1.

0 Foundation Design Philosophy for Rotating Equipment

References has been taken from,

1. Design of structures and foundations for vibrating machines by S. Arya, M.

O'Neill and G. Pincus
2. Foundation analysis and design by J. E. Bowels
3. Dynamics of bases and foundations by D. Barkan
4. Design of Machine Foundations - Lecture Notes of Professor M.H. El
Naggar, Department of Civil Engineering, The University of Western
Ontario, London, Ontario, Canada, N6A 5B9

In this page I will talk about the rigid block foundation for Centrifugal (Pump) and
Reciprocating machines (Compressor). We are considering the concrete block is
infinitely rigid and thus a lump mass model can be considered in computer 3D
modelling. To start the design of a block foundation, we need to follow the
following steps to collect the design data:

Step-1 : Review of pump / compressor drawing (Vendor Equipment Drawing)

The machine data pertinent to the dynamic analysis and design of the block
foundation should be obtained from vendors.

Plan dimension of pump / compressor base frame

Height of rotor / shaft center line from the bottom of skid
Anchor bolt location, size and embedment depth
Weight of machine parts and the rotor parts (pump / compressor rotor
and motor rotor)
Location of center of gravity both vertically and horizontally
Operating speed of machines and power rating of motor (RPM)
Magnitude and direction of unbalanced forces.
For reciprocating machines both primary and secondary unbalanced
forces and couples and respective CG locations needs to be
checked.
Limit of deflection and vibration amplitudes at center line of rotor.

Step-2 : Collection of Geotechnical / soil data (Pl discuss with soil consultant and
look into project design criteria)

The Geotechnical data are used for evaluating the soil / pile stiffness and
damping coefficients, and are required for both static and dynamic design and
analysis of of block foundations. Following soil parameters are required:

Soil weight density

Poisson's ratio
Dynamic shear modulus (G)

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 Shear wave velocity (vs)
Dynamic modulus of sub-grade reaction (ks)
Allowable soil bearing pressure or pile load carrying capacity for
design of foundation

Step-3 : Categorization of rotating machines based on machine speed:

The rotating machines are categorized based on machine speed. Following are
different categories of machines:

Low Speed machine: The low speed machines operate at a speed range
of less than 500 RPM. High tuned foundations, having first natural
frequency more than machine's operating speed, should be designed for
this type of machines. In this case machine do not pass the resonance
during machine start up and coast down condition.
Intermediate speed machine: The intermediate speed machines operate
at a speed range 500 RPM to 1000 RPM. Foundations should be
designed for this type of machines high tuned or low tuned side whchever
more practical. If the foundation is low tuned, dynamic amplitude shall be
checked during start up and coast down condition.
High Speed machine: The high speed machines operate at a speed range
of more than 1000 RPM. Low tuned foundations, having first natural
frequency less than machine's operating speed, should be designed for
this type of machines. In this case machine will pass the resonance during
machine start up and coast down condition. Dynamic amplitude shall be
checked during start up and coast down condition. You need to ensure
that there is no adverse effect to machine operation during the resonant
conditions.
Variable Speed machine: The variable speed machines operate at a
speed range as prescribed by vendor. Foundations should be designed
for this type of machines high tuned or low tuned side whchever more
practical. A detail dynamic analysis of foundation is required for a range
of machine operating speeds to ensure that the dynamic design criteria
are met.

Step-4 : Preliminary sizing of foundations:

A block foundation consists of massive concrete blocks, piers and mat

foundation. The preliminary sizinng of block should be based on the following:

Weight of the block foundation should be at least 4 times the weight of

reciprocating machines and 3 times the weight of centrifugal machines.
The width of foundation should be at least 1.5 times the vertical distance
from the bottom of foundation to the center line of the shaft / rotor.
The center of mass of machine foundation (machine+foundation system)
should coincide with the centroid of the soil foundation or pile group

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 resistance. Horizontal eccentricity should be limited to 5% of the
corresponding foundation dimension.
For a rigid mat, following criteria to be followed:

o Minimum thickness of the mat will be 600 mm or 1/5 th of least

foundation dimensions or 1/10 th of largest foundation dimensions,
whichever is greater .
o Maximum thickness of the mat will be 1500 mm
4 1/3
o Minimum thickness of mat, t = 0.0012 x (ks x (a) ) ft, ks = soil
3
dynamic modulus of subgrade reaction, lbs/in , from soil report, a
= maximum cantilever projection (inches), measured from face of
block (Refer: Foundation analysis and design by J E Bowles)

Step-5 : Requirement for dynamic analysis of foundations:

Dynamic analysis of concrete foundations are not required for all the foundations
supporting rotating equipment. You need to refer your project design criteria for
the conditions for dynamic analysis. Following are the general criteria for not
performing any dynamic analysis of foundation supporting rotating equipment:

Dynamic analysis is not required if the weight of machine is less than

25kN.
Dynamic analysis is not required if the power rating of motor is less than
200hp.

If you are not doing any dynamic analysis of concrete block foundation, then
follow Step-4 for foundation sizing and put it into 3D model for any interference
check.

If you are doing the dynamic analysis of concrete block, then follow the following
steps.

Step-6 : Calculation of un-balanced forces for dynamic analysis of foundations:

If unbalance force is not mentioned in the Vendor equipment drawing, then you
will calculate the force as follows:

Un-balance force for pump: Fpump = mp-rotor x e x w2

Un-balance force for motor: Fmotor = mm-rotor x e x w2

Where, mp-rotor = weight of pump rotor, mm-rotor = weight of motor rotor

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w = circular frequency = 2 x pi x (f / 60), f = speed of machine from vendor
drawing (RPM).

e = rotor eccentricity, depends on machine speed

Eccentricity Table ( Refer reference -1)

Machine Operating Speed (f in RPM) Eccentricity e (mils)

Pump / compressor f < 3000 (1.8-107) / (f)2
Pump / compressor f > 3000 (12000/f)1/2
Motor f < 1500 1.5
Motor 1500< f < 3000 1
Motor f > 3000 0.5

Now you are having all the information to start the foundation analysis and
design. You can put all the above data in any computer software program (say -
Dyna5) or use any text books to calculated the natural frequencies of foundation.
You can also use the different tables that I have attached here (click for the
table).

Natural frequency analysis of foundation:

This rigid block has six degree of freedom. So, you will calculate all the following
uncouple natural frequencies:

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 1. Sliding Frequency along horizontal X-direction
2. Sliding Frequency along horizontal Y-direction
3. Sliding Frequency along vertical Z-direction
4. Rocking Frequency about X, rotational mode
5. Rocking Frequency about Y, rotational mode
6. Rocking Frequency about Z, rotational mode

When the CG of foundation system is far above the foundation base, coupling
effect needs to be considered to calculate the foundation natural frequency. In
this case sliding mode and rocking mode frequencies overlap each other and as
a result foundation dynamic analysis may be more critical. You can calculate the
coupled natural frequency using the formula mentioned in the table.

Coupled condition: 1. Sliding along X & Rocking about-Y and 2. Sliding along
Y & Rocking about X

Once, analysis is completed, please check the foundation for the following
conditions:

Resonance Frequency Check:

Calculate resonanace frequency and check that the ratio of machine frequency

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vs resonance frequency (f / fd) is either less than 0.8 or greater than 1.2 in all six
degrees of freedom.

Resonance frequency can be calculated as follows: fd = fn / (1-2 x D2)

where, fn = foundation natural frequency, D = Damping ration (see table 5 and

12)

Soil Bearing Pressure / Pile Capacity Check

Soil bearing pressure or pile load should not exceed 75% of the allowable.
Please avoid any foundation upliftment in seismic / wind condition.

