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DETAILING OF MACHINE FOUNDATIONS

CHECK LIST FOR ANALYSIS, DESIGN AND DETAILING

OF MACHINE FOUNDATIONS

TCE CONSULTING ENGINEERS LTD.

414, VEER SAVARKAR MARG,
PRABHADEVI, MUMBAI – 400025.

FILE: M6-CV-CL-RC-020(R1).DOC VALID UPTO: 31-12-2006

REV.NO. R0 R1 ISSUE

INITIALS SIGN. INITIALS SIGN. INITIALS SIGN. INITIALS SIGN.

PPD.BY SSP Sd/- CCS

CHD.BY SVV Sd/- SND R1

APD.BY RDD Sd/- FFH

DATE 1997.07.01 31-12-2003

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REVISION STATUS SHEET

REV NO. DATE DESCRIPTION

Company name changed & validation status revised.
R1 31-12-2003
Minimum Grade of concrete changed to M25.

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For design of foundations of PUMPS, COMPRESSORS, MOTORS, DROP

and FORGE HAMMERS consider the following :

1. Classify the type of Machine Foundation as under:

a) Foundations for Reciprocating Type Machines:

For example: Compressors, Pumps, Diesel and Gas Engines and Steam
Engines.
b) Foundations for Low Frequency (less than or equal to 1500 RPM)
Rotary Type Machines:
For exmaple: Rolling mills, Crushing mills, Pumps, Motors, Generators,
Rotary Compressors.
c) Foundations for High Frequency (more than 1500 RPM) Rotary Type
Machines :
For example: Turbo Generators, Turbo Compressors, Blowers.
d) Foundations for Impact Type Machines - Drop and Forge Hammers
e) Foundations for Impact Type Machines other than Drop and Forge
Hammers:
For example: Forging and Stamping Press.

2. Data required:
Collect design data as given below from Vendor drawings. This data is
generally common for all types of machines.
A. General:

i. Description of the Driving and Driven Machinery:

Identify the parts driving the Machine and the parts driven.
Obtain the sizes of machine parts, their position and orientation,
their weights, the centre of gravity of these parts w.r.t. the
centre line of the machine (axis of rotation). This is required to
estimate the Mass Moment of Inertia of all machine parts about
the three Principal axes.
ii. Operating speed and speed ranges.
iii. Maximum capacity or Rated Output of the Machine in kW if the
loads due to Dynamic Short Circuit Moment conditions are not
given.

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iv. The exact configuration of the top of the foundation to suit

proper placement of the machine as desired by the Machine
manufacturer in plan and elevation, i.e. General arrangement of
foundation block indicating details of pockets, foundation bolts,
openings, inserts, pipe sleeves, etc. Also check who supplies
foundation bolts/ inserts.

B. Static Loads:

i. Obtain a Detailed loading diagram comprising plan, elevation

and section showing weights and dimensions of the components
and also the details of location of all loads on the foundation.
ii. Details of the layout of Auxiliary Equipment or Mechanical
Equipment.

C. Dynamic Loads:

i. Collect all the details of unbalanced forces and couples together

with the associated frequencies for all possible modes of
vibrations for the driving modes of vibrations for the driving and
the driven parts of the machine during its operation.
This includes:
External forces; External Primary Couples; External Secondary
Couples and Harmonic Torques as estimated by the
manufacturer.
ii. Loads due to Dynamic Short Circuit Moment conditions and
Abnormal Sudden stoppage.
iii. Details of Anti vibration mountings (Vibration Isolaters) w.r.t.
the type and positions.
iv. Loading as expected during the erection of the machine
(Constructional Loads). The jacking locations and the loads
thereon, during the maintenance of the machine must be
obtained.

D. Data on Ground and Site Conditions:

Obtain the Data as given below from the Soil Investigation Report for
the Static and Dynamic Design of the foundation.
i. Whether pile or open foundation.

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ii. Safe Bearing Capacity of the soil under static loads or pile load
capacity, length, diameter.
iii. The Coefficient of Elastic Uniform Compression (Cu).
iv. The Coefficient of Elastic Uniform Shear (CJ).
v. The Coefficient of Elastic Non-uniform Compression (CN).
vi. The Coefficient of Elastic Non-uniform Shear (C,).

