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Industrial Grouting Services & Machinery Foundation Repair

Cracked pedestals, spalled concrete and failed baseplate grout can leave pumps, fans, blowers and other machinery without consistent support. The resulting movement can contribute to vibration, alignment problems and premature component wear. Banks Industrial Group (BIG) assesses the damage and rebuilds existing foundations using Belzona repair and grouting systems selected for the equipment, operating conditions and available timeframe. Our crews restore support, protect repaired concrete where needed and help facilities return equipment to service promptly. We serve industrial and commercial facilities in New Jersey, Pennsylvania, Delaware and New York.

completed machine base grout repair with protective coating applied

BIG Machinery Foundation Repair & Grouting Services:

  • Rebuild deteriorated pump pedestals, machinery foundations and equipment support pads
  • Remove and replace cracked, loose or chemically damaged baseplate grout
  • Fill accessible voids beneath existing machinery bases when conditions permit
  • Install epoxy or specialty grout beneath pumps, compressors, fans and other industrial equipment
  • Set or grout anchor bolts and repair damaged anchor locations
  • Provide epoxy chocking and shimming to create uniform equipment support
  • Apply chemical-resistant protection to repaired concrete foundations
  • Install grout for new machinery foundations when required by the project

Why Epoxy Grout Is Used for Equipment Foundation Repair:

  • Faster return to service: Rapid-curing epoxy systems can reduce outage time compared with rebuilding an entire foundation using conventional concrete
  • Foundation preservation: Localized deterioration can often be repaired without demolishing and replacing the entire foundation
  • Resistance to demanding conditions: Selected systems can withstand dynamic loading, vibration, impact, moisture and chemical exposure
  • Uniform load transfer: Properly installed grout helps distribute operating loads between the baseplate and foundation
  • Low shrinkage: Suitable epoxy grouts maintain close contact beneath machinery bases as they cure
  • Strong adhesion: Epoxy grout bonds to properly prepared concrete and steel surfaces.
  • Cold-applied installation: Many systems require no welding or other hot work for grout placement

Need Industrial Grouting Services?

Request an estimate or consultation.
on-site evaluation of disintegrated pump baseplate grout

Evaluation of failed pump baseplate grout prior to repair work.

Signs Machinery Base Grout May Need Repair

  • Cracked or separated grout around the baseplate
  • Hollow areas or visible voids beneath the equipment base
  • Spalled or chemically deteriorated foundation concrete
  • Loose, corroded or damaged anchor locations
  • Baseplate movement or rocking
  • Recurring vibration after mechanical causes have been investigated
  • Oil, acid or process-chemical damage around the foundation
  • Previous patching that has debonded or cracked again
storage tank ring wall concrete repair

Refurbished ring wall beneath the shell of an above ground storage tank.

How BIG Repairs Machinery Foundations

  1. Evaluate the existing conditions. Review the damage, equipment requirements, chemical exposure, loading and customer specifications.
  2. Plan the outage and work controls. Coordinate equipment shutdown, isolation, access and the required return-to-service window.
  3. Remove failed material. Remove loose grout and deteriorated concrete, then prepare sound concrete and steel surfaces.
  4. Rebuild the foundation. Repair pedestals, address anchor locations and install forms or containment as required.
  5. Place the selected grout. Pour, pack or inject the specified material according to the baseplate geometry and repair design.
  6. Cure and return to service. Confirm cure requirements before the equipment contractor completes alignment checks and recommissioning.

Equipment Foundation Repair Examples

crumbled pump baseplate grout

Sulfuric acid damaged the pump pedestals and containment area.

completed pump pedestal baseplate grout repair and coating

Three pump pedestals and containment area coated with Belzona 4311.

Pump Pedestals Repaired During Operation

Leaking electrolyte containing 20% sulfuric acid damaged pump pedestals and containment concrete at a metallurgical plant. The damaged areas were rebuilt with Belzona 4131 Magma-Screed and protected with Belzona 4311. Repairs proceeded while the pumps operated, restoring support and chemical protection while helping avoid an interruption to metal production.

deteriorated pump foundation concrete

Acid-damaged concrete loss beneath the pump baseplate.

pump base concrete rebuilt with Belzona epoxy mortar

Belzona 4111 Magma-Quartz rebuild restores stable pump support.

