3.

8 MACHINERY FOUNDATION
Power plant machine foundations are important for lots of reasons. They give heavy machinery the
support it needs to remain stable and properly balanced. Additionally, they aid in the reduction of vibrations,
which might otherwise cause engine wear and tear.
Foundations make sure everything works smoothly by maintaining the machinery level and
alignment, which lessens wear and tear on the parts and enhances performance. By shielding the
equipment from environmental elements and dynamic loads, this also increases its lifespan.
Lastly, sturdy foundations improve safety by lowering the possibility of machinery moving or
collapsing, which could endanger workers and harm other equipment. In essence, the safe and effective
operation of power plant engines depends on a solid machine foundation. The procedure involves using a
certain hardening mixture to fill the tiny space left between a machine and its foundation after it has been
leveled and appropriately positioned.

● Monolithic Foundation: is made by continuously pouring the entire mixture of concrete into one
operation, enabling the structure to solidify and harden into a single, integrated piece.
● Grouting: the procedure involves using a certain hardening mixture to fill the tiny space left
between a machine and its foundation after it has been leveled and appropriately positioned.
FUNCTIONS OF MACHINE FOUNDATION
a. To support the weight of the machine and to distribute the weight of the machine and its own
over a safe sub-soil area
b. To absorb the vibration produced by the machine
c. To maintain the alignment of the machine
DESIGN PROCEDURE IN MACHINE FOUNDATION
1) Knowing the bedplate dimensions of the machine, determine the upper
dimensions of the foundations “a” and “L”. Allow a clearance from the edge of
about one foot or about 10% of the length of the bed plate
2) Knowing the weight of the machine, Wm. Determine the required weight of the
foundation, Wf, by any of the follow methods
a) Wf = (3 to 5) x We
b) Wf = e x We x √𝑁
c) Volume of the foundation can be computed based on HP of the engine
[See table 2.4.2.3(5)] PSME code
d) Weight of the foundation can be based on the HP of the engine.
[See p.108] MORSE 4-5
3) Knowing the bearing capacity of the soil, solve for the base width “b”. For
machine foundation, use only ½ of the given safe soil bearing capacity. The safe
bearing capacity is computed using a factor of safety of 5.
𝑆𝑏 𝑊𝑒 + 𝑊𝑓
2
= 𝑏𝐿
: : 𝑆𝑏 = 𝑠𝑎𝑓𝑒 𝑏𝑜𝑖𝑙 𝑏𝑒𝑎𝑟𝑖𝑛𝑔 𝑐𝑎𝑝𝑎𝑐𝑖𝑡𝑦
Note: If “b’ will come out less than “a”, then make b=a, that is, the foundation has
a rectangular cross-section.
 4) Using a density of 2,406 kg/m3 for concrete, determine the volume of foundation.
𝑊𝑓
𝑉𝑓 = 2.406
, 𝑚3
5) Compute the depth of the foundation “h”
𝑎+𝑏
𝑉𝑓 = ( 2
) ℎ𝐿
6) Finalize the design, make adjustments in the dimensions if necessary provided
the required volume is maintained, without and reducing the required base area.
7) Use class A (1:2:4) mixture that is, 1 part cement, 2 parts sand, 4 parts stone.
8) Determine the quantity of cement and sand and stone using 1:2:4 mixture the
following are needed: 6 sacks of cement, 0.44 cu. yd sand and 0.88 cu. Yd
Stone.
9) Weight of the steel bar reinforcements needed should be about ½ % to 1% of the
weight of the foundation.
10) Anchor bolts should be embedded in the concrete at least 30 times the bolt
Diameter.
11) The machine foundation must have a safety factor of 5.
12) Foundations should be isolated from the floor slabs or building footings at least
25mm around its perimeter to eliminate transmission of vibration.
13) The machine should not be placed on the foundation until 7 days have elapsed
or operated until another 7 days have passed.
14) Concrete foundations should have steel bar reinforcements placed both
vertically and horizontally, to avoid thermal cracking.
15) Foundation bolts specified size should be used and surrounded by a pipe sleeve
with an inside diameter at least 3 times the diameter of another bolt.
16) Foundation bolt lengths should be at least 18 times the diameter of the anchor
Bolt.
17) No foundation bolts should be less than 12 mm in diameter.
18) Machine should be leveled by driving wedges between the machine’s base and
concrete foundation and with the aid of a spirit level.
19) Grouting all spaces under the machine bed with a thin mixture of one-part
cement and one-part sand.
20) For foundation of stacks, the maximum pressure on the soil is equal to the
pressure due to weight and the wind movement.