Maximum Velocity check:

Maximum velocity should fall in "Good Condition" per table-1 of attached table

Environmental condition

Maximum displacement amplitude of vibration at foundation level should lie

within or below "Zone-B" of figure -1 and it should fall below the Zone
"Troublesome to persons" of figure -2 in the attached table.

Reinforcement:

Reinforcement shall be provided per project approved design code. However,

you can use minimum reinforcement as follows:

0.2% rebar on all face of concrete block and mat.

1% rebar for all concrete pedestal.

Rebar spacing should not be more than 300 mm.

Anchor Bolt:

Anchor bolt shall be checked for start-up and coast down contion.

For a typical pump foundation drawing click here

I hope this page will be very helpful to you to understand the basic design of a
Pump foundation.

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2.0 Pipe rack Design Philosophy (Non-conventional Pipe
rack)
In this page I will talk about the Non-continuous piperack system. I hope you
have read the Conventional pipe rack system design philosophy. If not, please
read that section before.

Non- Continuous Pipe rack:

This is a system comprised of independent cantilevered, freestanding 2D frames

not dependent on longitudinal beam struts for system stability. This system,
where feasible, should result in lower total installed cost (TIC).

Step-1: Data collection for pipe rack design:

Method of Data collections is same as continuous pipe rack. Please look into 3D
model and collect all the data as required.

Step-2: Design loads consideration:

Following loads are to be considered for the non-conventional pipe rack design:

Gravity load (D): For Gravity load calculation, refer Conventional pipe rack
system

Wind Load (W): For Wind load calculation, refer Conventional pipe rack
system,

Earthquake Loads (E): For Earth quake load calculation, refer Conventional pipe
rack system. Longitudinal seismic will be applied on anchor bay only.

Friction Loading (Tf): Friction forces caused by hot lines sliding across the pipe
support during startup and shutdown do not apply on individual frame, as frame
will deflect along the pipe direction. Therefore, this force will be considered on
anchor bay only.

Anchor and Guide Loads (Ta): For Anchor and Guide load calculation, refer
Conventional pipe rack system,

Step - 3: Load Combinations and allowable deflection of pipe rack:

For Load combinations and allowable deflection of non-conventional pipe rack,

refer Conventional pipe rack system,

Step - 4: Frames of non-conventional pipe rack:

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3.0 Pipe rack Design Philosophy

In this page I will talk about the pipe rack design philosophy. Pipe rack is the
main artery of any plant. This carries the pipes and cable trays (raceways) from
one equipment to another equipment within a process unit (called ISBL
piperack) or carries the pipe and cable trays from one unit to another unit (called
OSBL pipe rack). Some times you will also find the AIR COOLED HEAT
EXCHANGERS on the pipe rack.

There are different types of pipe rack:

Continuous Piperacks (conventional pipe rack) system

Non-continuous Piperacks system

Modular Pipe rack

Conventional / Continuous Pipe rack

Continuous Piperacks (conventional pipe rack) system: This is essentially a

system where multiple 2-dimensional (2D) frame assemblies (commonly called
bents), comprised of two or more columns with transverse beams, are tied
together in the longitudinal direction utilizing beam struts (for support of
transverse pipe and raceway elements and for longitudinal stability of the
system) and vertical bracing to form a 3D space frame arrangement. Piperacks
supporting equipment such as air-cooled heat exchangers must utilize the
continuous system approach.

Step-1: Data collection for pipe rack design:

Due to the fast track nature associated with most of the projects, often the final
piping, raceway, and equipment information is not available at initiation of the
piperack design. Therefore, as a Civil/Structural Engineer, you should coordinate
with the Piping group, Electrical, Control Systems, and Mechanical groups to
obtain as much preliminary information as possible. When received, all design
information should be documented for future reference and verification. In the
initial design, the Engineer should use judgement when applying or allowing for
loads that are not known, justifying them in the design basis under "Design
Philosophy" (a part of your calculation)

The following should be reviewed for design information:

Plot plans and equipment location plans

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 3D model showing piping layout, cable tray layout, Piperack bent spacing and
elevation of support levels in the transverse direction , Elevation of
longitudinal beam struts and locations of vertical bracing. and location of
pipe bridge, if any.

Piping orthographic drawings.

Vendor prints of equipment located on the rack, e.g., air coolers and
exchangers.The vendor prints should include the equipment layout,
mounting locations and details, access and maintenance requirements,
and the magnitude and direction of loads being transmitted to the
piperack.

Electrical and control systems drawings showing the routing and location of
electrical and instrumentation raceways and/or supports.

Underground drawings that show the locations of buried pipes,concrete

structures and foundations, duct banks, etc. in the area of the piperack.

Pipe rack construction material (Steel, Cast-in-situ concrete, Pre-cast

concrete) shall be as per project design criteria.

Please note that, Unless specifically explained in the project design criteria, no
allowance or provisions should be made for future additions for pipe or raceway
space and related loading.

Step-2: Design loads consideration:

Following loads are to be considered for the pipe rack design:

Piping Gravity load (D): In the absence of defined piping loads and locations, an
assumed minimum uniform pipe load of 2.0 kPa should be used for preliminary
design of piperacks. This corresponds to an equivalent load of 6 in (150 mm)
lines full of water covered with 2 in (50 mm) thick insulation, and spaced on 12 in
(300 mm) centers. This assumption should be verified based on coordination
with the Piping Group, and concentrated loads should also be applied for any
anticipated large pipes. When the actual loads and locations become known, as
the project develops, the structural design should be checked against these
assumed initial load parameters and revised as required. A concentrated load
should then be added for pipes that are 12 in (300 mm) and larger in diameter.
The concentrated load P should be:

P =(W - s x p x d), s = Spacing of piperack bent, p = pipe weight considered

(kPa), d = pipe diameter W = pipe concentrated load.

Where consideration of uplift or system stability due to wind or seismic

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occurrences is required, use 60% of the design gravity loads as an "all pipes
empty" load condition.

Loading due to hydrostatic testing of lines should be considered in the design if

applicable. Coordinate the testing plan(s) with Construction, Startup, and/or the
Piping Group as necessary, in order to fully understand how such loads will be
applied to the piperack structure. Under most normal conditions, multiple lines
will not be simultaneously tested. The hydro-test loads do not normally need to
be considered concurrently with the other non-permanent loads, such as live
load, wind, earthquake, and thermal. Typical practice is to permit an overstress
of 15% for the hydro-test condition. Because of these considerations, the hydro-
test condition will not normally govern except for very large diameter pipes.

Electrical Tray and Conduits (D): Electrical and control systems drawings and/or
the project 3D model should be reviewed to determine the approximate weight
and location of electrical trays, conduits, and instrumentation commodities.
Unless the weight of the loaded raceways can be defined, an assumed minimum
uniform load of 1.0 kPa should be used for single tier raceways.

Self weight of Pipe rack (D): The weight of all structural members, including
fireproofing, should be considered in the design of the piperack.

Weight of Equipment on pipe rack (D): Equipment weights, including erection,

empty, operating, and test (if the equipment is to be hydro-tested on the
piperack), should be obtained from the vendor drawings.The equipment weight
should include the dead weight of all associated platforms, ladders, and
walkways, as applicable.Special Loads: Special consideration should be given to
unusual loads, such aslarge valves, expansion loops, and unusual piping or
electrical configurations.

Live Load (L): Live load (L) on access platforms and walkways and on
equipment platforms should be considered, as applicable.

Snow Load (S): Snow load to be considered on cable tray and on large dia
pipes. This load shall be calculated per project approved design code and project
design criteria. Generally, you need to consider 100% snow load on top tier and
50% on other tier of pipe racks.

