COURSE OVERVIEW:

The stability and longevity of rotating machinery are fundamentally dependent on the integrity of the support structure. Baseplate grouting serves as the vital interface between the mechanical equipment and the concrete foundation, ensuring that loads and vibrations are effectively transmitted to the ground. This course explores the critical engineering principles required to design and execute a robust foundation system that prevents chronic misalignment and premature component failure. Proper grouting is more than just pouring material; it involves a sophisticated understanding of material science, surface preparation, and thermal dynamics.

The scope of this training includes the evaluation of cementitious versus epoxy grouts, the mechanics of anchor bolt tensioning, and the environmental factors that influence curing. Participants will analyze the lifecycle of a foundation from initial soil compaction and concrete pouring to the final precision leveling of the machine base.

Coverage extends to modern inspection techniques and troubleshooting methodologies for existing foundations that show signs of degradation. By examining case studies of foundation-related failures, the course highlights the importance of maintaining structural stiffness and damping characteristics. Attendees will gain the technical expertise necessary to oversee grouting projects that meet international standards and significantly improve the reliability of plant assets.

COURSE OBJECTIVES:

After completion of this course, the participants will be able to:

1. Explain the primary functions of machinery foundations and grout layers.
2. Differentiate between the physical properties of epoxy and cementitious grouts.
3. Select appropriate grouting materials based on equipment vibration profiles.
4. Execute comprehensive surface preparation on concrete to ensure a high bond strength.
5. Demonstrate the correct procedure for cleaning and degreasing metal baseplates.
6. Calculate the required grout volumes and flow rates for complex baseplate geometries.
7. Manage the curing process by controlling ambient and material temperatures.
8. Perform precision leveling and shimming of equipment before the grouting stage.
9. Identify and eliminate the root causes of grout voids and air entrapment.
10. Interpret the requirements of industry standards such as API RP 686.
11. Implement effective anchor bolt designs and proper tensioning sequences.
12. Diagnose common grout failures, including debonding, cracking, and oil saturation.
13. Conduct post-grout sound testing and vibration analysis to verify support integrity.

TARGET AUDIENCE:

Maintenance Engineers, Mechanical Technicians, Civil Engineers, Reliability Specialists, and Project Managers are involved in machinery installation and plant construction.

TRAINING COURSE METHODOLOGY:

A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximise the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.

The course participants shall be evaluated before, during, and at the end of the course.

COURSE CERTIFICATE:

National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants completing a minimum of 80% of the total attendance time requirement.