MACHINE FOUNDATION COMPUTATIONS

1. Weight of the Machine Foundation, 𝑊𝑓
𝑊𝑓 = 𝑒 × 𝑊𝑒 × √𝑁
Where:
𝑊𝑓 = Weight of the foundation in kg
𝑒 = Empirical coefficient (Table 2.2 PSME Code pg. 13)
𝑊𝑒 = Weight of the engine in kg
 𝑁 = Engine speed in rpm
Given:
𝑊𝑓 = Weight of the foundation in kg
𝑒 = 0. 11 (Table 2.2 PSME Code pg. 13)
𝑊𝑒 = 125,300. Kg
𝑁 = 720 rpm
Substituting:
𝑊𝑓 = 0.11 × 125,300 × √720
𝑾𝒇= 369,836.6992 𝒌𝒈
2. Volume of the Machine Foundation, 𝑉𝑓
𝑉𝑓 = 𝑊𝑓 𝜌
Where:
𝑉𝑓 = Volume of the machine foundation in 𝑚3
𝑊𝑓 = Weight of the foundation in kg
𝑘𝑔
𝜌 = Density of Concrete in 3
𝑚
𝑘𝑔
𝜌 = In computation 2,406 3 may be used (PSME code pg.12)
𝑚
Given:
𝑉𝑓 = Volume of the machine foundation in 𝑚3
𝑊𝑓 = 369,836.6992 𝒌𝒈
𝜌 = 2,406 𝑘𝑔/𝑚3 (PSME code pg.12)

Substituting:
369,836.6992 𝒌𝒈
𝑉𝑓= 𝑘𝑔
2,406 3
𝑚

𝑽𝒇 = 153.7143 m3
3. Lower Width of the Foundation, b
𝑆𝑏 𝑊𝑓 + 𝑊𝑒
𝑁
= 𝑏(𝐿)
Where:
𝑆𝑏 = Soil bearing capacity in 𝑚2
𝑆𝑏 = Vary from about 4,890 𝑘𝑔𝑚2 to 12,225 𝑘𝑔𝑚2 (PSME Code pg.12)
𝑊𝑓 = Weight of the foundation in kg
𝑁 = Factor of safety (usually 2)
𝑊𝑒 = Weight of the engine in kg
𝑏 = Lower width of the foundation in 𝑚
𝐿 = Length of the machine bedplate
𝐿 = 𝐿𝑒 + 2𝑐
Where:
𝐿 = Length of the engine
 𝑐 = Clearance
Given:
𝐿 = 11.680 m
𝑐 = 0.3 𝑚
Substituting:
𝐿 = 11.680 𝑚 + 2(0.3𝑚)
𝑳 = 12.28 𝒎
Given:
𝑘𝑔
𝑆𝑏 = 10,197.16 2
𝑚
𝑆𝑏 = Vary from about 4,890 𝑘𝑔 to 12,225 𝑘𝑔 (PSME Code pg.12)
𝑊𝑓 = 369, 836. 6992 𝒌𝒈
𝑁=2
𝑊𝑒 = 125,300 𝑘𝑔
𝑏 = Lower width of the foundation in 𝑚
𝐿 = 11.680 m
Substituting:
𝑘𝑔
10,197.16
𝑚
2
369,836.6992 𝒌𝒈 + 125,300 𝑘𝑔
2
= 𝑘𝑔
𝑏( 10,197.16 2 )
𝑚

b = 9. 5235 m
4. Bedplate Width, a
𝑎 = 𝑤 + 2𝑐
Where:
𝑎 = Width of the bedplate in 𝑚
𝑤 = Width of the engine in 𝑚
𝑐 = Clearance in m
Given:
𝑤 = 3.594 𝑚
𝑐 = 0.3 𝑚
Substituting:
𝑎 = 3.594𝑚 + 2 (0.3𝑚 )
𝒂 = 4.194 m

5. Depth of the Machine Foundation, h

𝑎+𝑏
𝑉𝑓 = ( 2
)ℎ × 𝑙
Where:
𝑉𝑓 = Volume of the machine foundation in 𝑚3
𝑎= Width of the bedplate in 𝑚
 𝑏 = Lower width of the foundation in 𝑚
ℎ = Depth of the machine foundation in 𝑚
𝐿 = Length of the machine bedplate in 𝑚
Given:
𝑉𝑓 = 153.7143 m3
𝑎 = 4.194 m
𝑏 = 9. 5235 m
𝐿 = 12.28 𝒎
ℎ = Depth of the machine foundation in 𝑚
Substituting:
4.194 𝑚 +9. 5235 𝑚
153. 7143 𝑚3 = ( 2
) ℎ × 12. 28𝑚
h = 1.825033882m

