Handbook Of Shaft Alignment Episode 1 Part 6 pot

The four bottles of hardener arrived and the pour began in earnest at 1245 h. The

procedure was to blend the liquids (epoxy and hardener) for 3 min and then slowly add

each bag of aggregate to the mixture as shown in Figure 3.47. Once the fourth bag of

aggregate was added, another 2 min of mixing was suggested before the grout should be

poured. An electric drill with a mixing blade was used to mix the contents. When the first

batch was mixed together, it became apparent that the mixture was very viscous (almost like

peanut butter). The drill motor quickly became overloaded and the windings began to

overheat and smoke. Another drill motor was at hand so the drills were swapped out and

by the second batch, it too became overheated. A larger drill motor was quickly found to

handle the mixing with one batch mixed at a time. After adding all the contents, the barrel

weighed around 250 lb, a little too heavy for two people to lift and pour directly into the

baseplate.

Because of the viscosity of the grout, the most effective way to pour was by hand, scooping

the grout out of the mixing barrel and then pouring it into a hole as shown in Figure 3.48.

After the barrel got half empty, it was light enough to be lifted by two people. We then would

fill up a 5 gal bucket and use it to pour while another one or two people would continue to

scoop it out with the smaller buckets (which were made with thick plastic 1 gal laundry

detergent containers). Thankfully, two barrels were available where one crew would pour the

grout whereas another crew would mix the next batch. Initially, each batch took 15 min from

the time the mix was started to the time the barrel was empty. After a quick calculation, it was

FIGURE 3.46 Protecting the baseplate and surrounding area with plastic covering.

FIGURE 3.47 Mixing the grout contents.

Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C003 Final Proof page 120 29.9.2006 5:53pm

120 Shaft Alignment Handbook, Third Edition

conveyed to the work crew that it would take 4 h to finish the pour, far in excess of the cure

time so additional personnel were called in to speed up the process as shown in Figure 3.49.

About the time the fifth batch was poured, we noticed that the wooden form around the

baseplate started to leak as shown in Figure 3.50. Thankfully, we had the foresight to have

some duct sealant at hand in the event that this happened and the leaks were plugged as

shown in Figure 3.51. It then took approximately 6 min for each batch with bodies scrambling

around feverishly mixing and pouring the grout. At 1530 h the final batch pour was made as

shown in Figure 3.52.

The top plate of the baseplate was designed with a slope toward the pump side so in the

event of a water leak, the water could drain off the base to prevent rust from damaging

the baseplate. Knowing this, we started the pour at the low end of the baseplate. Once the

entire baseplate was filled, the grout began to flow and seek its own level and we noticed that

the grout began to swell higher in the pour holes at the low end of the baseplate and drop

down at the high end as shown in Figure 3.53. As seen in Figure 3.54, we then topped off the

pour holes at the high end hoping that the epoxy would begin to harden at the low end where

the pour first began to prevent it from overflowing onto the top of the baseplate. The grout

indeed did begin to slowly harden and, in fact, became somewhat like a soft putty so it

was decided to begin carving off the grout that had leaked out around the form as shown in

Figure 3.55 and Figure 3.56.

FIGURE 3.48 Pouring the grout.

FIGURE 3.49 More people needed.

Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C003 Final Proof page 121 29.9.2006 5:53pm

Foundations, Baseplates, Installation, and Piping Strain 121

FIGURE 3.50 Grout leak around form.

FIGURE 3.51 Plugging the leak with duct sealant.

FIGURE 3.52 Finishing the pour.

Piotrowski / Shaft Alignment Handbook, Third Edition DK4322_C003 Final Proof page 122 29.9.2006 5:53pm

122 Shaft Alignment Handbook, Third Edition