20CEE604T DESIGN OF

REINFORCED
CONCRETE
FOUNDATIONS

MACHINE
FOUNDATIONS
 INTRODUCTION
Machine foundation is rather a specialized subject requiring knowledge of
dynamics and soil structure interactions. Most machines have many moving parts
having forces, accelerations and frequencies of motions which are partly
transmitted to the foundations. There are variety of machines having different
combination of forces and motions. Every machine is designed for certain operating
frequency to give optimal performance. The foundation of the machine must be
designed so as to transmit the forces to the soil with minimum disturbances to the
machine. Machines are anchored to the foundation through foundation bolts, so the
movement of the machine bases are partly damped and partly transmitted to the
foundations. The foundation which may be made of a block or a number of blocks
of concrete or piles, transmits the forces and part of the vibrations to the soil.
 INTRODUCTION

The response of the soil to the vibrations depends on the soil characteristic, mass
and inertia properties of the foundation system and characteristics of the machine.
Therefore, there is a considerable soil structure interaction in machine
foundations. It is difficult to classify the machines into a fixed set of groups as there
are hosts of machinery already developed and still being developed.
 INTRODUCTION
However, one can classify the machines into a number of groups depending on the
types of motions and forces transmitted to the foundation. Every point in three-
dimensional space has six degrees of freedom. A machine may have only one degree
of forced movement when isolated from the foundation but when mounted on a
foundation, the degrees of motion of the machine and foundation system can be
more or at least equal to that of the machine depending on the type of foundation,
and soil and anchorage system. The machines may be classified into following three
groups based on the dynamics of the foundation:
a) Rotary machines.
b) Reciprocating machines.
c) Impact machines
TYPES OF MACHINE FOUNDATIONS
 TYPES OF MACHINE FOUNDATIONS
• A Suitable foundation is selected depending on the type of machine
• For compressors and reciprocation machines, a block foundation is generally
provided.
• Such a foundation consist of a pedestal / pier supported by a thick footing
• If two or more similar machines are to be installed, a single mat may be
preferred. Such a foundation is also known as combined block-type
foundation
• Block foundation are normally modelled as rigid foundation for analysis
 MACHINE VIBRATIONS

Machines operate at certain frequencies and excite the foundations to vibrate. The
vibration of the machine-foundation system depends on several factors such as
masses, base area, inertia properties of the foundation, location and anchoring of
the machine with relation to the foundation and soil characteristics. The main aim
of the designer is to limit the amplitudes of vibrations and to see that the natural
frequency of the system is different from that of the operating frequency of the
machine. As the natural frequency tends towards the operating value, the
amplitude of vibrations increase—which sometimes may increase without bounds.
 ROTARY MACHINES

Rotary machines are classified into three groups based on their speeds:
• Low frequency machines with speeds less than 1500 rpm.
• Medium frequency machines with speeds between 1500 and 3000 rpm.
• High speed machines with speeds exceeding 3000 rpm.
Some of the typical machines that fall under the rotary type are: pumps, motors,
generators, lathes, drilling machines, boring machines, crushing mill, rolling mill
and turbines.
 ROTARY MACHINES

If the foundation is more or less symmetrical and the machine is mounted concentric with the
foundation, the foundation will have a maximum tendency of vertical vibration. The natural
frequency of the system is given by
fz = (K / m) 1/2
where m = total mass of the foundation and the machine.
K = equivalent of soil spring constant also called the vertical stiffness of the soil base
and it is K = keAf
ke = coefficient of elastic uniform compression of the soil.
= force per unit area per unit of settlement.
Af = area of the foundation.
STRUCTURAL DESIGN OF FOUNDATION TO ROTARY MACHINES
The following criteria can be used in the design of rotary machine foundations.
1. The vibrations developed should not cause disturbances to the foundations of the building and other machinery.
The amplitudes of vibrations at bearing levels be limited to the following:
a. For low frequency machines:
Vertical vibrations: 0.06 to 0.12 mm
Horizontal vibrations: 0.10 to 0.15 mm
b. For medium frequency machines:
Vertical vibrations: 0.04 to 0.06 mm
Horizontal vibrations: 0.07 to 0.09 mm
c. For high frequency machines
Vertical vibrations: 0.02 to 0.03 mm
Horizontal vibrations: 0.04 to 0.05 mm
As the frequency of the machine increases, the allowable amplitude of vibration should be reduced. The
amplitudes are also controlled by the service requirements of the machines.
d. The amplitudes of vibration of the foundation or its components be limited to 50% of the values specified
in (a), (b) and (c).
STRUCTURAL DESIGN OF FOUNDATION TO ROTARY MACHINES

2. The natural frequency of the system should not be within 20% of the operating frequency of the machine.
Preferably 40% off from the operating speeds.