Wind Load (W): Transverse wind load on structural members, piping, electrical
trays,equipment, platforms, and ladders should be determined in accordance
with project approved design code. Longitudinal wind should typically be applied
to structural framing, cable tray vertical drop (if any), large dia pipes vertical drop
(if any) and equipment only. The effects of longitudinal wind on piping and trays
running parallel to the wind direction should be neglected.

Earthquake Loads (E): Earthquake loads in the vertical, transverse, and

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longitudinal directions should bedetermined in accordance with the project design
criteria. Vertical, transverse, and longitudinal seismic forces generated by the
pipes, raceways, supported equipment, and the piperack structure should be
considered and should be based on their operating weights. Pipes must be
evaluated for seismic loads under both full and empty conditions and then
combined with the corresponding gravity loads.

Friction Loading (Tf): Friction forces caused by hot lines sliding across the pipe
support during startup and shutdown are assumed to be partially resisted through
friction by nearby cold lines. Therefore, in order to provide for a nominal
unbalance of friction forces acting on a pipe support, a resultant longitudinal
friction force equal to 7.5% of the total pipe weight or 30% of any one or more
lines known to act simultaneously in the same direction, whichever is larger, is
assumed for piperack design. Friction between piping and supporting steel
should not be relied upon to resist wind or seismic loads.

Anchor and Guide Loads (Ta): Piperacks should be checked for anchor and
guide loads as determined by the Pipe Stress Group. It may be necessary to use
horizontal bracing if large anchor forces are encountered. For conventional pipe
rack systems, it is normally preferred to either have the anchors staggered along
the piperack so that each support has only one or two anchors, or to anchor most
pipes on one braced support. For initial design, when anchor and guide loads
are not known, use a longitudinal anchor force of 5.0 kN acting at midspan of
each bent transverse beam (refer project design criteria). Guide loads are usually
small and may be ignored until they are defined by the Pipe Stress Engineer.
For non-continuous pipe rack systems, piping may be transversely guided or
anchored at both cantilever frames and anchor bays. Longitudinal anchors may
be located only at anchor bays.

Please note that, all friction forces and anchor forces with less magnitude, (say ~
5.0 kN), applied to the top flange of the beam, may be considered as resisted by
the total beam section. When anchor loads have large magnitude and are
applied to the top flange of the beam, the effect of torsion must be addressed.If
the beam section is inadequate to take care of this torsional force, alternatives to
be considered, such as provide horizontal bracings at the load locations.

Step - 3: Load Combinations and allowable deflection of pipe rack:

You need to create the load combinations per your project design criteria.
However, I have refered here some load combinations.

Please note the following:

Earthquake load is a factored load.

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 For load combinations that include wind or earthquake loads, use only the
non-friction portion (anchor and guide portion) of the thermal loads, i.e.,
friction loads are not combined with wind or seismic loads. Friction loads
are considered to be self-relieving during wind and earthquake and should
only be combined with anchor and guide loads when wind or earth-quake
loads are not considered.

Hydrostatic test loads need not be combined with wind and earthquake loads
unless there is a reasonable probability of the occurrence of either of
these loads during hydrostatic testing.

For calculation of foundation soil bearing pressures or pile loads, stability checks
against overturning, sliding, and buoyancy, and deflection checks, the following
unfactored load combinations (ACI 318) shall be used:

1. D
2. D + L + SL + Tf + Ta
3. D + Tf + Ta
4. D + 1.3W + Ta
5. D + L + 0.5SL + 1.3W +Ta
6. D + L + S +0.65W + Ta
7. 0.9De + 1.3W + Ta
8. D + E/1.4 + Ta
9. D + 0.2S + E/1.4 + Ta
10. 0.9De + E/1.4 + Ta

Load Combinations for design of foundations (ACI 318):

1. 1.4D
2. 1.4D + 1.7L +1.7S
3. 1.4D + 1.4Tf +1.4Ta
4. 0.75 (1.4D + 1.7L + 1.7S + 1.4Tf + 1.4Ta)
5. 0.75 (1.4D + 1.7L + 1.7S + 1.4Ta) + 1.6W
6. 1.2D + 0.2S + 1.0E + 1.2Ta
7. 0.9De + 1.6W + 1.2Ta
8. 0.9De + 1.0E + 1.2Ta

Steel Design load combinations: (AISC - LRFD)

1. 1.4D
2. 1.2D + 1.6L + 0.5S + 1.2Tf + 1.2Ta
3. 1.2D + 1.6S + 0.5L + 1.2Tf + 1.2Ta

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4. 1.2D + 1.6S + 0.8W + 1.2Ta
5. 1.2D + 1.6W + 0.5L + 0.5S + 1.2Ta
6. 1.2D + 1.0E + 0.5L + 0.2S + 1.2Ta
7. 0.9De + 1.6W + 1.2Ta
8. 0.9De + 1.0E + 1.2Ta

De is the minimum dead load on the structure.

FINAL ANCHOR AND GUIDE LOAD CHECK:

Where the design of transverse beams has been based on anchor loads as
explained in step-2,a final check of beams (and other affected members) should
be made when final definition of these loads is available from the Pipe Stress
Engineer.Based on the Engineer's experience and judgement, an overstress in
any element (of up to 10%) can be considered, provided proper justification is
given. Where such overstress cannot be properly justified, modifications should
be made to the piperack structure in order to bring the stress levels within the
normal allowables. Modifications could entail the addition of horizontal bracing to
the transverse beams to resist significant loads from the anchor(s), replacing
and/or adding members, strengthening members (i.e.,cover plating, etc.), and/or
relocating the anchor and guide load(s).

ALLOWABLE HORIZONTAL AND VERTICAL DEFLECTION:

Allowable deflections of piperack structures shall be as per project design

criteria. However, you can consider the following as limit of deflection:Lateral
deflection produced by load combinations that include wind or seismic
forces:Piperacks supporting equipment: h/100, unless a more stringent
requirement is given by the manufacturer of the equipment.Piperacks supporting
piping and raceway only: h/200 or as per project design criteria.Lateral deflection
produced by sustained static forces such as pipe and anchor loads: h/200 or as
per project design criteriaVertical deflection of beams due to gravity pipe loads:as
per project design criteria h is the total height of the pipe rack structure.

Step-4: Framing of Continuous/Conventional Pipe rack:

Frames

Main piperacks are usually designed as moment-resisting frames in the

transverse direction. In the longitudinal direction, there should be at least one
continuous level of beam struts on each side. For piperacks with more than one
tier, the beam struts should be located at a level that is usually equal to one-half
tier spacing above or below the bottom tier. Vertical bracing in the longitudinal
direction should be provided to carry the longitudinal forces, transmitted through
the beam struts, to the baseplate / foundation level.

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Transverse Beam

Transverse beams must be capable of resisting all forces, moments, and shears
produced by the load combinations. Transverse beams are generally a moment-
resisting frame, modeled and analyzed as part of the frame system. The
analysis model must reflect the appropriate beam end conditions. In the design of
beams, consideration should be given to

Large pipes that are to be hydro-tested.

Anchor and friction load with large magnitude (see step-2, anchor and
friction load)

Central Spine:

For steel piperacks with spans of more than 6 m, a center spine consisting of a
system of horizontal braces and struts located at midspan of each level of piping
should be considered . This additional light horizontal framing greatly increases
the capacity of the transverse pipe support beams to resist friction and anchor
forces, and also serves to reduce the unbraced length of the beam compression
flange in flexure and to reduce the unbraced length of the beam about the weak-
axis in axial compression. This concept reduces the required beam sizes and
provides a mechanism for eliminating or minimizing design, fabrication, or field
modifications that could otherwise be required due to late receipt of unanticipated
large pipe anchor forces.

