Compressor Skid and E-Motor Baseplate Grouting

Our epoxy resin specialists just finished a grouting assignment in a petrochemical plant in Germany. It consisted of the installation of a large compressor skid and of the corresponding electro motor.

For such projects, where the task is to install large machinery base frames or sole plates on a concrete foundation, we typically use a three-component epoxy grouting compound. Three-component grouts include, in addition to the usual epoxy resin and its hardener, also an inert aggregate that acts as a filler material. Typically, silicon dioxide (quartz sand) is used as aggregate. It makes up the bulk of the mix, about 85% by weight.

Epoxy resin compounds are ideally suited for application on concrete. They possess a much higher resistance to many chemicals than concrete and therefore act as a physical barrier, protecting the concrete. Their compressive strength is also superior to concrete.

And since they experience virtually no shrinkage during curing nor creep, they are ideal for maintaining critically aligned equipment firmly in position throughout their long life time.

Scope of work

The customer asked QuantiServ to perform the following services:

•  Select the grouting material suitable for the purpose
•  Define grouting standards and requirement (i.e. concrete roughness, pouring temperature,…)
•  Develop a detailed site grouting procedure
•  Supply the grout material and deliver it to site
•  Carry out the pouring at site, including damming and other related work

The material that we chose is Chockfast Red from ITW Performance Polymers. About 2.5 m3 of it was used for this job.

The work at site consisted of three steps:

1. Grouting of the anchor bolt cavities

2. Grouting of the centrifugal compressor/gear box sole plate and of that of its electro motor

3. Grouting of the approximately 100 mm gap between the concrete foundation  and compressor/gear box skid

Click on the pictures on the left below for a larger view of these steps.

Electro motor aligned on foundation block
Electro motor aligned on foundation block
After grouting of the anchor bolts
After grouting of the anchor bolts
Grouting completed, damming about to be removed
Grouting completed, damming about to be removed

Key Data 2022 – The Growth Journey Continues

We have steadily grown our reach and our customer base during recent years and have achieved a number of all-time highs in 2022.  During the last twelve months, our 395 staff have successfully processed just over 4’000 Reconditioning, In-situ Machining, Metal Stitching, Epoxy Resin or Mobile Team orders. Our staff have served more than 1’100 individual customers.

We carried out 63% of these orders in one of our 14 workshops. The remaining 37% of orders we executed on board ships or in customers’ plants all over the world.

The customers that we served stem from a very wide range of industries. On average, we commenced a new in-situ machining assignment every three hours, anywhere in the world.

Key Data 2022:

Number of Trained QuantiCast Applicators Grows Steadily

In 2020, we have introduced QuantiCast into the market. QuantiCast is QuantiServ’s very own brand of pourable epoxy resin. It is a top modern chocking or grouting system that offers a number of advantages over competing products:

  • Excellent adhesion on various substrates (concrete, steel, …)
  • High compressive and impact strength
  • Highly resistant to chemicals, solvents and moisture
  • Tough, durable and very corrosion resistant
  • Possibility to modify the hardener to resin ratio, to vary pot life and curing time
Successful graduates of our training program in July 2022

QuantiCast is most often used as equipment foundation in marine and industrial environments. It is equally popular in new equipment installation, as in retrofit projects and repair.

To keep up with the material’s increasing demand, we constantly keep on training and certifying applicators. Our in-house training courses equip them with the necessary skills and knowledge to master all situations and applications, such as static pours and resin injections.

We would like to congratulate the July 2022 cohort for having successfully completed their formal training, which consisted of a theoretical part, a practical part and an examination! They are now ready to join our experienced applicators to continue their learning in the field.

Follow the links below to learn more about epoxy resins and the services we provide, or about QuantiCast.

Epoxy Resin Services

 

QuantiCast

 

Key Data 2020 – Number of Customers and Orders Increased

We have steadily grown our reach and our customer base during recent years. In 2020, our 356 staff have successfully processed close to 3’000 Reconditioning, In-situ Machining, Metal Stitching, Epoxy Resin or Mobile Team orders from nearly 700 individual customers.

We carried out 70% of these orders in one of our 14 workshops. The remaining 30% of orders we processed on board ships or in customers’ plants.

The customers that we served stem from a wide range of industries. On average, we commenced a new in-situ machining assignment every three hours, anywhere in the world.

Key Data 2020:

QuantiCast Epoxy Resin Now Globally Available!




We are happy to announce that after the completion of extensive development and testing work, our very own epoxy resin compound is now globally available for purchase through the QuantiServ organization, starting from 01 January 2021 onwards.

The product is called QuantiCast. It was developed to suit a very wide range of applications in various industries. QuantiCast is an advanced chocking and grouting material for indoor and outdoor use.

This highly durable, non-shrinking material is characterised by high compressive and impact strength. It is absolutely non-poreous and is resistant to a wide range of chemicals, such as hydrocarbon fuel and lubricanting oils, solvents, sea water and many more.

Epoxy Resins that are to be used for marine applications do require classification society type approval. QuantiCast is type approved by DNV-GL and by Lloyds Register.

QuantiCast is priced very competitively. Do ask us for an offer!

Read more

 

Wrapping of a rudder shaft at QuantiServ Italy

New Video: Wrapping of Propeller Shafts and Rudder Stocks

Shaft wrapping is an activity that our specialists perform on a regular basis, mostly for new ships while they are under construction.

Whenever the design of a vessel mandates that the propeller shaft or rudder stock lies exposed to open seawater, then it should be protected against electro-chemical corrosion. This type of corrosion occurs in the presence of (sea-) water and air (or dissolved oxygen) and the usual way of avoiding it is to coat the shaft with a protective layer of fiberglass.

The following picture shows an example of a rudder stock showing severe signs of corrosion. This is the very outcome that wrapping prevents.

The wrapping process as such is very well established and the results are excellent. During dry docking, we have recently inspected some shafts that we have wrapped ten years ago. We found the wrapping in still perfect condition.

Witness here how our specialists are doing it:

Our Brand-new Case Study Page is now Online!

The new QuantiServ Case Study page is now online. It introduces recent work that we have done for customers coming from a variety of industries ranging from Marine, Mining, Hydro and Thermal Power Plants to Oil & Gas.

The cases are sortable by industry and cover services such as in-situ machining, metal stitching, reconditioning and many more. They each include a short description of the problem that the customer was facing, the solution and include many before/after and in-process pictures.

Case Studies

 

Protecting exposed rudder stocks with fiber glass

QuantiServ’s resin engineers are used to work on a very wide variety of equipment. They are equally versed in repair jobs as in new installation work.

The work shortly described here falls into the latter category. In December 2016 we received for fiber glass wrapping two rudder stocks from a multipurpose frigate currently under construction in an Italian shipyard. The shipyard used to carry out the wrapping by themselves, in the yard. But they lacked the expertise and the right equipment, so decided to give these two rudder stocks to QuantiServ for wrapping in our workshop in Genoa.

The work included the sandblasting of the area to be wrapped, the verification of the surface roughness, the wrapping and final coating itself, as well as the spark testing. The surveyor from the shipyard, who attended the whole process, appreciated the result and said that the speed as well as quality of the work was superior compared to the earlier ones done by the yard.

Because of the good service and result, the shipyard intends to have the next few rudder stocks done at QuantiServ Genoa too.