Note:

a) In case only the value of Cu is available the other Dynamic Soil

Constants as given above may be estimated as per formulae given
below:
Coefficient of Elastic Uniform Shear (CJ)
CJ = 0.5 Cu
Coefficient of Elastic Non-uniform Compression (CN)
CN = 2.0 Cu
Coefficient of Non-uniform Shear (C,)
C, = 0.75 Cu
b) In case the value of Cu is not given, then the value of Cu can be
estimated as per Clause 5.4.2 of IS:5249 and the values of the other
Dynamic Soil Constants can be worked out as per Clause 8.1 of
IS:5249 reproduced as below:
Coefficient of Elastic Uniform Shear (CJ)
CJ = 0.67 Cu
Coefficient of Elastic Non-uniform Compression (CN)
CN = 2.32 Cu
Coefficient of Non-uniform Shear (C,)
C, = 1.005 Cu
vii. The distance of all the existing/ future foundations of the
adjacent structures or other equipment from the foundation
under consideration, and their founding levels to avoid
interference.

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viii. Soil profile and exact nature of soil.

ix. Relative position of water table below ground at different times
of the year.

E. Dimensions of the Concrete Foundation : Check the dimensions w.r.t.

the following emperical rules:

i. Mass of the foundation shall be at least 2.5 times greater than

that of the machine in the case of foundations for reciprocating
and rotary type machines [(Clause 5.2.3 of IS:2974 (Part IV) ].
In case of framed type foundations, the mass of the raft shall be
at least equal to the mass of the machine and the superstructure
put together.
ii. The eccentricity of the common centre of gravity of the Static
weight of machine and foundation referred to the centroid of
base area should not exceed 5% of the corresponding base
dimension of the foundation in the case of Reciprocating type of
machines [Clause 5.4.2.2 of IS:2974 (Part - I)] and 3% in the
case of Rotary type of machines [Clause 8.6 of IS:2974 (Part-
III)].
iii. The proportion of foundation block shall be such that the soil
pressure is less than 80% of the Allowable SBC of soil under
static loads alone.
iv. Proportion of the foundation, block shall be such that the centre
of gravity of the foundation system is below the top of
foundation block.
v. Full value of permissible pressure and allowable stresses in
concrete and steel when dynamic loads are considered with
suitable dynamic and fatigue factor.
vi. The amplitudes of vibration under working conditions at the
bearing level should generally be within the permissible limits as
per IS:2974 unless otherwise specified by the manufacturer.
vii. Resonance should be avoided; i.e. the Natural frequency of the
foundation system should be at least 20% away from the
machine frequency as per IS:2974 or as per Manufacturer’s
Specifications. When several foundations for similar machines
are erected on a common raft, assume each machine foundation
as independent by breaking up the raft into sections

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corresponding to separate foundation. Permissible amplitutdes

can be increased by 30%.

F. Detailing of Foundations:

Check the drawing w.r.t. the following:

i. The overall dimensions of the foundation block and orientation
with respect to north line/ building grid.
ii. The Top of Concrete level.
iii. Dimensions of the opening for the foundation bolts.
iv. Centre line/s of the machine/s.
v. Centre line of the foundation block and its distance from the
centre line of the machine/s.
vi. Centre line of the openings w.r.t. either the centre line of the
machine or the edges of the foundation block.
vii. The foundations be separated from the adjacent building
components and foundations at all levels and directions by
means of expansion joints. However when a number of similar
machines are to be installed at close spacing and the soil
conditions do not permit construction of independent
foundations, then the foundations for all similar machines should
be combined by a common raft of adequately designed size so
that deformations are minor as compared to the resultant
amplitudes of vibration.
viii. The foundations be taken to a depth lower than or equal to the
depths of foundations of the adjoining buildings to avoid
transmission of any vibration through soil to the adjoining
building.
ix. The foundation be protected from machine oil by means of acid
resisting coating or suitable chemical treatment.
x. Any steam or hot air pipes embedded in the foundation be
isolated.

H. Check any special requirement in regards to grout such as Epoxy grout,

Non shrink grout.

3. Check List for Foundation for Reciprocating Type Machines:

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Collect additional design data as given below from the Approved Vendor
Drawings.