3. The bearing pressure on the soil should be within 60 to 70% of the allowable value used for building
foundations.

4. The weight of the foundation need to be at least 2.5 times the weight of the machine to minimize the
vibrations.

5. The allowable stresses in concrete under normal load condition in machine foundations shall be only 40% of
those allowed in building construction. This is to account for fatigue effects.

6. The allowable stress in reinforcement or steel shall be 55% of the allowable value in building construction.

7. The allowable stresses in the structural material under combined action of shrinkage, creep or in seismic
load condition can be increased to 33% of the allowable values under normal working load condition.
STRUCTURAL DESIGN OF FOUNDATION TO ROTARY MACHINES
8. Minimum reinforcement in each direction should be as follows:

0.20 % For low frequency machines

0.30 % for medium frequency machines

0.40 % for high frequency machines

and the total reinforcement for one cubic metre of concrete shall be 50 kg for low frequency, 75 kg for
medium and 100 kg for high frequency machines.

9. Minimum cover to the reinforcement should be:

75 to 100 mm at bottom

50 to 60 mm at sides

40 to 50 mm at top faces

10. Minimum diameter of the reinforcement bars be 12 mm and maximum spacing be 200 mm.
CASE STUDY
MAKINO V80S

Vertical Machining Center

Machine Type : Machining Center
Number of Axes : 5
Work Support : Table
Column Construction : Single
Operation Type : CNC
Number of Main : 1
Spindles
Top RPM : 20000
Horse Power (30 min : 29.50
rating)
Type : Fixed
Weight : 20 tons
Pay Load (Max) : 2.5 tons
 ANCHOR SECTION

MACHINING CENTRE
KEY PLAN
 GENERAL
ARRANGEMENT
DRAWINGS
PILE FOUNDATION DETAILS
REINFORCEMENT DETAILS
 TOP REBAR
ARRANGEMENT
 TOP REBAR
ARRANGEMENT
WORKING OF MAKINO 80s MACHINE
 FOUNDATION FOR IMPACT MACHINES:
Forge hammer consists of three main parts: anvil,
frame and ram or drop hammer called tup. The
anvil rests on good quality timber packing to
receive the impact loads. The impact load could be
imparted either by a drop hammer or by a
hydraulic ram. The anvil and the frame are be
provided solid concrete foundations. The impact
force on the anvil must be partly absorbed by a
semi-elastic padding so as to minimize the damage
to concrete.
 FOUNDATION FOR IMPACT MACHINES:
The impact force of the anvil will generate
vibration in the foundation block. The magnitude
of vibrations and the frequency of the system
depend on the masses and the elastic properties of
the soil. The foundation block can rest directly on
the soil exceeds the allowable limits, then the
foundation block should be supported on a set of
elastic springs or elastic pad. For the purpose of
vibration characteristics, the system is idealized
into two-degree system with two masses as
indicated.
Impact Machine Foundation block on Soil Idealised Vibration of Impact Machine Foundation
Impact Machine Foundation Block Idealised Vibration of Impact Machine Foundation
OPEN DIE FORGING MACHINE
FORGING MACHINE
FORGING MACHINE
DESIGN CONSIDERATIONS OF FOUNDATIONS TO IMPACT MACHINES

The mass of the system must be large so as to absorb the impact energy and provide
minimum disturbances. Therefore, the mass of the foundation is usually in the range of 30 to
200 times the weight of the tup or the hammer. The smaller value is chosen for small hammers
foundation on stiff clays or sandy soils. The depth of the foundation increase with increase in
the impacted energy. The thickness of the foundation varies from 1.5 to 6 m. The base area of
the foundation or the trough plate should be such that the maximum pressure on the soil is
within the limit.
 DESIGN CONSIDERATIONS OF FOUNDATIONS TO IMPACT MACHINES
Further, the combined effect of the base and mass of the foundation is such that the maximum
amplitude is within the allowable limits. The maximum allowable amplitudes are:

1 mm for 10 kN hammer,

2 mm for 20 kN hammer,

3 mm to 4 mm for 30 kN hammer and above.

The natural frequency of the system must be about two and half time the operating frequency of
the machine. In case the natural frequency falls less than the operating value, then it must be below
70% of the operating frequency.

The thickness of the cushion below the anvil must be able to absorb the energy and withstand a
large number of repeated blows. The stress in the cushion must not exceed 50% of the allowable
value under static load condition. The thickness of the cushion increase with increase in the weight
of the hammer. It varies from 200 mm to 1200 mm, the higher value is for heavy hammer. A
minimum reinforcement of 25 to 50 kg/m3 of concrete is recommended.
 Thank You
Dr.P.R.Kannan Rajkumar
95000 20279
[email protected]