6. The foundations should be concrete, 1 part Cement, 2 parts Sand and 4 parts broken Stone or Gravel
(50 mm max) (PSME Code 2008 pg.12). The foundation mixture are calculated as follows:

MATERIALS RELATIVE DENSITY DENSITY (

𝑘𝑔
3 ) PARTS
𝑚

Cement 3.15 1,440 1

Sand 2.66 1,680 2

Gravel 2.50 1,525 4

Using:
26 liters of water per bag of cement; assuming one bag of cement as 0.028 𝑚3
per bag of cement, loose volume.
Let:
𝑉𝑐𝑒𝑚𝑒𝑛𝑡, 𝑉𝑠𝑎𝑛𝑑, 𝑉𝑔𝑟𝑎𝑣𝑒𝑙, 𝑉𝑤𝑎𝑡𝑒𝑟= Compact volume of cement, sand, gravel and water respectively.

Table 3.2.2 Volume of Foundation Mixture

Volume Operation Volume per batch

3
𝑉𝑐𝑒𝑚𝑒𝑛𝑡 𝑘𝑔 3
𝑚
𝑉𝑐𝑒𝑚𝑒𝑛𝑡 =
1,440
𝑚
3 (0.028𝑚 )(1 𝑝𝑎𝑟𝑡)
0.0128 𝑏𝑎𝑡𝑐ℎ
𝑘𝑔
(3.15)(1000 3 )
𝑚

3
𝑉𝑠𝑎𝑛𝑑 𝑘𝑔 3
𝑚
𝑉𝑠𝑎𝑛𝑑 =
1,680
𝑚
3 (0.028𝑚 )(2 𝑝𝑎𝑟𝑡)
0.0354 𝑏𝑎𝑡𝑐ℎ
𝑘𝑔
(2.66)(1000 3 )
𝑚
 3
𝑉𝑔𝑟𝑎𝑣𝑒𝑙 𝑘𝑔 3
𝑚
𝑉𝑔𝑟𝑎𝑣𝑒𝑙 =
1,525
𝑚
3 (0.028𝑚 )(4 𝑝𝑎𝑟𝑡)
0.0683 𝑏𝑎𝑡𝑐ℎ
𝑘𝑔
(2.50)(1000 3 )
𝑚

26𝐿 3
𝑉𝑤𝑎𝑡𝑒𝑟 𝑚
1000
𝑘𝑔
3
0.026 𝑏𝑎𝑡𝑐ℎ
𝑚

3
𝑉𝑡𝑜𝑡𝑎𝑙 𝑚
0.1425 𝑏𝑎𝑡𝑐ℎ

Solving Total Number of Batches Per Machine Foundation

𝑉𝑓
𝑏𝑎𝑡𝑐ℎ𝑒𝑠 𝑡𝑜𝑡𝑎𝑙 = 𝑉𝑚𝑖𝑥

Where:
3
𝑉𝑓= Volume of the machine foundation in 𝑚
3
𝑚
𝑉𝑚𝑖𝑥=Total volume of batches in 1: 2: 4 ratio in 𝑏𝑎𝑡𝑐ℎ
𝑏𝑎𝑡𝑐ℎ𝑒𝑠 𝑡𝑜𝑡𝑎𝑙= Total number of batches
Given:
𝑉𝑓=153.7143 m3
3
𝑚
𝑉𝑚𝑖𝑥=0.1425 𝑏𝑎𝑡𝑐ℎ
𝑏𝑎𝑡𝑐ℎ𝑒𝑠 𝑡𝑜𝑡𝑎𝑙= Total number of batches
Substituting:
153.7143 𝑚3
𝑡𝑜𝑡𝑎𝑙 𝑛𝑜. 𝑜𝑓 𝑏𝑎𝑡𝑐ℎ𝑒𝑠 = 𝑚
3
0.1425 𝑏𝑎𝑡𝑐ℎ

