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Foundation process of any object consists in setting it on foundation and in proper centring with use of adjusting screws or wedges. Such object should be placed upper of about 0,001 - 0,002 of chocks' height with taking into consideration of contraction of materials during the time of its curing and strains, which may be caused by the weight and tension of foundation bolts. After the proper set-up of the object on foundation, there must be drilled the holes in foundation plate for foundation bolts.

Bedplate of engine and foundation should not be machined, but they must be only cleaned off mechanical impurities and lubricant. Only the presence of a thin coat of high-quality oil paint on bearing surfaces is to be allowed.

Foundation process
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In those places, where the chocks must be placed, the polyurethane and polyethylene moulds must be made. The inner dimensions of mould (L and B) have to meet the dimensions of chocks, according to the object foundation documentation. Headwall of the mould must be made of steel sheet, which should be attached to the foundation. Then the slot between sheet and foundation should be sealed.

Poured moulds must be performed with a gate of width of 15 - 30 mm which enables to fill up with liquid mixture. Near the above mentioned gate, the mould should be more higher above the chock in order to obtain the surplus of mixture, necessary to fill up the mould. Practically the gate to be made on the whole length L of the chock.

In order to enable dismantling, before the close of mould with the headwall, the surfaces adjoining with material are to be covered with release agent.

Into the holes of foundation bolts, there should be through-placed (with a little interference) tubes made of a soft rubber or foundation bolts have to be installed, on which the nuts must be slightly tightened up. Surface of the bolt, adjoining with EPY, is to be covered with release agent as well.

Moulding
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Foundation bolts - animation
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EPY compound consists of two components. It has been delivered with hardener in sets with mass of: 1.07, 3.21, 6.42 or 12.84 / 1 kg = 0,625 l /. The proper quantities of hardener have been delivered in separate containers. Both components should be accurately intermixed. Such mixing process lasts a few minutes and it has been done by hand with utilization of drill equipped with a special rabble. Since the commencement of mixing operation, there remains about 20 minutes until the creation of the gelation process of composition. The temperature of mixed components amounts to 15-25°C, and ambient temperature in close by chocks - minimum 10°C.

The moulds should be poured slowly and in continuous way until the moment of complete filling up of mould and top riser. The top riser creates proper hydrostatic pressure and ensures a reserve of EPY compound for the whole chock. It guarantees the proper contact of the poured chock with the bearing surface of machinery frame.

Time of hardening of chock depends on ambient temperature and amounts to:

72 hours in temperature of 10 °C,
48 hours in temperature of 15 °C,
24 hours in temperature of 20 °C.

Stirring
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Casting of chocks
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In foundation bolt connections of some object, there have been often applying some numbers of fitted bolts; the main aim of this bolts is to state of mutual position of joined elements. The fitting of the bolts with traditional way, consisting in grinding of arbors and reaming of holes, has been labour-consuming, expensive and arduous operation. Identical task can be accomplished by the fitted bolts in EPY compound. Fitting of the bolts in EPY means to place the bolts with the proper clearance into the holes of the foundation plate and frame of seated object and filling the poured mould with EPY material to the level of upper plane of frame of object; in such case EPY compund fills area around the bolt. After hardening of EPY compound, the bolt connection has been gained, and it meets all requirements concerning the connections with the fitted bolt.

Fitted bolts
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Fitted bolts - animation
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After hardening of chocks, there have been moved out the external elements of the mould and next the grind off of the feather edges of chocks have to be done. Then the adjusting screws should be unscrewed (or wedges must be moved out) and next - nuts of foundation bolt have to be properly tightened and finally foundation of object must be checked.

 

 

Chocks, which have been produced in such professional way, ensure precious and stable foundation of object in many-years time of operating.