CHAPTER II

DESIGN OF MACHINE FOUNDATION

1.1. Generating Set Specification:

Manufacturer: Mitsubishi

Generator Set Model: 14KU44 Diesel Generator Set

Length of Engine and Generator: 10,480 mm

Height of Engine and Generator: 4,950 mm

Width of Engine and Generator: 4,820 mm

Weight of Engine and Generator: 168,000 kg

13
1.2. Weight of Foundation:

From PSME Code, 2003 ed., Chapter 2, Sec. 4.0, Article

4.1 b

“Foundation mass should be from 3 to 5 times the weight

of the machinery it is supposed to support.”

For safety design, use the average which is 4 times.

W F =4 W M
Where:

W M =¿ Weight of the Machine or Generator Set

W F =4 (168 tons)
W F =672tons
1.3. Upper Width and Length of Foundation:

Allow a clearance from the edge of about one foot or

about 10% of the length of the bedplate.

For the Width of the Foundation, a:

a=4820 mm+ 2 ( 0.10 x 4820 mm )

a=5784 mm .
For the Length of the Foundation, LF:

LF =10480 mm+2(0.10 x 10480 mm)

LF =12,090 mm .
1.4. Lower Width of the Foundation:

14
S b W M +W F
=
2 b LF
From https://theconstructor.org/geotechnical/safe-

bearing-capacity-values-different-soils/35734/

Safe Bearing Power of Soils, Sb:

Since the proposed location of the designer is near

the sea coast for adequate supply of water for cooling

system, considering the soil quality of the location of the

Power Plant facility to be designed:

Sb = 245 tons/m2 (sandy gravel mixture, dry state)

2 ( W M +W F )
b=
Sb L F
Where:

Sb = Safe bearing power of soil

W M = Weight of the machine

W F = Weight of the foundation

LF = Length of the foundation

2 ( 96 tons+ 384 tons )

b=
( tons
)
245 2 (12.09 m)
m
b=324.099 mm .

15
 Since the lower width “b” come out to be less than the

upper width “a”, it is customary to make “b” equal to “a”,

that is the foundation has rectangular cross-section.

Therefore,

b=3,672 mm .
1.5. Volume of Foundation:

WF
V F=
PF
Where:

W F = Weight of the foundation

P F = Density of the concrete, 2406 kg/m3

384,000 kg
V F=
kg
2,406 3
m
3
V F=159 .6 m
1.6. Height of the Foundation:

VF
h=
LF x a
Where:

V F = Volume of the foundation

LF = Length of the foundation

a = Width of the Foundation

16
 3
159.6 m
h=
12.09 m x 3.672 m
h=3.595 m.
1.7. Area of Foundation:

A F =LF x W
Where:

LF = Length of the foundation

W = width of the foundation

A F =12.09m . x 3.672 m.
2
A F =44.39 m .
1.8. Net Weight Imposed by Machine and Foundation in Soil:

W net =W M +W F

W net =96 tons +384 tons

W net =480 tons

1.9. Stress Imposed by the Machine and Foundation in Soil:

W net
Si =
AF
480 tons
Si= 2
44.39 m
Si=10.81 tons/m 2
1.10. Foundation Factor of Safety:

Sb
FS=
2 Si
Where:

17
 Sb = Safe soil bearing capacity

Si = Stress imposed by machine and foundation

on soil

tons
245 2
m
FS=
( tons
2 10.81 2
m )
FS=11.33
Based on the computation, the foundation is safe since

its factor of safety exceeds the allowable factor of safety

discussed in PSME code, 2003 Edition, Chapter 2, Section

4.0, Article 4.1 which is 5.

2. FOUNDATION MATERIAL CALCULATION

2.1. Material Data:

2.2. Computed Dimensions of Foundation:

Foundation Geometric Figure = Rectangle

Length of Foundation = 12.09 m.

Width of Foundation = 3.672 m.

Height of Foundation = 3.595 m.

Volume of Foundation = 159.6 m.3

Area of Foundation = 44.39 m.2

18
Determine the Amount of Cement, Sand and Stone in the

Foundation:

From PSME Code, 2003 Edition, page 12, Section 4.2:

The foundation should be concrete, of 1 part cement, 2

parts sand and 4 parts broken stone or gravel (maximum of 50

mm; the entire foundation should be poured at one time, with

no interruption than are required for spading and ramming.

Table 4-1: DATA ON CONCRETE MIXES TO YIELD 1 CU. M.