Longitudinal Beam Strut

For typical continuous piperack systems, the longitudinal beam struts should be
designed as axially loaded members that are provided for longitudinal loads and
stability. Additionally, the longitudinal beam struts that support piping or raceway
should be designed for 50% of the gravity loading assumed for the transverse
pipe or raceway support beams, unless unusual loading is encountered. This
50% gravity loading will account for the usual piping and raceway take-offs.
Normally, the gravity loading carried by the beam struts should not be added to
the design loads for the columns or footings since pipes or raceway contributing
to the load on the beam struts would be relieving an equivalent load on the
transverse beams. Concentrated loads for large pipes may be treated as in step-
2.

For any continuous piperack system where the anticipated piping and raceway
take-offs are minimal or none, the 50% loading criteria does not apply. In such
cases, the beam struts should be designed primarily as axially loaded members.
Do not provide beam struts if they are not needed for piping or raceway support,
or for system stability. Conversely, the 3D model should be checked to verify
that beam struts subjected to unusually large loads (such as at expansion loops)

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have been given special consideration. All longitudinal beam struts, including
connections, should be designed to resist the axial loads produced by the
longitudinal forces.

When designing the longitudinal beam struts for flexural loads, the full length of
the beam should be considered as the unbraced length for the compression
flange.

Vertical Bracing

When moment-resisting frame design is not used in the longitudinal direction,

vertical bracing should be used to transmit the longitudinal forces from the beam
struts to the foundations. Knee-bracing or K-bracing is most often used for this
purpose. Unless precluded by equipment arrangement or interferences, bracing
should be placed equidistant between two expansion joints. Design calculations
and drawings must reflect a break in the beam strut continuity between adjacent
braced sections through the use of slotted connections or by eliminating the
beam struts in the bays designated as free bays. The maximum length of a
braced section should be limited to 48m to 50m. If the braced bay is not located
equidistant from the free bays, the maximum distance from the braced bay to a
free bay should be limited such that the maximum total longitudinal growth or
shrinkage of the unrestrained segment does not exceed 40 mm.

Column

The columns must be capable of resisting all loads, moments, and shears
produced by the load combinations.A moment-resisting frame analysis should
normally be used to determine the axial load, moment, and shear at points along
the columns.The frame analysis model should be based on the following:

Consider column base as hinge.

Use 4 bolt connections for safety purpose

For design of steel columns subjected to flexural loads, the distance between the
base and the first transverse beam or the knee brace intersection should be
considered as the compression flange unbraced length.

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4.0 Foundation Design Philosophy for Vertical Vessel / Tower
In this page I will talk about Vertical vessel/Tower equipment foundation load
calculation. Following are some pictures of Vertical vessel /Tower:

Picture-1 (Left) - A tall tower vessel resting on skirt and on Foundation.

Picture-2 (Right) - A small vertical vessel resting on legs and on fpundation.

Now you will follow the following steps to start the foundation load calculation
and design:

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Step-1 : Review of vessel drawing (Vendor Equipment Drawing)

You need to review Vessel drawings from foundation design point of view
and check whether you have all the following information:

Vessel Erection weight (De1):

Vessel Empty weight (De2):
Vessel Operating weight (Do):
Vessel Hydrotest weight (Dt):
Wind Shear and Moment
Seismic Shear and Moment (if the Project site is at Seismic zone)
Total Height of vessel
Vessel Center of Gravity location for Seismic load calculation and
application
Anchor bolt location (Bolt circle Dia) with respect to center of vessel
and also bolt offset with respect to Plant North line.
Anchor bolt supporting detail ( Anchor bolt size and detail of anchor
chair)
Base plate detail

Step-2 : Verification of foundation location, elevation and external fittings loads

You need to review Plot plan, Equipment location drawings and 3 -D Models and
check whether you have all the following information:

Verify the area available for foundation.

Verify Foundation location and Elevation
Pipe supports and Nozzle loads on Equipment (Dp)
Location and size of Platforms around the vessel
Locations of underground pipes
Electrical and Instrument duct banks
Locations and extent of adjacent foundations
Verify the location and extent of new/existing foundations not shown
in 3D model or plot plan.

Step-3 : Description of Foundation Loads:

Please follow this section to understand the different loads on foundation:

Vessel Erection weight (De1): The erection weight is the fabricated weight of the
vessel, plus internals, platforms, etc., that are actually erected with the vessel.
Data from Equipment drawing.

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Vessel Empty weight (De2): The empty weight is the in-place weight of the
completed vessel, including the fabricated weight of the vessel, plus the weight of
internals, piping, insulation, and platforms, but excluding the weight of fluids or
products which will be contained in the vessel during operation. Data from
Equipment drawings.

Vessel Operating weight (Do): Vessel Empty weight (De2) + Weight of Fluid
inside the vessel. Data from Equipment drawings.

Vessel Hydrotest weight (Dt): Vessel Empty weight (De2) + Weight of test
water

Pipe supports and Nozzle loads on Equipment (Dp): Please Coordinate with the
Pipe Stress Group for determination of nozzle loads and loads due to pipe supports
attached to the vessel.

Wind Shear and Moment: You will find this load data in vendor drawings. However,
you have to calculate this load based on project design basis. During wind load
calculation, you need to consider the pipes and platforms attached with the vessel.
Compare both the data (vendor load data and your calculated data) and apply the
critical one for foundation design.

Seismic Shear and Moment (if the Project site is at Seismic zone): You will find this
load data in vendor drawings. However, you have to calculate this load based on
project design basis. During seismic load calculation, you need to consider the
pipes and platforms attached with the vessel. Compare both the data (vendor load
data and your calculated data) and apply critical one for foundation design.

Step-4 : Pedestal Sizing Criteria:

Concrete pedestals supporting vertical vessels shall be sized according to the

following criteria:

Face-to-face pedestal size shall be the larger of the following:

(a) Bolt circle + 175mm

18
(b) Bolt circle + 8 x bolt diameters

(c) Bolt circle + sleeve diameter + 150mm

(d) Diameter of baseplate + 100mm

(e) Bolt circle + 2 x (minimum bolt edge distance)

Pedestals having a diameter or least dimension across sides that is equal to or

greater than 1.5m shall be octagonal in shape. All other pedestals shall be square
in shape. For ease of forming, use multiples of 25mm for each octagonal side or
side of square.

It is desirable to make the pedestal deep enough to contain the anchor bolts and
keep them out of the mat.

Step-5 : Anchor Bolt Check:

Design of anchor bolts shall be based on the following considerations. Corrosion

allowance should be considered when required by the project design criteria.

Tension Check:

The maximum tension force in the anchor bolts (Tmax) may be calculated
according with following formula:

Tmax = 4*M / (Nb x BCD) - (De1 or De2) / Nb

Where, M = total maximum moment on foundation

BCD = Bolt circle diameter
Nb = no. of anchor bolt

Use De1 or De2 whichever is critical.

The above formula provides a conservative value of Tmax compared to the concrete
transformed section method.

Shear Check:

When anchor bolts are utilized to resist shear, the unit shear per bolt shall be
calculated as follows:

19
Vmax = V / Nb where, V = total shear force on anchor bolt.

When oversized anchor bolt holes are provided in the vessel base plates or when
anchor bolt sleeves that are not grout-filled are used, anchor bolts should be
designed to resist tension only.

Frictional resistance to shear between the vessel base plate and the concrete or
grouted bearing surface shall be utilized to resist shears induced by wind or by
other static loads. Frictional resistance shall not be employed to resist shear
induced by seismic loads. For seismic-induced shear, adequate mechanical
means shall be provided to resist horizontal shear, either by means of properly
detailed anchor bolt / bolt hole arrangements or through a combination of anchor
bolts, shear lugs, or other anchorage devices. The static coefficient of friction
between steel and concrete or between steel and cementitious grout shall be
considered as 0.4 or specified in project design criteria.