Acid-Damaged Pump Foundation Rebuild

Acid exposure in this blending farm containment area deteriorated the pump’s concrete foundation, compromising support. BIG rebuilt the damaged base with Belzona 4111 Magma-Quartz. The fast-curing epoxy restored a stable mounting surface without full replacement, helping the client limit downtime and extend the foundation’s service life.

deteriorated equipment pedestal

Deteriorated grout beneath the sulfuric acid tank supports.

grout rebuild of concrete equipment pedestal

Rebuilt tank pedestal with Belzona 7111 beneath the steel supports.

Sulfuric Acid Tank Pedestal Regrouting

Failed grout had disbonded beneath a sulfuric acid tank at a water treatment plant. After loose material was removed and new anchors and shims installed, Belzona 7111 was poured beneath the steel supports. Filling the voids restored stable support and helped preserve the tank-support geometry without replacing the concrete pedestal.

corroded chemical storage tank support base

Before: Sulfuric acid damage to the concrete tank support base.

grout repair of corroded chemical storage tank support base

After: Tank base rebuilt with Belzona 4111 and finished with Belzona 4181.

Sulfuric Acid Tank Base Repair

Sulfuric acid exposure deteriorated this tank’s concrete support base. BIG rebuilt damaged areas with Belzona 4111, then applied Belzona 4181 AHR Magma-Quartz as an acid-resistant finish. The in-place repair preserved the existing foundation, restored support and helped protect against further chemical deterioration without full replacement.

industrial exhaust fan at mineral processing facility

Industrial exhaust fan before its baseplate grout repair.

exhaust fan baseplate to foundation grouting application

Regrouted baseplate restores firm support for the exhaust fan.

Exhaust Fan Baseplate Grout Repair

Operational vibration broke down the grout beneath this industrial exhaust fan, leaving its baseplate inadequately supported. BIG injected grout beneath the baseplate to fill voids and restore firm contact with the concrete foundation. The targeted repair improved equipment stability while avoiding a more disruptive foundation rebuild.

crumbled fan pedestal

Crumbled fan pedestal during demolition preparation in tight quarters.

fan pedestal base rebuilt with Belzona

Fan pedestal rebuilt with Belzona 4111 in place despite limited access.

Fan Pedestal Rebuilt in Tight Quarters

A crumbling concrete pedestal threatened stable support for an industrial fan. BIG rebuilt the damaged area in place with fast-curing Belzona 4111. The repair restored a sound base without full replacement, helping the client limit downtime and extend the pedestal’s service life.

deteriorated pulverizer foundation

Crumbling concrete and grout at the pulverizer base threatens operation.

pulverizer baseplate grout repair

Pulverizer foundation rebuilt with Belzona 4111 Magma-Quartz.

Pulverizer Foundation Rebuild

Crumbling concrete and failed grout compromise support at the pulverizer base. BIG rebuilt the damaged area with Belzona 4111, preserving the existing foundation. The fast-curing epoxy repair restored a sound support surface and helped the client limit downtime and avoid a more extensive replacement.

7111 chocking material poured into a form

Chocking material poured into a form beneath the pump baseplate.

pump base plate chocking

Cured chock provides stable support beneath the pump.

Epoxy Chocking & Shimming for Stable Equipment

Gaps beneath machinery bases can concentrate loads, increase vibration and accelerate wear. BIG uses Belzona chocking and shimming materials to fill gaps and restore support. Better load transfer helps preserve alignment, protect components and reduce the risk of unplanned downtime.

Request an Estimate or Consultation

If a machinery foundation is cracking, a pedestal is deteriorating or baseplate grout has failed, contact BIG to discuss an on-site assessment. Tell us about the equipment, visible damage, operating conditions and available shutdown window. We’ll recommend a repair approach suited to the problem and provide an estimate or consultation. Call 856-687-2227 or email our industrial grouting and machinery foundation repair team.

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