A. General:

i. Number and arrangement of Cylinders in respect of:

a) Single or two or multi cylinder machine;
b) Single stage or a multi stage machine;
c) The arrangement of cylinders w.r.t. the shaft axis;
d) Vertical or a Horizontal machine.
Note : This is required to be collected if the Mass Moment of
Inertia of all the moving parts of the machine about the
three principal axes, the details of Un-balanced forces
and couples are not given by the Vendor.
ii. Distance of the Axis of the main shaft of the machine from the
top of the foundation.
iii. Gear Box Ratio to know the frequencies of the driving and the
driven parts of the machine.
iv. Maximum operating temperature in the Machine Bases.

B. Concrete (IS-456 cl.6.1) and Reinforcement [(Clause 5.4.5 of IS:2974

(Part-I)]:

i. Concrete grade shall be at least M25.

ii. Minimum reinforcement in concrete block shall not be less than
25 kg/m3. For machines requiring special design considerations
of foundations like machines pumping explosive gases the
reinforcement shall not be less than 40 kg/m3.
iii. The minimum reinforcement in the block shall usually consist of
12 mm dia bars spaced at 200/250 mm centre to centre
extending both vertically and horizontally near all the faces of
the foundation block.
iv. The ends of mild steel (if used shall always be bent irrespective
of whether they are designed for tension or compression).
v. Reinforcement shall be provided around all pits and openings
and shall be equivalent to 0.5% to 0.75% of the cross sectional
area of the opening.

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4. Check list for foundations for Low Frequency (less than or equal to 1500
RPM) Rotary Type Machines:

Collect additional design data as given below from the Approved Vendor
Drawing.

A-1 General: For Motor Generators:

i. Collect the details of the driving motor and the generator, their
weights, weights of rotors for motor and generator separately,
weight of flywheel, and their centre of gravity w.r.t. the centre
line of the machine.

B-1 Dynamic Loads or Live Loads:

i. Construction loads during assembly.

ii. Loads due to machine itself multiplied by dynamic factor of 2.
iii. Torque Load.

C-1 Concrete (IS-456 cl.6.1) and Reinforcement [(Clause 7 of IS:2974

(Part-IV)]:

This is common for all Rotary Type of Machines.

i. Concrete used shall be controlled concrete of grade at least
M25.
ii. All units of Foundations shall be provided with top and bottom
two way reinforcement. Reinforcements shall be provided along
the surface only in case of block foundation.
iii. Amount of reinforcement in each foundation element shall not
be less than 50 kg/m3.
iv. In case of Framed type foundations stirrups as required shall be
provided to tie together main longitudinal bars.
v. Minimum Diameter of mild steel bars shall be 12 mm and
maximum spacing shall be 200 mm to cater for shrinkage in
concrete.
vi. Concrete cover for protection of reinforcement shall be 75mm
at bottom, 50 mm on sides and 40 mm at top.

A-2 General : For Pumps:

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i. Collect the details w.r.t. the mass of pump, speed of pump,

frequency of pressure changes in pump discharge.
ii. Number of impeller vanes to calculate the frequency (f) of
induced vibrations as below :
N .n
f =
60
Where N = Speed of the pump
n - number of impeller vanes

B-2 Dynamic Loads:

i. Construction Loads during assembly.

ii. Total mass of pump multiplied by 3.
iii. Frequency of the vibration due to increase in pressure surges to
perform Dynamic Analysis.

5. Check list for foundations for Impact Type Machines:

Collect additional design data as given below from the Approved Vendor
Drawing.

A. General :

i. Total mass of the Hammer, mass of falling parts (mass of Tup

and Top Die), mass of Anvil (in case, frame of the hammer is
attached to the anvil, the mass of the frame), Maximum Stroke/
Fall of Hammer, Energy of Impact, Number of blows per
minute, Base dimensions of the anvil, Coefficient of impact of
anvil, Effective area of Piston, Mean effective pressure on
Piston (The last two are required in the case of Steam/
Compressed Air Hammers).
The Manufacturer’s drawing showing general cross section,
plan, elevation of anvil, frame base, anvil base, etc. including
details of anchor bolts.
ii. Details of the Cushion pad between Anvil and Block in respect
of;
Material, Elastic Modulus, Maximum Allowable Deformation,
Allowable Stress Intensity.
iii. Details of Cushioning between Foundation Block and Soil :

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If Resilient pad is used, collect data in respect of Material,

Elastic Modulus, Maximum Allowable Deformation, Allowable
Stress Intensity.
If springs and dampers are used, collect data in respect of
maximum allowable spring deflections for normal working as
well as extreme conditions and also for static and dynamic
loads, spring constant.