CONCRETE

(from Power Plant Engineering by Frederick T. Morse, p.90)

Mixtu Cemen Sand Ston Applicati Weigh Safe Density,

re t, , e, on t, Comp
Kg/m3
.
Sacks m3 m3 t/m3
Stre

ss,

t/m2

1:2:4 7.8 0.44 0.88 Foundatio 2.66 328. 2.406

ns 10

2.3. Number of Cement Sacks:

NS C =V F x 7.8 sacks/m3
Where:

19
 V F = Volume of foundation = 159.6 m3

3
NS C =159.6 x 7.8 sacks/m
NSC =1244.88 sacks

Say use, NSC =1245 sacks/foundation

NS C =1245 sacks (4 +1reserve )

NS C =6225 sacks

2.4. Volume of Sand:

3
m sand
V S =V F x 0.44 3
m concrete

m3 sand
V S =159.6 m3 x 0.44
m3 concrete
3
V S =70.224 m

V S =71 m3 /foundation

V S =71 m3 (4+1 reserve )

3
V S =355 m

2.5. Volume of Stone:

m3 sand
V ST =V F x 0.88
m3 concrete

3 m 3 sand
V ST =159.6 m x 0.88
m3 concrete

V ST =140.448 m3

V ST =141 m3 /foundation

V ST =141 m3 ( 4+ 1reserve )

20
 3
V ST =705 m
2.6. Quantity of Plywood to be used as Foundation Form

At Mirola Construction Supply, the standard dimension

of plywood available is 4’ x 8’. The actual price per piece

is Php 590.00

a. For the Surface Area of the Machine Foundation where

the Plywood would serve as the Guide of Foundation:

SAmf =2 ( b x h ) +2(h x LF )

SAmf =2 ( 3.672m x 3.595 m )+2(3.595 x +12.09 m)

2 2
SAmf =57.77 m =621.83 ft

b. For the Number of Plywood to be used as Foundation

Guide:

SA mf
N PW =
ft 2
(4 x 8)
pc
2
621.83 ft
N PW = 2
ft
(4 x 8)
pc
N PW =19.43∨20 pcs
c. For Cutting Loss: Additional 10% as allowance

'
N PW =20 pcs x 1.1

21
 pcs
N PW ' =22
foundation
' pcs
N PW =22 ( 4 +1 reserve )
foundation

N PW ' =110 pcs

2.7. Quantity of Reinforced Lumbers

a. For Scaffoldings use: 2” × 3” × 12’

From Architectural and Construction Data by G. Salvan

and S. Thapa, p. 657

“To get the board feet of 2”×3” of lumber, multiply the

total area of plywood in 60%”

Thus,

Total board feet of 2” ×3 ” lumber=(621.83 ft .)( 0.6)

2
Total board feet of 2” ×3 ” lumber=373.098 ft

Therefore, the quantity of 2”×3”×12 ' lumber, N LRT required:

2
373.098 ft
N LRT =
6 board feet / pcs
N LRT =62.183 pcs x ( 4 +1reserve )=310.915 311 pcs
2.8. Quantity of Nails

a. For Plywood

No . of kegsof 2 C.W. nails= {Total area of plywood( {m} ^ {2} )} over {2303
Where:

22
 1 keg = 45.5 kg. of nails

No . of kegs of 2 C.W. nails= {57.7 { m} ^ {2}} over {2303

No . of kegsof 2 C.W. nails=0.025054277 keg
Quantity of 2 Nails for Plywood=0.025054277 kegs× {45.5kg} over {1kegs
2 Nails for Plywood=1.14 kg. x (4+1 res)=5.7 ~ 6 kg

b. For Lumber
No . of kegs of 4 C.W. nails= {Total board foot of Lumber} over {2800
Where: 1 keg = 45.5 kg. of nails

No . of kegsof 4 C.W. nails= {373.098 { ft} ^ {2}} over {2800

No . of kegsof 4 C.W. nails=0.13325 keg
Quantity of 4 Nails for Lumber=0.13325 kegs× {45.5kg} over {1kegs
4 Nails for Lumber=6.06 kg. x (4+1 res)=30.3 ~ 31 kgs

2.9 Steel Bar Reinforcement:

a. Weight of the Steel Bar Reinforcements:

From PSME Code, 2003 Edition, p.11, Sec. 4.0, Art. F:

“Concrete foundations should have steel bar

reinforcements placed both vertically and horizontally, to

avoid thermal cracking. Weight of reinforcing steel should

be from 0.5% to 1% of the weight of the foundation.”

For safety design, use the average which is 0.75%.

W SBR =0.75 % W F

W SBR =0.75 % (384,000 kg)

23
W SBR=2,880 kg
b. Volume of the Steel Bar Reinforcements:

From Kent’s Mechanical Engineering Handbook, Power

Volume, Page 6-02, the density of structural steel is equal

to 490 lb./ft3.

¯
Weight of steel reinforcement
V SBR =
Density of steel
lb
2880 kg x 2.2
kg
V SBR =
lb
490
ft 3
3 3
V SBR =12.93 ft =0.366 m
c. Volume of the Steel Bar Reinforcements per Piece:

Say use, Standard size of steel bar reinforcements with

standard diameter equal to 16 mm and length of 6 m.

