CHAPTER II

MACHINE FOUNDATION

The power plant be situated nearby the river area for easy access to water supply

for cooling purposes where the bed soil is composed of ordinary rock

1.1. MACHINE DESIGN PARAMETERS

Brand MAN

Model Name 9L48/60B

Genset Weight Wm = 146 metric tons (146,000 kg)

Length L = 11,425 mm

Width W = 3,325 mm

Height H = 5,360 mm

Soil Type Ordinary Rock

Safe bearing power stress of soil 85-110 (average = 97.5)

Engine L48/60B

3,325 mm

5,360 mm

700
700

1,280
1,2 80

9,895 mm 2,100

11,425 mm
1.2 WEIGHT OF THE FOUNDATION

From the Philippine Mechanical Code, 2008 Edition, Chapter 2, Sec. 4.0, Article

4.1 b, states that “Foundation mass should be from 3-5 times the weight of the machinery

it is supposed to support.” For safety design, use the maximum which is 5.

Wf = 5 (Wg)

Therefore,

Wf = 5 (146 tons)

Wf = 730 tons

1.3 LAYOUT AND DIMENSIONS OF TRAPEZOIDAL CONCRETE

FOUNDATION (based on Prime’s Mechanical Engineering Pocket Reference Manual

by R.S. Capote and J.A. Mandawe, 2009)

Wm

Wf

Where:

c = clearance

W m = weight of the machine

 W f = weight of the foundation

L = length

a = upper width of foundation

b = lower width of foundation

h = height of foundation

Bed Plate Dimensions:

Length = 11,425 mm

Width = 3,325 mm

Length of Foundation

Allow a clearance from the edge of 20% of the length of the bed plate.

Thus:

For the length of the foundation, L

L = 11,425 mm + 2(0.20 x 11,425mm)

L = 15,995 mm

Say use: 16 m
Upper Width of Foundation, a

a = w + 2c

Where:

w = width of the bed plate

c = clearance

Thus,

a = 3,325 mm + 2(0.20 x 3,325 mm)

a = 4,655 mm

Say use: 4.66 m

Volume of Machine Foundation, V f

Wf
Vf=
ρ

Where:

ρ = 2,406 kg/m 3 (for density of concrete)

Thus,

730,000 kg
Vf= 3
2,406 kg /m

V f = 303.41 m3
Lower Width of Foundation, b

S b W m +W f
N = b(L)

Where:

Sb = safe bearing power of soil

Wm = weight of the machine

Wf = weight of foundation

L = length of foundation

N = factor of safety, usually 2

From Soils and Their Bearing Capacity by civilengineering.blog (2017)

SAFE BEARING POWER OF SOILS

Soil Type Tonnes/m2

Ordinary Rock ………………………..…………………….…… 85 – 110

The safe bearing power of soil for ordinary rock is within the range of 85-110

tons/m3. Use average bearing stress.

Thus,

2(W ¿ ¿ m+W f )
b= ¿
Sb ( L f )

2(146 +730) tons

b= 2
(97.5 tons/ m )(16 m)
 b = 1.123m

Since the lower width “b” comes out to be less than the upper width “a”, therefore

it is customary to make “b” equal to “a”, and so the foundation has a rectangular cross-

section.

Thus,

a = b = 4,655 mm

= 4.66 m

Depth of Machine Foundation, h

2V f
h=
aL

Thus:
3
2( 303.41m )
h=
( 4.66 m)16 m

h = 8.14 m

AREA OF RECTANGULAR FOUNDATION, AF

AF = LF x a

AF = 16 (4.66)

AF = 74.56 m2
TOTAL WEIGHT IMPOSED BY THE MACHINE AND FOUNDATIONS ON

SOIL, Wt.total

Wt.total = Wm + Wf

Wt.total = (146 + 730) tons

Wt.total = 876 tons

STRESS IMPOSED BY THE MACHINE AND FOUNDATION ON SOIL, Si

Wt . total
Si =
AF

876tons
Si = 2
74.56 m

Si = 11.75 tons/m2

1.9 FOUNDATION FACTOR OF SAFETY, FS

Sb
Fs =
Si

97.5tons /m2
Fs =
11.75tons /m 2

Fs = 8.29

Based on the foregoing computation, the foundation is calculated to be safe since

it’s factor of safety exceeds the allowable factor of safety discussed in Philippine

Mechanical Code, 2003 Edition, Chapter 2, Sec. 4, Art. 4.1 c, which is 5.

ITEM NO. 2.

MACHINE FOUNDATION MATERIAL ESTIMATES

2.1 DESIGN CONSIDERATIONS

a) Use Class A (1:2:4) mixture that is:1 part of cement, 2 parts sand and 4 parts

stone.

b) Determine the quantity of cement, sand and stone using the following data:

To produce 1 cu yard of concrete using 1:2:4 mixture the following are needed

6 sacks of cement, 0.44 cu yd sand and 0.88 cu yd stone.

