CONCRETE powerpoint rev 12 2008

Epoxy Injection Repair MethodEpoxies are a Composite that consist of 2 or more components to make a material specifically designed for certain Applications and Chemical Exposures Epo

Presented By: Jason Lewis

Concrete and Composites Regional Manager

Grout Packing Injection Repair

Foundation Repair

Foundational Failure Is One Of The Most Common Factors Leading To Vibration In Pump and Motor Basins

If Foundational Failures Are Not Addressed You May Experience

Significant Particle And Coupling Wear Which May Result In Premature Replacement And Unscheduled Shut Downs

-Corroding Reinforcing

Steel in the Basin

- Chemical Attack To The

Basin

Foundational failures can occur from-

Deteriorating Grout Packing Is a Major Contributor

Of Motor And Pump Foundational Vibrations

- As Grout Packing deteriorates

it cracks and refines itself to

granules or dust due to

Vibration Transfer from the

Pump and Motor to the sole

plate

- This deterioration

Causes voids under the sole plate

creating foundational Instability and

Vibration

- Combined with centrifugal force the Sole Plate will lift from the Grout Packing allowing voids

to move linear

Including the Footpads & Anchor

Points transferring to the Motor ,

Pump and possibly the Pipe

This will allow

Vibration to travel

throughout the Sole

The Footpads And Equipment Anchor Points

Previous Vibratory Solution Methods Included Shimming the Anchor Areas

Although this method has been

widely accepted for aligning the

Pump and Motor and Specked by

some Manufactures, It may have

adverse affects when related to

Vibration

The Machine Level- Where the Pump and Motor

meet- Should be Laser aligned

If the Machine Level is out of alignment It is

recommended to Mill to near perfect conditions

This Method is only recommended if you have taken

steps to ensure the Foundation and Soul Plate are Sound

Epoxy Injection Repair Method

Epoxies are a Composite that consist of

2 or more components to make a

material specifically designed for certain

Applications and Chemical Exposures

Epoxies used for Grout Pack

Solidification and Basin Injection have a

compressive strength ranging from

8,500 PSI (when applied at 73°F and 1

day cure) To 12,000 PSI (at 73°F and 28

day full cure)

The Injection Method Is Minimally

Invasive Only Requiring Holes to be

drilled in Hollowed Locations and can

be Pumped under High or Low

Epoxy Injection Repair Method

Where Can Epoxy Injection Can Be

Structural Reinforcement Applications

Reinforcing Steel Mitigation

Steps For Epoxy Injection Repair Method

(Please Note That it is Best That The Pump And Motor Are Removed Prior to Injection for access to the Interior Sides of the Footpads)

1-Perform Acoustic Testing Of Entire Sole

Plate to Determine the Hollowed Areas

2-Mark Hollowed Areas To Be Drilled

3- Drill areas marked with 1/8 Bit

4- Place Injectors in Drilled Holes and Apply

High Modulus Epoxy Gel around Injectors to

secure in place and coat any potential leak

sources and allow to cure for 1 hour

Steps For Epoxy Injection Repair Method

(Please Note That it is Best That The Pump And Motor Are Removed Prior to Injection for access to the Interior Sides of the Footpads)

5- Begin Injecting Epoxies under desired

pressure ( not to exceed 25 PSI)

6- Transfer of Materials Under Pressure will

Travel the path of least resistance do to

Viscosity ( around 200 cps)

7-When Product is Visibly flowing out of a

port, the port that is being injected will be

capped and the Injector valve will be moved

to the flowing port to ensure product

movement linearly

Steps For Epoxy Injection Repair Method

(Please Note That is Best That The Pump And Motor Are Removed Prior to Injection for access to the Interior Sides of the Footpads)

8- Once product has Visibly been seen

flowing out of all installed Ports and then

capped, the operator will flow product to the

maximum 25 PSI to test resistance, if none is

found, the final port will be capped and

Materials will be allowed to Cure

Foundational Repair

Foundational Repair

Foundational repairs are

required when the stability

of the structure has been

Foundational Repair

Concrete breathes or expands and contracts do to the Environmental or Chemical elements it is subjected to

This allows water,

moisture vapors and

Even the smallest of

cracks in the structure

will allow absorption of

moisture providing a

direct path to the

reinforcing steel

Foundational Repair

If steps are not taken

to mitigate corrosion

the reinforcing steel

will absorb the

moisture, expand and

create a spawl

weakening the

structure

This will also allow the

corrosion to move linear

through the steel creating

significant damage which

may result in total failure of

the basin

Foundational Repair

Repairs can include:

1- Cement Repair

2-Pressure Grouting

3- Epoxy Mortar Repair

4- Epoxy Injection Method

Maximizing Asset Uptime

Everything we do centers around keeping

your assets operational

profitable at all times

Hot-Tapping and Line Stopping OEM for World Class Tapping and Stopping Machines Engineering Services

Online Leak Sealing On-Site Machining and Bolting Valve Repair Shop or On-site Trevitest On-line

Valve Testing Tank Roof Repair Concrete and Composite Repairs Heat Treatment Services

