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Alphatec Engineering

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Valencia
Alphatec Engineering

Since 1977 we have been repairing foundations, installing new machinery, aligning, and regrouting all kinds of Reciprocating and Rotating Machinery.

03/09/2026

Some of the foundations we get called to are older than the plant's own maintenance records.

Cracking nobody logged. Old anchor bolt pockets from a repair three owners ago. A cold joint someone patched and never mentioned again.

What is the oldest foundation you have inherited, and what condition was it in when you first took it on? Photos welcome in the comments, we would genuinely like to see them. ⚙

01/09/2026

A geothermal turbine foundation, built in an H-shape, had been showing rising vibration for some time. The engineers on site calculated the foundation's mass-to-power ratio and found it too low, so they added new concrete to build up the mass. Vibration stayed high.

The real problem wasn't mass. It was a cold joint between the old and new concrete. Cold joints aren't a structural defect under static load, but they don't transmit vibration energy well, so only the concrete above the joint was doing any damping.

We repaired it with an epoxy resin injection. Vibration dropped back to normal parameters.

If you're running geothermal turbines or pumps and seeing vibration that adding concrete won't fix, get in touch. This is exactly the kind of foundation problem we work on, in geothermal and across heavy industry.

27/08/2026

Most LNG maintenance budgets are optimised for the 20% that barely moves profitability.

Benchmarking across LNG facilities shows that 80% of profitability gains come from increasing reliability and availability, only 20% from cutting costs. The industry benchmark for top performers is "0-99-97-95": zero incidents, 99% reliability, 97% availability, 95% utilisation. Unplanned downtime, not spend, is what separates plants that hit those numbers from plants that do not.

Reciprocating compressors and their foundations are among the most maintenance-intensive assets on an LNG train. A degraded foundation left unaddressed does not just cause vibration and misalignment, it risks the shutdown itself.

Alphatec carries out foundation repair and regrouting with the compressor in place, avoiding the extended outage a full replacement would require. Avoiding two days of downtime on an LNG train pays for the repair many times over.

Reach out to discuss a foundation assessment ahead of your next planned outage. 📊

Sources: Plant Reliability – Hint Global

25/08/2026

Rip out the foundation and start again, or repair what's already there?

At a combined cycle power plant, a gas turbine had failed and its foundation mat was cracked deep inside, where testing found anomalies no surface patch could reach. The rebuild called for reusing the mat, not replacing it.

So we went in through 24 injection points: 126 litres of AT342 epoxy resin, seven hours straight, each point sealed under pressure with AT800 grout. The resin filled the cracks, voids, and cold joints and set into a monolithic mat, verified by core testing.

Four days on site. No new foundation. A turbine base sound enough to rebuild on.

New case study here: https://alphatec-engineering.com/success-cases/gas-turbine-mat-foundation-epoxy-resin-injection/ ⚙️

18/08/2026

Nobody photographs anchor bolts. Everybody photographs the equipment they hold up.

This is Week 10 at DEG 6, Saipan. Full bolt replacement, in progress.

Drill the hole. Set the rod. Grout it in. Repeat, bolt by bolt, in a space too tight to rush.
It is unglamorous work. It is also the difference between a machine that runs for decades and one that shakes itself apart.

Reach out to talk anchor bolt replacement or foundation rehabilitation. ⚙️

13/08/2026

You cannot align your way out of a failed foundation.

Here's a failure chain reliability engineers see constantly but rarely trace to the root:
- Vibration causes grout to crack.
- Cracked grout amplifies vibration.
The two aren't independent problems, they feed each other. So the plant that keeps replacing bearings without ever inspecting the grout is treating symptoms while the actual cause gets worse.

Realignment, rebalancing, another bearing, none of it holds if the foundation underneath has already failed. You're resetting the clock, not stopping it.

This is why the first step should be diagnosis, not a regrout.

Alphatec's root-cause inspection plus Motion Amplification® visualizes exactly where and how the machine is moving, so you fix the cause instead of paying for the symptom on repeat.

Diagnose, don't just patch.

11/08/2026

The oil didn't stay on the surface. It soaked into the concrete, and your standard re-grout is about to seal it in.

On a 20-year-old plinth, "clean, remove laitance, pour" is textbook prep. It's also why the repair fails.

Years of leaks migrate deep into the pore structure, past anything a wire brush or solvent can reach. Pour epoxy grout over that and the bond looks sound, but it's stuck to a contaminated layer, not the substrate. It lets go once you're back in service.

So ask one question before any re-grout on an aged foundation: has this plinth seen chronic leaks? If yes, prep-and-pour is working against you.

That's what AT370 is for. A low-viscosity injection resin that penetrates oil-soaked concrete and cures in place to restore the bond.

Diagnose the substrate. Don't just pour over the problem.

06/08/2026

From a misaligned coupling to a destroyed bearing — what's the actual chain of events, and how fast does it happen? ⏱️

A few thousandths of an inch of offset you'd never feel by hand. Weeks later, a bearing "suddenly" fails. What happened in between?

We put the whole chain reaction on video. Watch it play out 👇

04/08/2026

Foundation integrity is a safety event, not a maintenance item. Especially for hydrogen.

Reciprocating hydrogen compressors run at high pressures with a gas that's uniquely unforgiving: very low molecular weight and a real risk of hydrogen embrittlement.
At those conditions, grout cracking or anchor-bolt loosening isn't a routine repair, it's a reliability and safety issue that can take a unit offline.

That's exactly where the right grout matters. Alphatec's AT808 is pumpable, high-strength, and bonds to cracked concrete ideal for both new installations and remediation. For high-temperature duties, AT130 is rated to 200°C.

As green hydrogen hubs scale around the world, EPC teams have a chance to design foundation reliability in from day one rather than engineer it back in later.

30/07/2026

A compressor starts showing excess vibration. No obvious cause. Where do you look first?

Most people reach for alignment or bearings. The foundation is usually further down the list, and that is often where the answer is.

What is your first check? Curious where reliability engineers land on this.

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Avda 9 De Octubre 1
Valencia
46136

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Lunes	09:00 - 17:00
Martes	09:00 - 17:00
Miércoles	09:00 - 17:00
Jueves	09:00 - 17:00
Viernes	09:00 - 17:00

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