2.2 COMPUTED DIMENSIONS OF RECTANGULAR FOUNDATION

Length, L 16 m

Width, a 4.66 m

Height, h 8.14 m

Area, AF 74.56 m2

Volume, VF 303.41 m3

2.3 NUMBER OF SACKS OF CEMENTS

No. of sacks = VF x 6 sacks/ yd 3

No. of sacks = 303.41 m3 (6 sacks/ yd 3) (1.307951 yd3/1 m3)

 No. of sacks = 2,381.07 sacks

Say use 2,400 sacks

21,600 sacks of cement for 9 foundations (including future expansion)

2.4 VOLUME OF SAND

Vol. of sand = VF (0.44 yd 3)

Vol. of sand = 303.41 m3 (0.44 yd3sand/yd3 concrete)

Vol. of sand = 133.50 m3

Say use vol. of sand ≈ 140 m3

1,260 m3 for 9 foundations (including future expansion)

2.5 VOLUME OF STONE

Vol. of stone = VF (0.88 yd 3)

Vol. of stone = 303.41 m3(0.88 yd 3 stone / yd 3 concrete )

Vol. of stone = 267 m3

Say use vol. of stone ≈ 275 m3

2,475 m3 for 9 foundations (including future expansion)

2.6 STEEL BAR REINFORCEMENTS

2.6.1 Weight of steel bar reinforcement

(From the Philippine Mechanical Code, 2008 Edition, Chapter 2, Sec.4, Article 4.1 f)
 “Concrete foundation should have steel bar reinforcements placed both vertically

and horizontally, to avoid thermal cracking. Weight of reinforcing steel should be from ½

% to 0.01% of the weight of foundation”.

For safety design, use an average 0.75 %.

Weight of steel bar reinforcement = 0.0075 (WF)

Weight of steel bar reinforcement = 0.0075 (730,000 kg)

Weight of steel bar reinforcement = 5475 kg

2.6.2 Volume for steel bar reinforcement

(From Kent’s Mechanical Engineering Handbook, Production Volume)

Page 6-02 the density of steel is equal to 490lb/ ft 3.

¯
weight of steel reinforcement
Volume for steel bar reinforcement =
density of steel

Volume for steel bar reinforcement =

( 5475 kg x 2.205 )
lb
kg
lb
490 3
ft

1m3
Volume for steel bar reinforcement = 24.64 ft 3 ( )
3.283 ft 3

Volume for steel bar reinforcement = 0.6983 m3

2.6.3 Volume of Steel Bar Reinforcement per Piece,

(Use standard size of steel bar reinforcement with diameter of 16 mm and length of 6 m.)
 2
πD L
Vol. of steel bar reinforcement per piece =
4

Where:

Db = diameter of steel bar reinforcement per piece

Lb = length of steel bar reinforcement per piece

Vol. of steel bar reinforcement per piece = π ¿ ¿

Vol. of steel bar reinforcement per piece = 0.00121 m3/ pc

2.6.4 Total Number of Steel Bar Reinforcement,

¯
Vol . of Steel Reinforcement
Quantity of steel bar reinforcement = ¯
Vol . of Steel Reinforcement per piece

0.6983 m3
Quantity of steel bar reinforcement = 3
0.00121m / pcs

Quantity of steel bar reinforcement = 577.12 pcs

Say use; 580 pcs

5,220 pcs for 9 foundations

2.7 Grouting
Grouting is a process of filling a small clearance between the machine and the foundation

with a hardening mixture. Grout is usually made of a 2:1 mixture of sand and cement,

mixed wet enough to be fully fluid – from PPE by Frederick T. Morse, page 112.
Machine should be levelled by driving wedges between the machine’s base and the

concrete foundation and with the aid of a spirit level. Grout all spaces under the machine

bed with a thin mixture of one part cement and two parts of sand.

The level wedges should be removed after the grout has thoroughly set and fill wedges’

holes with grout.

Foundation should be isolated from floor slabs or building footings by at least 25 mm

around its perimeter to eliminate transmission of vibration.

Volume of the Grout, V G

Using a standard thickness of the grout to be 25mm.

V G =0.025 x A F

Where:

A F =area of foundation

V G =0.025 m *74.56 m2
3
V G =1.864 m

2.7 QUANTITY OF TIE WIRE (G.I WIRE)

From Architectural and Cons. Data by G. Salvan and S. Thapa, Pg. 657, Estimate Guide

for Lay-out and Scaffoldings.

 “For the tie wire, multiply the no. of horizontal bars to the no. of vertical bars,

this gives the number of connections. Then multiply by 0.40 to get the total length of G.I.

wire. Then divide by 126 to get the number of G.I. wire.”

(Assuming the number of bars is placed 1 ft (0.3 m) apart to another both vertical and

horizontal, which means 1 vertical bar is placed vertically per foot of length and width of

foundation and 1 horizontal bar per foot of height both length and width side of

foundation)

No. of Vertical Bars = 1 bar per 1ft of length and width = 23.99

No. of Horizontal Bars = 1 bar per 1ft of height both length and width = 19.84

2.7.1 For the Number of Connections

Number of connections = (Vertical bars x Horizontal bars)

Number of connections = (23.99/0.3 x 19.84/0.3)

Number of connections = 5,288.46 connections

2.7.2 Total Length of G.I. wire,

Total Length of G.I. wire = 5,288.46 (0.4)

Total Length of G.I. wire = 2,115.38 m ≈ 2,120 m

2.7.3 Total Weight of G.I. wire,

2,120
Total Weight of G.I. wire =
126

Total Weight of G.I. wire = 16.83 kg

For cutting loss, add another 10 % allowance

16.83 kg +¿ 0.10(16.83) = 18.51 kg

Say use; 19 kg of G.I wire.

171 kg for 9 foundations