Tension Shear Interaction check:

When anchor bolts are subjected to combined shear and tension loads, the design
shall be based on satisfying interaction formula (say Appendix-d of ACI 318).

Please note that anchor bolt edge distance, spacing and load capacity shall be
as per project design criteria.

Step-6 : Load combinations for foundation sizing / Pile loads and Foundation
design:

You need to create the load combination per your project design criteria. However, I
have created this load combination based on ACI 318:

Load combination for Foundation sizing and Pile load calculation (un-factored
load calculation):

LC1: Do + Dp
LC2: (De1 or De2) + Wind
LC3: De2 + Seismic
LC4: Do + Dp + Wind
LC5: Do + Dp + Seismic
LC6: Dt + 025*Wind

Load combination for Pedestal and Foundation design (factored load

calculation):

20
 LC7: 1.4*(Do + Dp)
LC8: 0.75 [1.4 De2 (or 1.4 De1)] 1.6 Wind
LC9: 1.2 De2 +1.0 E
LC10: 0.75 (1.4 Do + 1.4 Dp) 1.6 Wind
LC11: 1.2 (Do + Dp) 1.0 E
LC12: 0.75 (1.4 Dt) 1.6 (0.25 W)

The weight of the foundation and of the soil on top of the foundation shall be
included as dead load in all of these load combinations.

Now from above steps, you have learnt the following:

Different types of loads on foundation

Different criterias for the pedestal sizing
Maximum tension and shear force on each anchor bolt
A sample load combinations.

To complete the foundation design, your work will be to create following

calculation sheets:

o A calculation sheet for anchor bolt embedment length check (ex:

ACI 318 appendix-D).

o A calculation sheet for foundation sizing (considering soil bearing

pressure, Sliding, Buoyancy and overturning) or pile load (tension,
compression and shear on each pile) calculation and check with
soil consultant for acceptable values.

o A calculation sheet for foundation and pedestal reinforcement

calculation per your project design criteria.

21
5.0 Foundation Design Philosophy for Horizontal Vessel
In this page I will talk about Horizontal vessel / Horizontal Drum equipment
foundation load calculation. Following is a picture of Horizontal vessel / Drum:

Now you will follow the following steps to start the foundation load calculation
and design:

Step-1 : Review of vessel drawing (Vendor Equipment Drawing)

You need to review Vessel drawings from foundation design point of view
and check whether you have all the following information:

Vessel Erection weight (De1):

Vessel Empty weight (De2):
Vessel Operating weight (Do):
Vessel Hydrotest weight (Dt):
Wind Shear and Moment in transverse direction
Seismic Shear and Moment in transverse direction (if the Project site is
at Seismic zone)
Vessel operating temperature and confirm with Mechnaical discipline
Total length of vessel and spacing of saddle supports
Vessel Center of Gravity location with respect to saddle
Anchor bolt location on fixed and sliding saddle
Detail of equipment saddle (fixed and sliding)

Step-2 : Verification of foundation location, elevation and external fittings loads

You need to review Plot plan, Equipment location drawings and 3 -D Models and
check whether you have all the following information:

Verify the area available for foundation.

22
 Verify Foundation location and Elevation
Pipe supports and Nozzle loads on Equipment (Dp)
Location and size of Platforms around the vessel
Locations of underground pipes
Electrical and Instrument duct banks
Locations and extent of adjacent foundations
Verify the location and extent of new/existing foundations not shown
in 3D model or plot plan.

Step-3 : Description of Foundation Loads:

Please follow this section to understand the different loads on foundation:

Vessel Erection weight (De1): The erection weight is the fabricated weight of the
vessel, plus internals, platforms, etc., that are actually erected with the vessel.
Data from Equipment drawing.

Vessel Empty weight (De2): The empty weight is the in-place weight of the
completed vessel, including the fabricated weight of the vessel, plus the weight of
internals, piping, insulation, and platforms, but excluding the weight of fluids or
products which will be contained in the vessel during operation. Data from
Equipment drawings.

Vessel Operating weight (Do): Vessel Empty weight (De2) + Weight of Fluid
inside the vessel. Data from Equipment drawings.

Vessel Hydrotest weight (Dt): Vessel Empty weight (De2) + Weight of test
water

Pipe supports and Nozzle loads on Equipment (Dp): Please Coordinate with the
Pipe Stress Group for determination of nozzle loads and loads due to pipe supports
attached to the vessel.

Wind Shear and Moment (W): You will find this load data in vendor drawings.
However, you have to calculate this load based on project design basis. During
wind load calculation, you need to consider the pipes and platforms attached with
the vessel. Transverse and longitudinal wind load shall be calculated per design
project criteria. No allowance shall be made for shielding of winds by nearby
equioment. The calculated design moments and shears due to wind load should be
compared to those shown on the vessel drawings and maximum loads shall be
used for foundation design.

23
Seismic Shear and Moment (E) (if the Project site is at Seismic zone): You will
find this load data in vendor drawings. However, you have to calculate this load
based on project design basis. During seismic load calculation, you need to
consider the pipes and platforms attached with the vessel. The longitudinal seismic
force shall be resisted by the fixed end pier only unless the piers are tied together
by tie beams below the base plates. Transverse seismic forces shall be resisted by
both piers using saddle or base plate reactions as the basis for computing base
shear. The calculated design moments and shears due to seismic should be
compared to those shown on the vessel drawings and maximum loads shall be
used for foundation design.

Thermal Load (T): The thermal load is defined as the load which results from
thermal expansion or contraction of the exchanger/vessel in the longitudinal
direction. The maximum thermal force is equal to the maximum static friction force
(frictional resistance) acting at the equipment sliding support before the saddle
begins to move. The frictional resistance equals the coefficient of friction (see
project design criteria) times the vertical support reaction.

The thermal load considered in foundation design shall be the smaller of the
following:

4. The maximum pier reaction at the sliding end times the coefficient of friction
of the sliding surfaces
4. The force required to deflect each pier one-half the amount of the total
thermal expansion between supports (assuming thermal loads of equal
magnitude, but opposite directions, act on each pier).

Generally, for short piers, the frictional force discussed in item (a) above governs
the design.

Step-4 : Load combinations for foundation sizing / Pile loads and Foundation
design:

You need to create the load combination per your project design criteria. However, I
have created this load combination based on ACI 318:

Load combination for Foundation sizing and Pile load calculation (un-factored
load calculation):

LC1: Do + Dp + T
LC2: (De1 or De2)+ Wind
LC3: De2+ Seismic
LC4: Do + Dp + Wind + T

24
 LC5: Do + Dp + Seismic + T
LC6: Dt + 025*Wind

Load combination for Pedestal and Foundation design (factored load

calculation):

LC7: 1.4*(Do + T + Dp )
LC8: 0.75 [1.4 De2 (or 1.4 De1)] 1.6 Wind
LC9: 1.2 De2 +1.0 E
LC10: 0.75 (1.4 Do +1.4 T + 1.4 Dp) 1.6 Wind
LC11: 1.2 (Do +T + Dp) 1.0 E
LC12: 0.75 (1.4 Dt) 1.6 (0.25 W)

The weight of the foundation and of the soil on top of the foundation shall be
included as dead load in all of these load combinations.

Step-5 : Anchor Bolt Check:

Maximum shear and tension on anchor bolt shall be calculated based on above
load combinations and shall be compared with project acceptable value. Anchor
bolt embedment length shall be checked per any project approved code (ex: ACI
318 appendix-D).