B. Design Criteria:

i. The foundation block should be such that the centre line of the
anvil and the foundation block and the resultant forces in the
elastic pad and the foundation support, act as far as possible so
as to coincide with the line of the fall of the hammer tup.
ii. For hammers having continuous impacts, the foundation shall be
so designed that the natural frequency of the foundation system
is not a whole number multiple of the operating frequency of
impact. Natural frequency of the foundation system > 2.5 times
or < 30% of the frequency of impact is considered as safe.
iii. The permissible stresses and deformations in cushioning pads
should be within the limits specified by the manufacturer.
iv. Permissible amplitudes of vibration depending upon the mass of
Tup shall be as per IS:2974 (Part II).

C. The machine foundation shall be designed as a 2 - Mass system as per

IS: 2974 (Part II) to estimate the frequency and amplitude of vibration.
This shall be checked as per Para B above. (Refer Chapters I and II of
reference ‘B’ and Chapter 4 of references ‘E’).

D. Dimensional Criteria:

Check the dimensions of the foundation block w.r.t the following

emperical rules (Clause 4.4 of IS:2974 - Part-II):
i. The area of the foundation block at the base shall be such that
the safe loading intensity of soil is never exceeded during the
operation of the Hammer.
ii. The depth of the foundation block shall be such that the block is
safe both in Punching Shear and Bending. The minimum depths
of the foundation block below the Anvil for various Tup weights
shall be provided as follows:

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Upto 1.0 ton ... 1.00 metre

1.0 ton - 2.0 ton ... 1.25 metre
2.0 ton - 4.0 ton ... 1.75 metre
4.0 ton - 6.0 ton ... 2.25 metre
Over 6.0 ton ... 2.50 metre
iii. Mass of the foundation block shall be at least 60 times the mass
of Tup. For foundations resting on stiff clays or compact sandy
deposits the mass of the block shall be 4 to 5 times that of the
Anvil. For moderately firm to soft clays and for medium dense
sandy deposits, the mass of the block shall be 5 to 6 times that
of the Anvil.
iv. In case there are adjacent foundations, the foundation block
shall be so dimensioned that the straight line connecting the
adjacent edges should form an angle not exceeding 25 degrees
with the horizontal. If they lie close to each other, identical
foundation depths may be adopted for the foundations and the
building.

E. Concrete (IS-456 cl.6.1) and Reinforcement:

This is common for all Impact Types of Machines.

i. Concrete used shall be of grade at least M25.
ii. If casting of the entire foundation block is not possible in one
operation, the following measures are recommended (Clause 6.2
of IS:2974 Part-II):
Dowels of 12 to 16 mm diameter at 60 mm centres should be
embedded to a depth of at least 30 cms on both sides of the
construction joint.
iii. Reinforcement shall be arranged along the three axes and also
diagonally to prevent shear. More reinforcement shall be
provided at the top side of the foundation block than on other
sides. Reinforcement at the top may be provided in the form of
layers of grills made of 16 mm diameter bars suitably spaced to
allow easy pouring of concrete. The topmost layers of
reinforcement shall be provided with a cover of at least 50 mm.
The reinforcement provided shall be at least 50 kg/m3 or as
specified in IS:2974 (Part II).

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iv. In case of framed foundations, seismic effects are to be

considered.

6. REFERENCES:

A) Dynamics in Civil Engineering (Analysis and Design) Vol. I by A.Major

B) Dynamics in Civil Engineering (Analysis and Design) Vol.II by A.Major

C) Dynamics of Bases and foundations by D.D.Barkan.

D) IS:2974 (Parts I, II, III, IV, V) - Code of Practice for Design and
Construction of Machine Foundations.

E) Hand book of Machine Foundations - By P.Srinivasulu.

F) Solved Numerical Examples for Block Foundations - Section 4.4.8 of

‘E’ above.

G) Solved Examples for Foundations for Reciprocating Type Machines

(Page 137 to 160) of ‘B’ above.

H) Solved Examples for Foundations for Impact Type Machines - 1 and 2

of ‘B’ above.

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