2
π Db L b
V RPP=
4
Where:

D b = diameter of steel bar

Lb = length of steel bar

2
π ( 0.016 m ) ( 6 m )
V RPP= =0.001206 m3 / pc
4

d. Total Number of Steel Bar Reinforcements:

24
 ¯
Volume of steel reinforcements
T SBR =
¯
volume of steel reinforcements per piece

0.366 m3
T SBR= 3
m
0.001206
piece
T SBR =303.48

Say use, T SBR =304 (4 +1 reserve)

T SBR =1520 pcs

2.10 Quantity of Tire Wire (G.I wire)

Assume that the weight of the GI wire to be used in the

foundation is approximately 2% of the weight of steel bars

in foundation. (Construction estimate)

a. Weight of GI Wire to be used in the Foundation, WGI:

W GI =2 % W SBR

W GI =2 %(2,880 kg)
W GI =57.6 kg
For Cutting loss, add another 10% allowance:

W GI ' =(57.6 kg x 4+1)x 1.1

W GI ' =316.8 kg

W GI ' =317 kgs

2.11. Anchor Bolts

a. Selection of Anchor Bolts:

From PSME Code, 2003 Edition, page 13, Section 4.2,

Article F:

25
 “To prevent pulling out of the bolts when the nuts are

tightened, the length embedded in concrete shall be equal to

or more than thirty (30) times the bolt diameter. The upper

ends shall be surrounded by a 50 mm or 75 mm sheet metal

pipe, 460 mm to 610 mm long to permit them to be bent

slightly to fit the holes of the plate.”

Dimensions:

D x L x C x T

For specification of anchor bolts:

From PSME Code 1984, Chapter 2, Statement 2.4.1.7

“Foundation bolts of specified size should be used and

surrounded by a pipe sleeve with an inside diameter of at

least three (3) times the diameter of the anchor bolt and a

length of at least 18 times the diameter of the bolt. No

foundation bolts shall be less than 12 mm diameter.”

b. Diameter of anchor bolts:

For the availability of size in the market say use and to

fit with the statement above,

26
 3
D AB= inch=19.05 mm
4
c. Length of anchor bolt imbedded in concrete:

Since the standard lengths of a 100 mm. anchor bolt

that suits the statement in the PSME Code, 2003 edition

stating “the length embedded in concrete shall be equal to

or more than thirty (30) times the bolt diameter”.

Therefore:

LIB =(30)(19.05mm)
LIB =571.5 mm .=22.5∈.
For the availability in the market and considering the

Length of the bolt, from catalog of All America Threaded

Products:

Say Use, LIB =24 ∈.

Other dimensions of the selected anchor bolt:

SKU: 45200

Thread Length: 4 inches

Hook Length: 3 inches

d. Foundation Bolt Length, T:

The foundation bolt length should be at least 18 times

the diameter of the anchor bolt. The designer assumes 18

times the diameter.

27
Therefore,

T =(18)(19.05 mm)
T =342.9 mm=13.5∈¿ 14 inch( for availability)
e. Quantity of Bolts, BQ:

Assuming that there are 2 bolts per meter of the

bedplate.

BQ=2(W + L) x 2 pcs /m

Where:

W = width of bedplate

L = length of bedplate

BQ=2(3.06 m+10.075 m) x 2 pcs /m

BQ=52.54 pcs /bedplate

BQ=53 pcs (4 +1reserve )=265 pcs

2.12. Bill of Materials

QTY UNIT DESCRIPTIO UNIT COST TOTAL COST

N (PHP) (PHP)
6225 Sack Portland 250.00 PHP
Cement 1,556,250.
(Home & 00
More

28
 Hardware
and
General
Merchandis
e)
355 m3 Sand 550.00 PHP.
(Sunrise 195,250.00
Sand,
Gravel and
Hollow
Blocks)
705 m
3 Stone 900.00 PHP.
(Sunrise 634,500.00
Sand,
Gravel and
Hollow
Blocks)
110 pcs Plywood 590.00 PHP.
(Mirola 64,900.00
Constructi
on Supply)
311 pcs Lumber 70.00 PHP.
2”X3”X12” 21,770.00
(Mirola
Hardware)
6 kg Nails 2” 70.00 PHP.
Cement 420.00
(Home &
More
Hardware
and
General
Merchandis
e)
31 kg Nails 4” 80.00 PHP.
Cement 2,480.00
(Home &
More
Hardware
and

29
 General
Merchandis
e)
1520 pcs Steel Bar 105.00 PHP.
16mm x 6m 159,600.00
(Home &
More
Hardware
and
General
Merchandis
e)
317 kg G.I Wire 52.00 PHP.
#16 (Home 16,484.00
& More
Hardware
and
General
Merchandis
e)
265 pcs Anchor 976.00 PHP.
Bolts 258,640.00
(Unisorb)
Total Material Cost PHP.
2,910,294.00
Labor Cost (30% Of Material Cost) PHP.
873,088.20
TOTAL COST PHP.
3,783,382.20

30