Step-6 : Pedestal Sizing and reinforcement:

Unless controlled by other factors, the minimum pier dimensions in each

direction should equal to the dimensions of the base plate plus 100mm.
Piers shall be sized in 50mm increments. The minimum thickness of the
pier should be approximately 10% of the pier height, with a minimum of
250mm.

Pier size should be adjusted to ensure the factored vertical force on the pier
does not exceed the value of 0.1Agfc (Refer ACI 318 section 10.3.5)

Piers should be designed as axially loaded cantilever flexural members

When the size of the pier cannot be adjusted and the value of the axial load
exceeds 0.1Agfc, the piers should be designed as compression members
subjected to combined flexure and compressive axial load.

For piers with slenderness ratio equal to or exceeding 22, moment

magnification effects should be considered (refer section 10.13 of ACI 318).

25
 In calculating the slenderness ratio, a "K" factor of 2 should be used. The P-
M column interaction check may also be considered in pier design.

Shears on piers along both the longitudinal and transverse directions of the
equipment shall be checked per code requirements (refer ACI 318, Chapter
11).

Reinforcement should normally be arranged symmetrically. Both the fixed

end and sliding end piers shall be sized and reinforced identically. For pier
height less than 7 feet, the vertical reinforcement may be extended from the
foundation with no dowels being required.

A double tie shall be placed at the top of piers, spaced 50mm and 125mm
below the top of concrete (or below the bottom of grout), to protect the top of
concrete piers against cracking.

Step-7 : Slide plate :

Slide plates are placed at the sliding end pier to allow longitudinal movement
of exchangers and vessels due to the thermal growth. The steel slide plate
on the sliding end is generally coated with Dow Corning G-n Metal Assembly
Paste or similar lubricant in order to reduce the coefficient of friction. Slide
plates should be galvanized or painted to prevent corrosion.

For large movements and/or heavy horizontal vessels, it may be necessary

to use slide plates with low coefficient of static friction, such as lubrite, teflon,
etc. Design of lubrite and teflon slide plates shall be in accordance with the
recommendations of the slide plate manufacturer, as the coefficient of static
friction varies with the temperature and pressure at the bearing surface.

Typical coefficients of friction () are as follows

0.15, for mild steel slide plates coated with Dow Corning G-n Metal
Assembly Paste
0.20, for mild steel to mild steel without lubricant
0.06, for teflon slide plates with bearing pressure over 100 psi

Now from above steps, you have learnt the following:

Different types of loads on foundation

Different criterias for the pedestal sizing
Maximum tension and shear force on each anchor bolt
A sample load combinations.

To complete the foundation design, your work will be to create following

calculation sheets:

26
o A calculation sheet for anchor bolt embedment length check (ex:
ACI 318 appendix-D).

o A calculation sheet for foundation sizing (considering soil bearing

pressure, Sliding, Buoyancy and overturning) or pile load (tension,
compression and shear on each pile) calculation and check with
soil consultant for acceptable values.

o A calculation sheet for foundation and pedestal reinforcement

calculation per your project design criteria.

27
6.0 Design of Concrete Ring Beam for Storage Tank

In this page I will talk about the design philosophy of ring beam for storage water
tank. The granular fill foundation of the tank shall be designed per project design
criteria / specification. This type of foundation is mostly common to all project
site. However, sometimes we design concrete ring beam around the tank
foundation. Following are some reasons for design of concrete ring beam, though
this is more costly and take longer to construct than granular fill ring:

Sometimes clients ask to provide concrete ring beam around tank

foundation.
Prevent uplift of the tank due to wind or earthquake
Prevent edge failure of the soil at the tank shell
Prevent local uplift of the tank due to internal pressure.

Now you will follow the following steps to start the foundation load calculation and
design:

Step-1 : Review of Tank detail drawing (Vendor Drawing)

You need to review tank drawings from foundation design point of view and
check whether you have all the following information:

Tank Dimension, Diameter and Height

Type of Roof (Floating or fixed roof), weight of roof
Detail of tank shell and weight of tank shell
Detail of tank base plate, location of base sump, annular plate and total
weight of base plate
Detail of anchor bolt (BCD, no of bolt and dia of bolt) and anchor bolt fixing
detail
Location and detail of man-hole at bottom portion of tank
Product density and and maximum height of product
Maximum height of water inside the tank for the hydrotest* Internal
pressure or suction
Live load
Wind Shear and moment on tank shell
Seismic shear and moment on tank shell

Step-2 : Verification of foundation location, elevation and external fittings loads

You need to review Plot plan, Equipment location drawings and 3 -D Models and
check whether you have all the following information:

Verify the area available for foundation.

Verify Foundation location and Elevation

28
 Pipe supports and Nozzle loads on tank (Dp)
Location and size of Platforms around the tank
Locations of underground pipes
Electrical and Instrument duct banks
Locations and extent of adjacent foundations
Verify the location and extent of new/existing foundations not shown in 3D
model or plot plan.

Step-3 : Loads on concrete ring beam and on the confined compacted granular
fill in-side the ring:

You need to place concrete ring beam in such a way that outer surface of the
tank shell should be the center of ring beam. Consider the following loads on ring
beam and on granular compacted fill inside the concrete ring.

Geotechnical Data:

Before starting the design, you need to collect the following information about
soil:

Allowable Bearing Pressure

Density of Soil
Co-efficient of earth pressure at rest (Ko)

Loads on Ring beam:

Total weight of tank shell (vertical load), kN / m (DL)

Total weight of roof , for fixed roof case. For floating roof, part of the roof
weight will come on the ring beam, kN / m (DL)
Total live load on roof , for fixed roof case. For floating roof, part of the
live load will come on the ring beam, kN / m (LL)
Part of annular base weight on ring beam, kN / m2 (DL)
Part of product / test water load on ring beam, kN / m2 (PL)
Seismic shear and wind shear on ring beam, kN / m
Part of internal pressure / suction load on ring beam, kN / m2(IP)

Loads on compacted granular fill inside the ring beam:

Floating roof weight on compacted granular fill, kN / m2(DL)

Annular base weight on compacted granular fill, kN / m2 (DL)
Live load on floated roof, kN / m2 (LL)
Product / test water load on compacted granular fill, kN / m2(PL)
Internal pressure / suction load on compacted granular fill, kN / m2 (IP)

Following load combimations can be used for soil bearing pressure check (at
bottom of ring beam level) :

29
 Load Combination: LC1 - Self weight of soil / Beam + Self weight of tank
+ Product weight + Internal pressure
Load Combination: LC2 - Self weight of soil / Beam + Self weight of tank
+ Product weight + Internal Pressure + Live Load
Load Combination: LC3 - Self weight of soil / Beam + Self weight of tank
+ Product weight + Internal pressure + Wind Load
Load Combination: LC4 - Self weight of soil / Beam + Self weight of tank
+ Product weight + Internal pressure + Seismic Load
Load Combination: LC5 - Self weight of soil / Beam + Self weight of tank
+ Product weight + Internal pressure + Live Load + Wind Load
Load Combination: LC6 - Self weight of soil / Beam + Self weight of tank
+ Product weight + Internal pressure + Live Load + Seismic Load
Load Combination: LC7 - Self weight of soil / Beam + Self weight of tank
+ Test water weight

Load combinations for Ring beam design for Hoop tension:

Load Combination: UC1 - 1.7 x (Surcharge load of confined soil) + 1.7 x

Surcharge load of (Self weight of tank + Product weight + Internal
pressure)
Load Combination: UC2 - 1.7 x (Surcharge load of confined soil) + 1.7 x
Surcharge load of (Self weight of tank + Product weight + Internal
pressure)+ 1.4 x surcharge of Live Load
Load Combination: UC3 - 1.7 x (Surcharge load of confined soil) + 1.7 x
Surcharge load of (Self weight of tank + test water weight)

Step-4 : Determination of concrete ring beam size:

The ring wall should be a minimum 300 mm thick and extend to a suitable
bearing stratum, whch may be natural ground or built-up compacted granular
material. It should be 500 mm below ground level and extend below frost line.
The bearing capacity of the soil below the ringwall should be calculated using a
strip foundation analysis loaded with vertical load as mentioned in step-3.