FURMANITE S HISTORY & EXPERTISE

Since 1929, Furmanite has maintained its leadership role in the research and development of on-site repair and maintenance

2006 , Furmanite purchases the Global Services Group (GSG) of Flowserve

Furmanite is the single most authoritative source for all of your global industrial services needs

DOMESTIC SERVICE CENTERS

For a complete listing of regional and global Furmanite locations, visit us online at www furmanite com

Central to Everything We Do

Furmanite has a full-time safety director and a comprehensive safety program

In 2005, we completed one-million man hours (over two years) without

a lost-time injury Every technician must be certified

in safety training

FURMANITE TECHNICIANS

Safety Backed by Training

New hire (8 hours)

HAZWOPER (40 hour)

OSHA (10 hours)

Annual refresher (8 hours)

Area safety councils Supervisor s training (four days)

SAFETY DOCUMENTATION

Tracking Safety Success

On-site job reference manual Daily job safety analysis

Weekly safety meetings Equipment safety logs Corporate safety audits Site specific SOPs

Servicing All Types Of Industry

Pharmaceutical

Servicing :

Maintenance Outages Turnarounds Capital Projects Call-Outs

SERVICES AND SOLUTIONS FOR

EVERY BUSINESS SECTOR

MUNICIPAL

- Sanitary Sewer Systems

- Water Treatment and Distribution Plants

- Airports

- Schools

- Hospitals

- Bridges , Ports, Roadways and Tunnel Systems

- Stadiums and Arenas

SERVICES AND SOLUTIONS FOR

EVERY BUSINESS SECTOR Industrial

SERVICES AND SOLUTIONS FOR

EVERY BUSINESS SECTOR Commercial

- Building Management and Investment Groups

Epoxy Injection

Urethane Injection

Water Stops

Surface repair and Coatings

Restorations and Secondary Containment

Structural repairs

Pipe and Structural Composite Wraps

Structural Repair and Expansion Joints Water Control (Leak Stoppage)

Surface Repair (coatings and linings) Epoxy Injection

Pump and Motor Base Repair Soil Stabilization

Pipe Penetrations Secondary containment Restoration projects

EPOXY INJECTION:

Low Viscosity Moisture Insensitive Easy Application

Can be done under low or high pressure

Extreme High Strength Chemical Resistance 100% Solids

Holes drilled into concrete at strategic locations

Two part epoxy resin is injected

24 to 72 hours for final cure

High and low modulus gels Viscous ( to +/- 0 cps) 100% solids

GROUTS, EPOXIES & COATINGS

Polymer cementitious products and chemical resistant coatings repair surface damage as a

result of:

Corrosion Chemical Attack Freeze/Thaw Wear & Abrasion Physical damage

URETHANE GROUT INJECTION:

Cost Effective Non-Toxic Single component Void Fill Capability - Vertical and Horizontal Can be used as a flexible joint or gasket

No Down Time - Work can be completed while components are online

Stops water intrusion in cracks, joints and pipe penetrations

Can be used in potable water applications

Repair sealant capabilities:

Thin enough to penetrate hairline cracks

Work in flowing water Bond to wet surfaces Remain flexible and inert after quick curing

Solution for problems such as:

Freeze / thaw damage Corrosion of reinforcing steel Erosion of the structure

Mineral deposits Loss of dry environment

COATINGS AND LININGS

COATINGS:

Rapid Cure, Fast Turnaround, Minimal Downtime

Available Equipment to Heat Treat for Specialty Coatings

Resistant to Acids and other Chemicals

Odorless

Tough Elastomeric Membrane Liners

Excellent Wear & Adhesion

Traffic Resistant

Wide Variety of Colors

Surface Overlayments &

Toppings

Expansion Joint Design & Repair

Spall Repair With Epoxy Adhesive & Polymer Concrete

PIPE & COMPOSITE WRAPS

PIPE WRAP & COMPOSITE WRAP:

Low Cost

Pipe Wrap gives back to 100% integrity with up to 80%

wall loss due to corrosion or blunt defects

Utilizes High Strength Carbon Fiber or Urethane

Impregnated Fiberglass Cloth

No Downtime work can be done on-line

Engineered Solution

Conforming -Can Easily turn Elbows and Tee s unlike most Materials

Is Water Insensitive - Resistant To Bad Rain Weather, Can be Applied Underwater

in Splash Zones and Transition zone

How Composite Wraps Work

Permanent pipe repair Stronger than the existing material Pipe rehabilitation

Small-bore pipe repairs Nozzle repair

Tank repairs Structural repairs

Applied on site

No Workshop Simple Preparation

Resin-impregnated fiberglass tape adheres to PVC, fiberglass, concrete and all forms of metal pipes

Immediately repairs non active leaks and

reinforces pipes Protects against corrosion, abrasion and impact

Effectively stops leaks on pipes

of all sizes Resistant to a wide range of dangerous chemicals

Specialized Product:

Durable and cost-effective solution for permanent reinforcement and repairs

Resin-impregnated fiberglass composite wrap

Stronger than steel, high and high flexural-strength product Increases axial load strength

tensile-and load bearing capabilities in steel (pipe) and concrete

Specialized Product:

Remediates pipes, elbows, tees and concrete structures

Inhibits corrosion and restores pipeline integrity

Resistant to a wide range of dangerous chemicals

Works in wet or dry conditions, including underwater repairs Classified according to ANSI/NSF 61 standards for drinking water safety

Specialized Product:

FurmaWrap- FW2 (continued)

Design and Construction Guidelines

Used for:

Increasing load bearing capacity

Correcting design/construction errors Restoring strength lost from damage/deterioration

Improving seismic performance of existing structures

Blast hardening structures

Traditional Strengthening Techniques

Traditional Strengthening Techniques

Steel Plate Bonding

-Slab flexural strengthening

-Steel plates bonded with epoxy adhesive

-Supplemental anchor bolts

Carbon fiber reinforced polymer (CFRP) laminate applied to surface of the substrate

Material Characteristics

Very High StrengthLight weight

Non-corrosiveNon-magnetic

Materials

Carbon fiber composites Advanced composites Fiberglass composites Structural plastics

Fiber Reinforced Polymers (FRP)

Polymer (Resin)

Fiber Reinforcement

Types of Fiber Reinforcements-

Carbon Fiber

Aramid Fiber

Glass Fiber

Types of Polymers

-Epoxy -Vinyl Ester -Silicone -Phenolic -Polyimide -Ceramic -Geopolymer

CF 130 CF 530 EG 900 AK 60 Design

Thickness 0.0065 0.0065 0.0139 0.0110

Guaranteed Strength 550 ksi 510 ksi 220 ksi 290 ksi

Elastic Modulus 33 Msi 54 Msi 10.5 Msi 17.4 Msi Elongation

at Rupture 1.7% 0.9% 2.1% 1.7%

0 100 200 300 400 500 600

Used for:

External reinforcement of existing structures

Increasing load bearing capacity Restoring strength lost from damage/deterioration Improving seismic performance of existing

structures Blast hardening structures

System Types:

Fabric Systems Laminate Systems

Flexible, unidirectional fabrics woven of high strength fibers that are 10 times stronger than steel

Apply two-component epoxy resin directly onto substrate

Fabric Systems

Fabric Systems

Application

-Apply two-component epoxy resin directly onto substrate

-Place dry fiber fabric into resin

-Apply a second layer of resin to encapsulate the fabric

-Allow the epoxy to cure and form a rigid FRP plate bonded to the

substrate

Laminate Systems

Rigid FRP plates, precured with high strength fibers and resin

Laminate Systems

Application

-Adhesive is placed onto one side

of rigid FRP laminate

Positive Moment Flexural Cracking

Column Wrapping

- Some increase in axial

capacity is possible (very

limited for prismatic members)

-Large increase in ultimate

deformation is possible

-3X to 4X increase in ductility

index is reasonable

- Large columns require

significant number of layers

Lateral failures of columns in a seismic event

Masonry Wall Retrofit

Slab Cut-out

8 Concrete Slab

New 3 x4 opening cut

12 #6 reinforcing bars cut

Strengthening around Openings and Cutouts

The MBrace® System

Replaces steel reinforcement and

prestressing that is cut

Controls cracking

THE INDUSTRIES BEST TWO STAGE EPOXY PUMP

GROUT INJECTION PUMPS

45:1 SPRAY PUMP

BENEFITS OF CONCRETE &

COMPOSITE REPAIR

RESOLVES VIBRATION PROBLEMS

STOPS WATER LEAKAGE

STOPS REBAR EXPANSION

REPAIRS SPAWLED AREAS

SOIL STABILIZATIONS (PERMIABLE SOILS)

REPAIRS PIPING -ELIMINATES COSTLY SHUT

DOWNS OR REPLACEMENTS

MAINTENANCE -ADDS LIFE TO THE

STRUCTURE OR PIPE LINE

SAFETY

FURMANITE QUALITY ASSURANCE

Furmanite is a NUPIC Approved 10CFR 50 Appendix B Supplier and is a member of the Nuclear Industries Assessment Committee (NIAC).

Furmanite s Quality Assurance Program consists of the following manuals:

QA Manual to Nuclear & ISO 9000 format

QA Procedures and Forms Standard Procedure Manual Training Program

Measurement and Calibrations

NIST Traceable NUPIC Approved Calibration Supplier Onsite Pre & Post Calibration

Procedures to applicable Industry Codes

ASME BPVC Sections I, III, VIII and XI ASME B31.1 and B31.3

API, NBIC, AWS

WHY CHOOSE FURMANITE?

Backing of a company

with a global presence and

knowledge base

Over 75 years of proven

experience in solving unique problems

and managing large projects

Quick response with over 25 locations in USA

Diverse and flexible solutions for proactive repair,

maintenance and turnaround support

Experienced, field-proven and motivated technicians

State-of-the-art equipment and tools

Patented technology

Visit Furmanite online at

www Furmanite com

Contact your Local Office:

Jason Lewis 704-488-1140

Or for immediate assistance