AERATED CONCRETE FACTORY UDK

At continuous production facilities, the condition of the foundation under the equipment is a matter not only of safety but also of profitability. For an aerated concrete plant, any foundation settlement becomes a serious challenge.

Reason for contacting: Violation of technological accuracy

The plant management faced the problem of uneven foundation settlement in a large area (953.4m²!). This led to:

• Violation of the alignment of process equipment components;
• Increased wear of bearings and drive mechanisms;
• The emergence of vibration loads that began to destroy the structure of the production building itself.

Problem: Vibration and soil fatigue

Technical inspectionrevealed a classic industrial problem – the combinationnatural heterogeneity of soilsand constantdynamic impact.

1. Man-made vibration:High-frequency and impact loads from the equipment acted as a “vibratory compactor” for loose soil layers, causing them to compact further and settle.
2. Deficiency of bearing capacity:The heterogeneous composition of the foundation resulted in the soil remaining stable under one part of the foundation, while zones of loose soil formed under the other.

Technical Solution: Synergy of Deep Lifting and Floor Lifting

To restore the site, a comprehensive geopolymer resin injection strategy was used, allowing for surgically precise work without dismantling equipment.

Stage 1: Deep Lifting

The primary objective was soil consolidation. Geopolymer was injected into the foundation layers to the calculated depth to create a reinforced structure.

Этап 2: Floor Lifting

After the soil was stabilized, engineers began workraising the floorand foundation.The foundation, along with the equipment placed on it, was smoothly returned to its design levels, which allowed the machines to be restored to their factory settings.

Why is GeoResin the industry standard?

Application of geopolymer technologies at facilities of this scaleprovides a number of undeniable advantages over traditional concreting or cementation:

• Work without stopping the workshop:The plant continued to operate. The injection equipment is compact and does not require shutting down adjacent production lines.
• Polymerization speed:Geopolymer gains its design strength in15 minutesThis means that the equipment can operate at full capacity almost immediately after injections are completed.
• Dynamic stability:Unlike rigid concrete, which can crack under vibration, the geopolymer structure has the necessary viscosity and elastic modulus to perfectly absorb dynamic loads.
• Process purity:The absence of excavations, dust, and water guarantees the safety of high-precision electronic and mechanical components of the equipment.

Results of the project implementation

1. The area of ​​953.4 m² is fully stabilizedThe foundation under the equipment has been transformed into a reliable monolithic structure.
2. Elevation differences have been eliminated and the equipment has been aligned in accordance with technological requirements.
3. The reinforced soil is no longer subject to vibrations, eliminating the risk of re-settlement.

Engineering conclusion:

In modern manufacturing, time is the most precious resource. GeoResin technology enabled an aerated concrete plant to avoid months of downtime associated with equipment dismantling and foundation recasting, solving the problem in just a few working days.

Does your equipment need leveling or is your foundation slipping from under you?Don’t wait for critical failure of mechanisms.