GIW Technical Series: Sub-Base Design
GIW Technical Series: Sub-Base Design
Sub-Base Design
GIW pumps with large horsepower motors are normally installed on a fabricated steel sub-base. The primary
function of this structure is to maintain the shaft alignment of the mechanical components and provide a
means to anchor the assembly to the concrete foundation. This is shown on the General Assembly (GA)
drawing. Sub-bases are typically fabricated from A36 structural steel shapes, or flame cut steel plate with
welded webs. Machined mounting pads are provided for the drive components, with longitudinal machined
rails used to align and anchor the pump pedestal. This structure supports the full weight and operating forces
of the assembly and provides the necessary anchor holes for the concrete foundation. The design, materials
and construction of the foundation are all the responsibility of the purchaser. Shims, jack bolts, jack pads and
anchor bolts are not generally supplied by GIW. The procurement, size, grade and foundation attachment
method of these items are all the responsibility of the customer and/or installation contractor.
There are a number of standards in various sectors of the pump industry that relate to sub-base design and
pump mounting. Many of these are applicable to clear water or smaller process pumps. GIW Sub-Base
design is governed by the GIW Engineering Design Guide EDG 02, which has been developed from the
latest edition of the American National Standard for Centrifugal Pumps for Horizontal Baseplate Design
(ANSI/HI 1.3 -2000, Tolerancing Section 1.3.5.4) as published by the Hydraulic Institute. These dimensions
and tolerances are more appropriate to heavy duty slurry pumps and severe duty applications than those
found in API 610 or similar standards.
GIW sub-bases are designed as “Grouted Baseplates” in accordance with Hydraulic Institute standards. The
structural steel sub-base assembly is designed to locate all the system components and must be mounted
properly on a concrete foundation to maintain correct alignment. Jack bolts in the lower flange are used to
level the sub-base, and steel shims are installed between the concrete and the sub-base. When grouting is
complete and the anchors are properly torqued, the resulting structure provides a solid foundation. The motor
and other drive components are installed and shimmed independently to align them with the pump shaft.
Adjustable mounting devices such as Vibracons are available as an option to replace shims at bolt locations.
Threaded features for push bolts may be provided to assist in the lateral and axial location of drive
components if specified in the GIW proposal. These may be loose, bolted or welded to the sub-base at the
discretion of GIW. Due to possible changes in tolerance or flatness resulting from welding, push bolt tabs
may be added before or after final machining or heat treat, depending on the design and fabrication
requirements.
Since the sub-base must be leveled and shimmed to the foundation, and the drive components shimmed to
the sub-base, manufacturing tolerances are not as critical for this design as they are on small API style base
plates. Pumps larger than 200 HP (159kW) are generally mounted on machined sub-bases, which are termed
“Class A Baseplates” in the HI design guide. The following table outlines the tolerances used by GIW for the
design, manufacture and inspection of these structures. Dimension ‘A’ shall be measured from the plane of
the bottom of the sub-base to the corners of the pads. Tolerances are based on a minimum 12”x12” area.
I-beams and other structural shapes normally have a certain amount of twist and residual stress created
during the manufacturing process. After the sub-base is welded, the mounting pads are machined relative to
each other. The flatness and dimensions of the non-machined areas are not considered a controlled feature.
Finished dimensions and tolerances are based on final inspection performed while the sub-base is sitting
unrestrained on the machining fixture. These dimensions should repeat when the structure is correctly
leveled, shimmed and anchored to the foundation. Sub-bases can not be accurately inspected while on a truck
or resting on the ground, since normal shipping and rigging could produce slight twisting or warping. It is
the responsibility of the installer to adjust the structure back to the correct level and parallel dimensions by
using shims and anchor bolts.
Tighter tolerances are available only as an option that must be specifically detailed in writing as “ANSI/HI
Special Tolerances”. This must be detailed on the Purchase Order, work order and the Engineering drawing.
The following ANSI/HI 1.3.4-1997 tolerances shall then apply:
Unless specifically detailed in written GIW specifications, sub-base weldments are not designed to be lifted
with the pump or any drive equipment installed. This can cause twisting or distortion of the structure. Sub-
bases are usually rigged using slings around open cross members. Lifting lugs can be added if defined in the
written specifications, included in the GIW work order and added to the sub-base drawing.
Variations for structural shapes and plates as received from the mill are established in ASTM A6/A6M-04b
Section 12. These historically developed standard tolerances define the acceptable limits of variation from
theoretical dimension for the cross-sectional area, flatness, straightness, camber, and sweep for rolled
sections. It should be noted that cross-sectional tolerances are expressed as a percentage of weight or area,
not as tolerances on dimensions such as the flange and web thicknesses. Non-machined areas of structural
shapes and rolled plates are not subject to standard title block tolerances unless specifically called out on the
drawing.
All GIW sub-bases are designed to be completely grouted after installation, unless an exception is
specifically detailed in the written GIW proposal. Filling the sub-base with grout provides additional rigidity
to the system to reduce vibration and noise levels. Epoxy grout is preferred rather than concrete for its
adhesion and low shrink properties. Access holes are provided in the top plates of the motor and reducer
risers as well as in the sides of the pump pedestal. Additional vent holes may be provided if requested on the
order. Weldments are not guaranteed to be leak proof, which may require the customer to tape or caulk joints
prior to grouting. Exceptions to any of these provisions must be specifically detailed in writing. Since the
construction of the sub-base forms a series of captive box sections, the addition of hooks or anchors to the
welded structure is not normally required but may be ordered as an option. This can be bolts or rivets welded
to the vertical web, or rebar welded diagonally across each box section. Small structural members or anchors
can be cast into the concrete foundation to provide additional bonding between the grout and foundation.
Machined areas are protected with a preservative and non-machined areas are normally painted prior to
shipment. Sandblasting or other surface treatment to enhance bonding of the grout shall be the responsibility
of the customer. This should be done on site, just prior to installation. All grouting work is the responsibility
of the customer and must be done in compliance with the grout manufacturer’s instructions, including all
safety related considerations.
Secondary heat treatment or stress relief of sub-base weldments before or after machining is not part of the
standard GIW construction. If required as an option, it must be specifically detailed in writing by the
customer and added to the Work Order. Engineering must be notified to add this to the drawing.
The illustration below shows the key points for correct sub-base installation. All materials, dimensions and
the construction of the foundation and anchor bolt system are the responsibility of the Purchaser. These must
comply with any relevant local or national Building or Construction Codes. Compliance with local or
national building and/or construction codes shall be the sole responsibility of the pump Purchaser and/or their
designated contractor. GIW shall not determine or guarantee compliance in any manner to any code.
Pump sub-base
Fill all areas with Grout structure
Anchor bolts