API 650, appendix-B, clause B.4.2.2 states that it is desireable that the ringwall
width be such that the average unit soil loading under the ring wall will be
approximately equal to the earth pressure under the confined earth at the same
depth (in maximum liquid level condition).

Once, the ringwall thickness is determined from above condition, it should be

reviewed to ensure that excessive quantities of concrete are not used for tanks
with low liquid levels and that the permissible ground pressure for the width of the
wall is not exceeded.

Please note that, soil bearing pressure under the ring beam and under the
confined earth at same depth should not exceed the allowable soil bearing

30
pressure for any of the above described load and any load combinations.

Step-5 : Determination of Hoop Tension on concrete ring beam and

reinforcement calculation:

The concrete ring beam shall be designed for hoop tension. This hoop tension
will be generated from surcharge load due to confined soil and loads on confined
soil.

Load calculation:

Surcharge due to confined soil: Sursoil = 0.5 x (height of ringwall)2 x soil density
x Co-efficient of earth pressure at rest (Ko)

Surcharge due to uniform load on confined soil: Surudl = (Load on confined soil)
x (height of ringwall) x Co-efficient of earth pressure at rest (Ko)

Total Hoop tension (T) = (Sursoil + Surudl) x (0.5 x centerline diameter of ring
beam)

Factored Hoop Tension load can be calculated as per step-3.

Required area of Hoop reinforcement is, Ast = (Factored Hoop tension) / (0.9 x
yeild stress of rebar---fy)

The ringwall must also be designed to take care circumferential bending

moments due to the vertical load being applied eccentrically to the ringwall center
line.

The ringwall should be reinforced on both faces, with vertical reinforcement

(stirrups) closest to the concrete surfaces. Not more than 50% of the hoop
reinforcement should be lapped at any one position.

Step-6 : Anchor Bolt Design:

Anchor bolt shall be checked per design criteria and Tenssion & Shear load
supplied by vendor. If wind and shear forces are not supllied by vendor, you need
to calculate the anchorage load from API 650. Anchor bolt shall be designed for
ductility failure. If required, additional reinforcement to be provided around the
anchor bolt.

31
6.0 Anchor Bolt Design Philosophy
In this page, I will tell you about the design philosophy of anchor bolt design and
also to define the different terms used for anchor bolt design.

Anchor bolt is the most important part to transfer the load from superstructure to
sub-structure (say Foundation system). So, though anchor bolt design is very
simple, but still you have to give more care to design this small element as load
transfer mechanism. Otherwise, super structure and sub-structure, designed
separately, will not behave as a single structure, in other words, a failure of total
structural system.

Whenever you start the design of anchor bolt, you will see the words like "Cast in
place anchor", "Post installed expansion anchor", "Preloaded anchor", "Ductile
design", "Anchor Bolt Projection" "Edge distance for shear", and "edge distance
for tension". Please look below for the definition of some of the different terms:

Cast in place anchor:

When a headed bolt, headed stud, or hooked bolt is installed before placing
concrete, is called "Cast in place anchor". See project standard for dimensions
and areas. The recommended minimum embedment depth for cast-in anchors
varies from eight (8) to twelve (12) bolt diameters (see project design code). The
design engineer should note that minimum embedment requirements have an
impact on concrete thickness, especially in designs such as area slabs and
building slabs.

Cast-in anchors have many benefits, including the following:

They are capable of supporting very large loads.

Drilling or cutting of reinforcement is not required for installation.

Strength is not sensitive to installation procedures and techniques.

Supplementary reinforcement may be easily included in the design.

Some disadvantages are as follows:

Labor and materials are required to create templates for placement in the
form-work.

Re-work is costly when anchors are incorrectly placed (location and

elevation).

Fabrication lead time is required to support concrete placement.

32
Please click here for details of different types of anchor bolts used in the different
projects.

Post installed expansion anchor:

When an anchor rod is installed after placing concrete, making a hole in concrete
with drill-bit, is called "Post installed expansion anchor". This type of anchors
rely on bond to transfer load to the concrete. Post-installed anchors have many
benefits, including the following:

Savings in labor and materials on templates required for cast-in anchors

Placement locations that may be adjusted as required to accommodate
attachments
Flexibility in the construction schedule

Some disadvantages include:

Performance that is highly dependent on installation procedures and

techniques
Potential for cut or damaged reinforcing bars if drilling is required for
installation
Limited load capacities
Difficulty including supplementary reinforcing in the design
Prohibited preloading

In these cases we generally use HILTI Anchor (adhesive or grouted anchor).

Preloaded anchor:

An anchor is subjected to a large tensile force by intentionally elongating the

entire length of the bolt. A nut is generally advanced along the bolt threads until
the desired tensile force is achieved. In general, there are no standard criteria
for preloading anchor bolts. The level of the required preload generally
depends on the specific application of the anchor bolt. In general, preloaded bolts
will require a sleeve or bond breaker to permit elongation to occur along the
entire length of the bolt. Without a sleeve or bond breaker, the concrete would
bond to the shank of the bolt during construction. The bond may not be
completely broken during the preloading process. Over time, the bond may
become completely broken and may cause a significantly reduced preload in the
bolt.
Anchor bolts used for equipment supports should be preloaded to the equipment
manufacturer's recommendations when specified. This is especially true for bolts
anchoring rotating or vibrating equipment.

Anchor bolts of ASTM F1554 Grade 36, A307, or A36 material (i.e., regular
carbon steel bolts) should have only a nominal preload applied. It is

33
recommended that they be tightened to a snug tight condition. Snug tight is
defined as tightness attained by a few impacts of an impact wrench or the full
effort of a man using an ordinary spud wrench. When bolts are anchoring
equipment or are subject to possible loosening during operation, a locking device
should be provided. Acceptable locking devices include double nuts or jam nuts,
interrupted threads, and tack welds (for weldable materials only).

The three basic methods used for applying a preload to a high-strength anchor
boltusing hydraulic tensioners, torquing to a specified level, and using turn-of-
the-nut methodare described in detail below.

Hydraulic Tensioners: Hydraulic tensioners should be used when a

precise preload on large diameter anchor bolts is required. The tensioner
applies a direct load to the bolt by threading onto the projected end of the
bolt and then jacking against the adjacent concrete surface. Once the
jacking is complete, the nut is hand tightened down to a snug position to
lock the tension in the bolt. The anchor bolt must project a minimum of
one diameter past the end of the nut to allow for use of the tensioner. The
residual preload should be specified, as there will be a loss of
pretensioning (depending on the length and diameter of the bolt) when the
tensioner is released.

Torquing to a Specified Level: Applying a specified torque to an anchor bolt

is another method of obtaining a preload. This method results in a preload
that varies significantly as a function of field conditions (cleanliness of bolt,
existence of lubrication, etc.) and is no longer recognized by AISC.
Therefore, use of a predetermined torque for preloading purposes is not
recommended (with the exception of equipment manufacturer
requirements).

Turn-of-the-Nut Method: This method is described in the AISC Specification

for Structural Joints for ASTM A325 and A490 bolts. The specification lists
the required nut rotation from the snug tight condition for bolt lengths up to
12 diameters.

Refer to the relevant specification for requirements for hardened washers. For
example, AISC Specification for Structural Joints describes the requirements for
ASTM F436 washers for certain preload applications.

