Code of practice for design and construction of machine foundations, Part 5: Foundations for impact machines and other than hammer (forging and stamping press, pig breaker, drop crusher and jolter)

IS 2974 Part 5 - Scope & Key Data for Machine Foundations

This part covers design data and specifications for foundations of forging presses, pig and scrap breakers, and jolters.

Scope Highlights:

• Applies to machine foundations excluding elevator/hoist towers.
• Focus on dynamic loads from forging presses, pig breakers, and jolters.
• Emphasis on obtaining manufacturer data for accurate design.

Key Data to be Obtained (Clause 3.1):

Rounding Off Results:

• Follow IS 2-1960 for rounding test or calculated values to match significant figures of specified values.

This ensures foundation design accounts for dynamic and static loads accurately, improving safety and performance.

flowchart TD
    A[Manufacturer Data] --> B{Machine Type}
    B --> C[Forging Press]
    B --> D[Pig & Scrap Breaker]
    B --> E[Jolter]
    C --> F[Pressure, Stroke, Weights, Load-Time Curve, Moment]
    D --> G[Ram Weight, Fall Height, Scrap Weight]
    E --> H[Jolting Table Weight, Frequency, Stroke, Pressure]

IS 2974 Part 5 - Key Definitions & Data Requirements

• Definitions: Refer to IS 2974 Part 1 (1982) for all foundational definitions related to machine foundations.

• Necessary Data for Design (Clause 3.1):
  For Forging, Sheet Metal, and Stamping Presses, obtain:

  • Layout & outline drawings
  • Anchor bolt details
  • Press pressure (p), stroke (S)
  • Weights: cross head (we), gross (wp), material (wm)
  • Load-time pulse relationship (p vs t)
  • Dynamic forces/moments for eccentric presses (M)
  • Steel column dimensions

  For Pig and Scrap Breakers:

  • Ram weight & fall height
  • Pig scrap weight
  • Constructional loads

  For Jolter Tables:

  • Weight of jolting table with charge (wt)
  • Anvil weight (W)
  • Jolts frequency (blows/min)
  • Stroke/fall height (S)
  • Max steam/air pressure (p)

• Soil Data (Clause 3.2):

  • Soil profile & characteristics to 3× foundation depth or hard strata
  • Soil investigation per IS 1892 (1979) and dynamic properties per IS 5249 (1977)
  • Water table position seasonally

Summary Table of Key Parameters

IS 2974 Part 5: Necessary Data & Key Specifications

1. Soil and Site Data (Clause 3.2)

• Soil profile depth: At least 3 × mean plan dimension of foundation or up to hard strata.
• Soil investigation: As per IS 1892-1979 for geotechnical data; IS 5249-1977 for dynamic soil properties.
• Water table position: Relative depth below ground at various times.

2. Machine Data for Design (Clause 3.1)

• For Pig and Scrap Breakers, additional data like ram weight, fall height, and constructional loads are required.
• For Jolter Tables, key data include weight of table + charge, anvil weight, jolting frequency, stroke, and max steam/air pressure.

3. Design Note (Clause 4.7.1)

• Jolter table foundations designed per Clause 4.4.
• Moving weight = jolter table weight + charge weight.

Summary Table of Key Parameters

IS 2974 Part 5 – Design Criteria Summary

Key Design Data (Clause 3)

• Soil Data:
  • Soil profile & characteristics up to depth = 3 × (mean plan dimension of foundation) or hard strata.
  • Dynamic soil properties per IS 5249-1977.
  • Water table position seasonally.
• Machine Data (from manufacturer):
  For presses, pig breakers, jolters:
  • Layout, anchor bolt details.
  • Pressing pressure (p), stroke (S).
  • Weights: cross head (we), gross (wp), material (wm).
  • Load-time curve (p vs t), dynamic forces/moments (M).
  • Frequency of jolts, height of fall, max pressure (steam/air).

Design Approach (Clause 4.7.1)

• Jolter table foundations:
  • Moving weight = jolter table + charge weight.
  • Design procedure per Clause 4.4 (dynamic load considerations).

