seen in a repair or rehabilitation project, but they will perform very well in new installations of all types of rotating machinery, with the following provisos:

1) The right product for the job must be used. Epoxy grouts come in several flavours: high-temperature types (150°C at the footing); underwater or moisture-tolerant types, which can be very useful when working in the open in a wet climate; low-temperature curing types - good for winter projects, or high latitude/high altitude projects. Please consult…

New Installations

The Alphatec teams are highly specialised in installing and grout all kinds of machinery: Compressors, Hyper - compressors, Pumps, Diesel Engines, Gas Turbines, all kind of skids… providing high quality materials and the best solutions following the API RP686, ACI and GMRC norms.

The innovative ALPHATEC® branded resin-based products that we use can be formulated for different conditions depending on temperature, curing time, loads...

Foundation Repairs

The development of vibration problems in the machinery is greatly enhanced by unbound construction joints in the foundation, grout failure and bad anchor installation. Alphatec provides the best engineered solution, where epoxy resins are injected after inserting high tensile strength Dywidag bars, to ensure a monolithic behaviour in the foundations.

Condition Surveys of Grout and Foundation Status

Review of history of installation, outages and vibration levels. Analysis of foundation design and construction, with calculations of mass and evaluation of form. Identification of actual and potential cold joints, stress risers, and stress-induced cracking. Analysis of support system, including the original grout and anchor bolts. Analysis of grout disbonding, corrosion, oil degradation and other anomalies. Verification of levels and deflection readings. In addition, at the clients request, we can take core samples to check various parameters, such as carbonation testing (phenolphthalein test), chloride testing and directly measured compressive strength. Other possible tests include Schmidt hammer testing, ultrasonic p-wave and s-wave testing, impact-echo testing, eddy current rebar location, etc. Preparation of report indicating recommended actions

Alignment

We all agree that machinery will perform better when it is properly aligned. The snag is that word "properly". We believe that all machines have an optimum alignment profile, which takes into account the changes in the shaft train when the unit is operating. Differential thermal growth, rotational displacement, and foundation fastening restraints all affect the final position of the shaft/shafts, and need to be considered.

Due to our wide experience with all types of rotating machinery, we can often predict the offsets required with accuracy. Where doubt exists, we can measure the movements of the machine casing during shutdown, using precision optics and laser-based systems, and factor the measured offsets into the final re-alignment.
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