Elongation Checks For Preloaded Bolts: Where precise preloads are required,
the elongation of the anchor bolts may be checked as a verification that the
proper preload has been applied. Elongation checks are usually performed only
when tensioners are used as the preloading device. Dial gauges can be used to
measure the projection of the bolt from a reference surface before and after
preloading. The required elongation for a given preload can be calculated as
follows:

34
For plain rod: de = (P*L) / (Ab*E)

For full threaded rod: de = (P*L) / (At*E)

For partial thread rod: de = (P/E)*[(Lt/At) + (Ls/Ab)]

where
de = Elongation of anchor bolt, mm.
P = Desired preload, kN
L = Effective length of bolt, mm. (usually taken from centers of nut to
anchor nut)
Ab = Nominal cross sectional area of bolt (area of shank), mm2
E = Young's Modulus of Elasticity, MPa
Lt = Length of thread below nut, mm
Ls = Length of shank, mm.
At = Area of threaded section, mm2

The preload is generally considered acceptable if the actual elongation is within +

5 percent of the calculated value for the given preload.

Sleeves:

Two basic types of sleeves are partial depth and full depth anchor bolt sleeves.
Partial depth sleeves typically have a corrugated profile and are made from high
density polyethylene (say, Plastic Wilson or equal). Full depth sleeves are
typically made from a steel pipe section with a steel bearing plate seal welded to
the embedded end. Sleeve diameters are generally two to four times the
diameter of the anchor bolt. Sleeves serve two purposes:

First, partial depth and full depth sleeves afford the opportunity to move
the top of the bolt slightly when trying to align the attachment. However,
the presence of a sleeve does not imply that an anchor bolt may be freely
bent or otherwise deformed in order to account for placement that was out
of construction tolerance.
Second, a full depth sleeve may be used in conjunction with preloaded
bolts. The sleeve permits elongation along the entire length of the bolt,
and the bearing plate transfers the tension force from the anchor bolt to
the concrete. It must be emphasized that the bearing plate must be sized
to ensure that the anchor does not pull through or cause the plate to
deform excessively. Also, the nut on the bottom of the anchor plate must
be held securely in place to prevent loosening during construction
activities.

In most applications, the sleeves are cut flush with the top of concrete and then
filled with nonshrink grout after the attachment has been placed and aligned.

35
Prior to grouting the sleeves, precautions must be taken to prevent water from
freezing inside the sleeves.

Anchor Bolt Projection

The length of an anchor bolt that projects from the concrete surface where the
length is measured from the concrete surface to the free end of the anchor bolt.
Any thickness of grout placed on the concrete surface must be included in the
projection length.

Baseplate Leveling Systems

Some of the most common methods used for leveling base plates, are, the use of
shim stacks and leveling nuts. It must be emphasized that the shims and leveling
nuts should be removed before preloading the bolts. Leveling nuts may be used
only on anchor bolts where preloading is not required. Use of leveling nuts on
anchor bolts that are preloaded would result in bolt tension only in the region
between the leveling nut and the top nut.

Ductile Design

The ability of an element to deform beyond the point of elastic yield prior to total
failure is called ductility. Ductile design referring to an anchor with design
strength equal to the design strength of the steel element. All potential concrete
failure modes must have design strengths greater than the steel element
(supplemental reinforcing may be used to increase the design strength of
concrete failure modes).

Design discussions for Cast in place anchor:

As with all designs, anchor bolt designs must meet the project design criteria and
project commitments to codes and standards. Here, this discussions follow the
provisions of ACI 318-05, Appendix D, for the design of cast-in anchors.

Much consideration is given to ductility in the design of anchor bolts. In general,

steel is a ductile material and plain concrete is not. For anchorage to concrete,
ductility usually means that in the event of overload, the ductile steel anchor will
yield before the concrete can fail in a brittle manner. In this discussion, ductile
designs are also referred to as developed anchors. Ductile designs are
therefore preferable for most applications.

During anchor bolt design, you may find that proper ductile design is not possible
for some reasons and following are some cases:

Piers/pedestals or other concrete elements where the edge distances and

bolt spacings preclude development of the steel anchor strength -The

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 addition of supplemental reinforcing can often provide restraint and
confinement capable of producing a ductile design.
Large diameter bolts specified by machine manufacturers - Machine
anchor sizes are often much larger than the sizes that would be required
for strength considerations only. In such cases, supplemental
reinforcement should be provided in order to come as close as practicable
to a ductile design. Note that manufacturers sometimes specify ductile
anchors as part of their design criteria.
Supports for architectural, mechanical, and electrical components - This
case consists primarily of post-installed adhesive or grouted-in anchors for
medium to light duty service.
Supports for structures or equipment where anchors are not required to be
designed for an applied load - Such cases would include posts subject to
gravity load only, equipment skids subject to gravity load only, etc. In
these cases, anchors should be provided with minimum recommended
embedment depths given in Project design criteria.

Anchors must be designed for Tension load , Shear Load and combination of
Shear and Tension. Following are some method of transferring Shear and
Tension Load to concrete:

Shear Load: There are several alternatives for transferring shear from an
attachment to the concrete.

Anchor Shear: An anchor may be loaded in shear, and, in turn, transfer

the shear to the concrete. Welded studs are most commonly used to
transfer shear in this manner. Welded studs have the advantage of being
securely welded to the attachment. An anchor bolt inserted through a hole
in an attachment requires special consideration to assure shear transfer
from the attachment to the anchor. Usually, the bolt holes in the
attachment will be oversized to accommodate anchor installation
tolerances. Oversized holes make it unlikely to achieve bearing at all
anchors in a given attachment. There are two methods to deal with
oversized holes: First, the number of anchors considered to resist the
shear may be limited to half of the total no of anchor used; second,
washers without oversized holes may be provided and then welded to the
attachment to transfer the shear to the anchor.

Friction: For cases where a sustained compressive force exists between

the attachment and the concrete surface, friction will be developed.
Project criteria and codes must be reviewed to determine if it is permitted
to rely on frictional resistance.The friction load should be based on the
dead load and any portion of the live load that causes the shear. Care
must be taken not to overestimate the dead load. If the applied shear load
exceeds the shear that can be transferred by friction, additional means

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 must be provided to transfer the applied shear that is in excess of the
friction.

Shear-Friction: Shear-friction may be developed as a result of the

anchors effectively clamping the attachment to the concrete surface. In
this case the anchor must be designed for the tension resulting from shear
friction as well as any tension applied directly.

Shear Lugs: Shear lug is the preferred methods of shear transfer when
friction is not an option or is not sufficient to resist the applied shear. This
method requires pre-formed pockets in the concrete. The shear lug is
generally a steel element, welded to the attachment, that transfers the
shear directly to the concrete through bearing. Shear lugs are most
commonly single cantilever plates but may be wide flange shapes or box
sections for very large loads. Use of cantilever shear lugs greater than the
thickness of the attachment plate is not recommended, and shear lugs
should be designed using a minimum of 50 mm. embedment into the
concrete. Fillet welds are preferred over penetration welds by fabricators
for attaching shear lugs to baseplates. For the case of extremely large
shear loads, shear lugs made from wide flange sections or box sections
may be necessary. The behavior of large shear lugs with deep
embedments will be dependent on the stiffness of the shear lug and the
stiffness of the attachment.

Tension Load: Tension may be transferred from an attachment to the anchor by

a number of means. Most commonly, the anchor is welded directly to the
attachment, as with welded studs, or secured with nut and washer, as with
column base plates. Where attachments are provided with oversized holes, a
plate washer may be required to ensure that there is adequate bearing and that
the anchor does not pull through the attachment.

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