Typical Formulae & Parameters

Design Considerations

• Use dynamic soil parameters from IS 5249 for foundation design.
• Account for load-time variation in dynamic forces.
• Design for anchor bolts and embedment as per machine layout.
• Consider water table effects on soil bearing capacity.

flowchart TD
    A[Machine Data] --> B[Dynamic Loads (p, M)]
    C[Soil Data] --> D[Soil Profile & Properties]
    B --> E[Foundation Design]
    D --> E
    E --> F[Foundation Dimensions & Reinforcement]
    F --> G[Construction Details]

For full design, refer to IS 2974 (Part 1)

IS 2974 Part 5: General Provisions of Design - Key Points

1. Soil Data Requirements (Clause 3.2)

• Soil profile & characteristics must be known up to 3 times the mean plan dimension of the foundation or up to hard strata.
• Soil investigation per IS 1892-1979 (soil investigation) and dynamic properties per IS 5249-1977.
• Water table position below ground at different times of the year must be recorded.

2. Design Criteria (Clause 4.3)

• Center of Gravity Alignment: Machine and foundation centers of gravity should ideally align vertically through the base centroid.
• Avoid Resonance: Natural frequency of foundation-soil system ( w_n ) should not be an integer multiple of the machine's operating frequency ( w_m ).

3. Resonance Avoidance Inequality

[ w_n \neq n \times w_m \quad \text{for} \quad n = 1, 2, 3, \ldots ]

Where:

• ( w_n ) = natural frequency of foundation-soil system
• ( w_m ) = operating frequency of the machine

Summary Table: Key Design Data

flowchart TD
    A[Start: Machine & Foundation Design] --> B[Soil Investigation per IS 1892]
    B --> C[Determine Soil Dynamic Properties per IS 5249]
    C --> D[Check Water Table Position]
    D --> E[Align Center of Gravity Vertically]
    E --> F{Check Natural Frequency \(w_n\)}
    F -->|\(w_n \neq n w_m\)| G[Design Foundation]
    F -->|\(w_n = n w_m\)| H[Modify Design to Avoid Resonance]

This ensures safe, stable foundation design avoiding resonance

IS 2974 Part 5: Permissible Stresses Summary

• Steel & Concrete:
  Use full permissible stresses as per IS 456:1978 if dynamic loads are detailed with appropriate dynamic and fatigue factors (Clause 4.2.1).

• Soil Stresses:

  • Under combined static and dynamic loads, soil stress ≤ 80% of allowable static soil stress per IS 6403:1981 (Clause 4.2.3).
  • For seismic design, soil allowable stresses may be increased per IS 1893:1984 (Clause 4.2.4).

Key References for Permissible Stresses

Formula for Soil Stress Limit under Dynamic Loads

[ \sigma_{soil, dynamic} \leq 0.8 \times \sigma_{soil, static} ]

Where:

• (\sigma_{soil, static}) = allowable soil stress from IS 6403
• (\sigma_{soil, dynamic}) = permissible soil stress under combined loads

flowchart TD
    A[Design Load] --> B{Load Type}
    B --> |Static| C[Use IS 6403 soil stress]
    B --> |Dynamic| D[Apply fatigue/dynamic factors]
    D --> E[Use full IS 456 stresses for steel/concrete]
    D --> F[Soil stress ≤ 0.8 × IS 6403 value]
    B --> |Seismic| G[Increase soil stress per IS 1893]

Summary: Use IS 456 for steel/concrete stresses with dynamic factors, limit soil stresses to 80% of static values under dynamic loads, and increase soil stress limits per IS 1893 during seismic design.

IS 2974 Part 5: General Provisions of Design – Key Points

1. Soil Data Requirements (Clause 3.2)

• Soil profile depth: At least 3 times the mean plan dimension of foundation or up to hard strata.
• Soil investigation: As per IS 1892-1979 for soil properties; IS 5249-1977 for dynamic soil properties.
• Water table position: Known at different times of the year.

2. Design Criteria (Clause 4.3)

• Alignment: Centre of gravity (machine & foundation) should align vertically through base centroid.