𝑡𝑜𝑡𝑎𝑙 𝑛𝑜. 𝑜𝑓 𝑏𝑎𝑡𝑐ℎ𝑒𝑠 = 1106. 767018 batches

Table 3.2.3 Volume of Mixture per Foundation

Materials Operation Volume per Foundation

Cement 𝐶𝑒𝑚𝑒𝑛𝑡 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑

3 30. 9895 𝑏𝑎𝑔𝑠𝑐𝑒𝑚𝑒𝑛𝑡
=1106.767018𝑏𝑎𝑡𝑐ℎ𝑒𝑠(0. 028𝑚 )(1 part)

Sand 𝑆𝑎𝑛𝑑 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑

3
=1106.767018𝑏𝑎𝑡𝑐ℎ𝑒𝑠(0. 028𝑚 )(2 part)
3 61.97895 𝑚

Gravel 𝐺𝑟𝑎𝑣𝑒𝑙 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑

3
=1106.767018𝑏𝑎𝑡𝑐ℎ𝑒𝑠(0. 028𝑚 )(4 part)
3 123.95791 𝑚
 Water 𝑊𝑎𝑡𝑒𝑟 𝑅𝑒𝑞𝑢𝑖𝑟𝑒𝑑
=30. 9895𝑏𝑎𝑔𝑠𝑐𝑒𝑚𝑒𝑛𝑡(26 L of water) 805.727 L of water

7. Concrete foundations should have steel bar reinforcements placed both vertically and horizontally, to
1
avoid thermal cracking. Weight of reinforcing steel should be from 2
% to 1% of the weight of the
foundation. (PSME Code 2008 pg.11)

● Weight of steel bar, 𝑊𝑟𝑏

𝑊𝑟𝑏 = 𝑊𝑓 x Steel bar percent
Where:
𝑊𝑟𝑏= Weight of steel bar in kg
𝑊𝑓 =Weight of the foundation in kg
1
𝑆𝑡𝑒𝑒𝑙 𝑏𝑎𝑟 𝑝𝑒𝑟𝑐𝑒𝑛𝑡 = From 2
% to 1 %
Given:
𝑊𝑟𝑏= 141,667.2671 𝒌𝒈
𝑆𝑡𝑒𝑒𝑙 𝑏𝑎𝑟 𝑝𝑒𝑟𝑐𝑒𝑛𝑡 = 1 %
Substituting:
𝑊𝑟𝑏= 141,667.2671 𝒌𝒈 (0.01)
𝑊𝑟𝑏 = 1416.672671 kg
𝑊𝑟𝑏= 3123. 228412 𝑙𝑏
● Length of Steel bar, 𝐿𝑟𝑏
𝐿𝑟𝑏=𝑊𝑟𝑏 × 𝑊 1
2
𝑠𝑡𝑒𝑒𝑙 𝑏𝑎𝑟

Where:
𝑊𝑟𝑏 =Computed weight of steel bar in lb.
1
𝐿𝑟𝑏 = Length of 2
inch steel bar in ft.
1 𝑙𝑏
𝑊1 = Weight of 2
inch of steel bar in 𝑓𝑡
2
𝑠𝑡𝑒𝑒𝑙 𝑏𝑎𝑟

Given:
𝑊𝑟𝑏= 3123. 228412 𝑙𝑏
𝑙𝑏
𝑊1 = 0.668 𝑓𝑡
2
𝑠𝑡𝑒𝑒𝑙 𝑏𝑎𝑟

Substituting:
𝑙𝑏
𝐿𝑟𝑏 = 3123.228412 lbs × 0.668 𝑓𝑡
 𝑓𝑡
𝐿𝑟𝑏 = 2086.316579 𝑙𝑏

No. of Steel Bar; using 16 mm diameter

𝑊𝑟𝑏/𝑝𝑐= (ρ𝑆𝑡𝑒𝑒𝑙 )(𝑉𝑅𝐵)

π 2
𝑊𝑟𝑏/𝑝𝑐= (ρ𝑆𝑡𝑒𝑒𝑙)( 4 (𝑑 ))(𝐿𝑓)
𝑘𝑔 π 2
𝑊𝑟𝑏/𝑝𝑐 = (7800 3 ) ( 4 (0. 016𝑚 ))(6.69064m)
𝑚

𝑘𝑔
𝑊𝑟𝑏/𝑝𝑐 = 10.49281732 𝑝𝑐

𝑊𝑟𝑏 1416.672671 𝑘𝑔
𝑊𝑟𝑏/𝑝𝑐
= 𝑘𝑔
10.49281732 𝑝𝑐

=135.0135648 ≈ 136 pcs of reinforcement bar