• Frequency Avoidance: To prevent resonance,

  [ \frac{w_n}{w_m} \neq \text{integer} ]

  where:

  • ( w_n ) = natural frequency of foundation-soil system
  • ( w_m ) = operating frequency of impact machine

3. Foundation Design Notes

• Jolter table foundations consider combined weight of machine + charge (Clause 4.7.1).
• Use IS 2974 Part 1 for definitions and further design criteria.

Summary Table: Frequency Relation

graph TD
    A[Machine Centre of Gravity] -->|Aligns Vertically| B[Foundation Centroid]
    C[Operating Frequency \(w_m\)] -->|Avoid Resonance| D[Natural Frequency \(w_n\)]
    D -->|Not Integer Multiple| C

Dynamic Analysis per IS 2974 (Part 5) - Key Formulas & Specifications

1. Dynamic Magnification Factor (Clause 4.5.2)

For stamping machines on hard rock without pressure-time data:

[ n = \frac{V}{Wh} ]

• ( V = 2 m f_m S ) (velocity at mid-stroke)
• ( W ) = weight of machine (excluding crosshead)
• ( h = \frac{E A}{h} ) (where ( A ) = cross-sectional area, ( h ) = height of anchor column)
• ( f_m ) = operating frequency (cycles/sec)
• ( S ) = stroke length

For large eccentric presses, consider dynamic loads as:

• Dynamic moment = 5 × normal torque
• Dynamic force = 5 × centrifugal force at flywheel center

2. Amplitude of Foundation Motion (Clause 4.4.1)

When impact duration is negligible but blows are periodic:

[ A = \frac{2 I}{k m} \sin \left(\pi \frac{T_1}{T}\right) ]

• ( A ) = amplitude of foundation motion
• ( I ) = impact momentum
• ( k ) = subgrade stiffness
• ( m ) = mass of machine + foundation
• ( T_1 ) = periodicity of blows
• ( T ) = natural period of foundation-soil system

Approximate when ( I ) unknown:

[ A = \frac{2 w v}{\omega_p} \sin \left(\pi \frac{T_1}{T}\right) ]

• ( w ) = falling weight
• ( v ) = terminal velocity
• ( \omega_p ) = natural frequency

3. Dynamic Force Calculation (Clause 4.4.2)

For non-negligible impact duration and single blow:

• Step 1: Find natural period ( T ) (see IS 2974 Part 1)
• Step 2: Obtain dynamic magnification factor ( y ) from ( t_1/T ) ratio (Fig. 1)
• Step 3: Calculate dynamic force:

[ F_a = y \cdot \alpha \cdot P

IS 2974 Part 5 — Forging and Stamping Presses: Key Points

Design Inputs (Clause 3.1a)

For forging, sheet metal, and stamping presses, obtain from manufacturer:

• Layout & outline drawings
• Anchor bolts & embedded parts details
• Pressure exerted by press (p)
• Stroke of press (S)
• Weight of crosshead (we)
• Gross weight (wp)
• Weight of material forged (wm)
• Load-time relationship (p vs t)
• Dynamic force & moment for eccentric presses (M)
• Height & cross-section of steel columns

Types of Presses (Clause 4.5.1)

• Hydraulic
• Eccentric
• Friction

Dynamic analysis of foundations follows Clause 4.4 (vibration and impact considerations).

Typical Foundation Design Considerations

Foundation Design Steps

1. Calculate static loads: sum of wp + we + wm.
2. Determine dynamic loads: use load-time curve p vs t.
3. Consider eccentric moments (M) for uneven loads.
4. Design anchor bolts & embedments per layout drawings.
5. Analyze vibration per Clause 4.4 for dynamic stability.

flowchart LR
  A[Manufacturer Data] --> B[Static Loads (wp, we, wm)]
  B --> C[Dynamic Loads (p vs t)]
  C --> D[Moment Calculation (M)]
  D --> E[Foundation Design]
  E --> F[Anchor Bolts & Embedments]
  E --> G[Vibration Analysis]

Reference:

• IS 2974 (Part

IS 2974 Part 5: Pig Breakers / Scrap Breakers Foundation Design

Key Data Required (Clause 3.1 b):

• Layout & outline drawing of installation
• Details of anchor bolts & embedded parts
• Weight of ram and height of fall
• Weight of pig scrap
• Constructional loads

Important Parameters for Design:

Fundamental Formula for Impact Force Estimation:

[ F = \frac{W_r \times g \times h}{\Delta t \times v} ]

Where:

• ( F ) = Impact force (N)
• ( W_r ) = Weight of ram (kg)
• ( g ) = Acceleration due to gravity (9.81 m/s²)
• ( h ) = Height of fall (m)
• ( \Delta t ) = Impact duration (s) (from manufacturer or test)
• ( v ) = Velocity of ram just before impact (m/s), ( v = \sqrt{2gh} )

Design Considerations:

• Use dynamic load factor based on impact pulse (load-time relationship)
• Anchor bolts and embedded parts per manufacturer’s details
• Foundation must resist dynamic forces and moments
• Check soil bearing capacity for foundation sizing

Summary Table for Design Inputs:

flowchart TD
    A[Manufacturer Data] --> B[Weight of Ram & Fall Height]
    A --> C[Anchor Bolt Details]
    A --> D[Layout Drawings]
    B --> E[Calculate Impact Force]

IS 2974 Part 5: Jolters Foundation Design Key Points

1. Design Basis (Clause 4.7.1)

• Jolter foundations are designed per Clause 4.4 (general machine foundation procedure).
• Moving weight (Wm) = Weight of jolter table + Charge on it.

2. Essential Data to Obtain from Manufacturer (Clause 3.1)

For jolters, obtain:

• Layout and outline of installation.
• Details of anchor bolts and embedded parts.
• Weight of jolting table with rated charge (Wt).
• Weight of anvil (Wa).
• Frequency of jolts (blows/min).
• Stroke or height of fall of table (S).
• Maximum pressure of steam/compressed air (p).

3. Design Considerations

• Dynamic forces depend on jolting frequency and stroke.
• Load-time relationship (pressure vs time) to be considered.
• Foundation block designed to resist dynamic loads from jolting action.

Typical Formula for Dynamic Load Estimation

[ F_d = W_t \times g + m \times a ]

• ( W_t ) = Total weight (table + charge)
• ( g ) = Acceleration due to gravity (9.81 m/s²)
• ( m ) = Mass of moving parts
• ( a ) = Acceleration due to jolting (can be estimated from stroke and frequency)

Summary Table of Jolter Parameters

This data feeds into dynamic load calculations and foundation sizing per IS 2974 Part 1 & 5.

flowchart TD
    A[Manufacturer Data] --> B[Calculate Moving Weight (Wt)]
    B -->

IS 2974 Part 5: Construction Details for Block Foundations

Key Points from Clause 5.8 (Construction Details)

• Foundation bolts must be properly anchored to ensure stability and transfer of loads.
• Block foundations supporting jolter tables consider the total moving weight = weight of jolter table + charge.
• Design procedure follows Clause 4.4 (not detailed here).

General Construction Specifications:

• Use plain or reinforced concrete as per IS 456 (Code of Practice for Plain and Reinforced Concrete).
• Soil investigation per IS 1892 and dynamic soil properties per IS 5249 are essential for foundation design.
• Foundation depth and size depend on soil profile and loading conditions.

Typical Construction Details (Summary Table)

Formula for Total Moving Weight (Jolter Table Foundation):

[ W_{total} = W_{jolter\ table} + W_{charge} ]

Where:

• (W_{total}) = Total moving weight for design
• (W_{jolter\ table}) = Weight of the jolter table
• (W_{charge}) = Weight of the charge on the table

Summary Diagram: Foundation Load Transfer

flowchart TB
    A[Load on Jolter Table] --> B[Total Moving Weight]
    B --> C[Foundation Block]
    C --> D[Soil Bearing]

Note: For detailed bolt anchorage, embedment lengths, and reinforcement details, refer to IS 456 and specific project structural drawings.