Deep Hole Drilling Machine Installation Guide

A deep hole drilling machine weighing 30 tons and spanning 16 meters must maintain spindle-to-guideway parallelism within 0.01 mm over its full travel. This precision is not built into the machine alone — it depends on the foundation it sits on, the way it is leveled, and the care with which it is commissioned.

Deep hole drilling machines are among the largest and most precise production machine tools. A typical BTA drilling machine weighs 15–40 tons, has a bed length of 6–20 meters, and must produce bores with straightness measured in hundredths of a millimeter per meter. The installation process — from foundation design through final acceptance — directly determines whether the machine can achieve this precision.

This article provides a practical guide to installing deep hole drilling machines, covering foundation requirements, leveling procedures, alignment verification, and commissioning.

Foundation Design ​

Machine Classification by Foundation Need ​

Deep hole drilling machines typically fall into Group II or III based on their size and rigidity requirements:

Foundation Specifications ​

Critical rule: The foundation must be isolated from the surrounding floor slab. A saw-cut separation joint filled with elastic compound prevents building vibrations from transmitting to the machine and prevents machine vibrations from disturbing adjacent equipment.

Foundation Design Process ​

1. Geotechnical survey — Assess soil bearing capacity and groundwater level
2. Foundation design by structural engineer — Size and reinforce based on machine weight, dynamic loads, and soil conditions
3. Excavation and formwork — Excavate to design depth, install forms with anchor bolt templates
4. Reinforcement and embedment — Place rebar, anchor bolts, conduit for cables and coolant lines
5. Concrete pour — Continuous pour with vibration to eliminate voids
6. Curing — Maintain moisture for minimum 14 days (Group II) or 28 days (Group III)
7. Surface preparation — Grind high spots, apply epoxy grout bedding

Anchor Bolt Installation ​

Anchor bolts transfer machine loads to the foundation and maintain alignment. Two methods are used:

Method 1 — Cast-in-place bolts:

• Bolts positioned using a template plate matching the machine foot pattern
• Template must be rigid enough to hold bolt positions within ±1 mm during concrete pour
• Bolts extend 50–80 mm above finished foundation surface

Method 2 — Epoxy-anchored bolts (retrofit):

• Holes drilled into cured concrete
• Epoxy cartridge injected, bolt inserted
• Suitable for existing foundations but lower pull-out strength

Anchor bolt torque sequence: When tightening anchor bolts during installation, use a cross-sequence pattern and achieve final torque in three increments (30% → 60% → 100% of final torque).

Machine Placement and Leveling ​

Preparation ​

Before the machine arrives:

1. Verify foundation dimensions and anchor bolt positions against the machine base drawing
2. Clean foundation surface — no oil, dust, or loose material
3. Place leveling wedges or leveling screws at each mounting point
4. Check that all anchor bolts are clean and threads are undamaged

Leveling Methods ​

Recommended wedges for deep hole drilling machines: Two-piece or three-piece leveling wedges placed at each machine foot. Wedges provide rigid support and allow re-leveling as the foundation settles over time.

Leveling Procedure ​

Step 1 — Rough leveling:

1. Lower the machine onto the leveling wedges using a crane or hydraulic jacks
2. Align the machine to the anchor bolts
3. Tighten anchor bolts to 30% of final torque
4. Rough-level using a precision spirit level (0.02 mm/m) on the machine bed
5. Adjust wedges at each foot to bring the bed to within 0.05 mm/m of level

Step 2 — Precision leveling:

1. Place the precision level at each critical location along the bed:
   • At each guideway section
   • At the spindle mounting area
   • At the tailstock area
2. Record readings at each position
3. Adjust wedges incrementally to achieve:
   • Longitudinal level: ≤ 0.02 mm/m over full bed length
   • Lateral level: ≤ 0.02 mm/m across bed width
   • Twist (difference between left and right guideways): ≤ 0.02 mm/m

Step 3 — Tighten and recheck:

1. Tighten anchor bolts to 60% torque in cross-sequence
2. Recheck bed level — adjust wedges if tightened bolts changed alignment
3. Tighten to 100% torque
4. Final level check — record all readings for baseline documentation

Important: Leveling wedges should be adjusted only when the machine is supported at the correct height. Never force wedges beyond their adjustment range. If a wedge bottoms out, replace it with a thicker wedge before continuing.

Grouting ​

After leveling is complete and verified, the machine must be grouted to the foundation:

Grouting procedure:

1. Build a dam around the foundation perimeter using foam or wood forms
2. Seal all gaps to prevent grout leakage
3. Wet the foundation surface (for cementitious grout)
4. Mix grout per manufacturer specifications
5. Pour continuously from one side of the machine
6. Use a thin rod to work grout into all voids under the base
7. Allow to cure per manufacturer specification (typically 24–72 hours before full loading)

Alignment Verification ​

After grout has cured and anchor bolts have been retorqued, perform alignment verification.

Spindle-to-Guideway Parallelism ​

Guideway Straightness ​

Tailstock Alignment ​

Coolant System Alignment ​

The coolant induction system must be aligned to the spindle axis:

Coolant System Commissioning ​

The coolant system is the most critical subsystem for deep hole drilling and requires dedicated commissioning steps:

Coolant System Checklist ​

Coolant Preparation ​

1. Fill system with clean water and circulate to flush debris from piping
2. Drain and refill with coolant mixture
3. For oil-based systems: fill with specified oil grade, circulate for 30 minutes, check filter elements
4. For emulsion systems: mix to specified concentration, verify with refractometer
5. Add biocides if required for long-term emulsion stability

Electrical and Control Commissioning ​

Axis Calibration ​

Test Drilling and Acceptance ​

Dry Run ​

Before cutting metal, run the machine through a complete dry cycle:

1. Jog all axes through full travel — smooth, no binding
2. Cycle spindle through speed range — no unusual noise or vibration
3. Cycle coolant system — pressure stable, no leaks
4. Run chip conveyor — smooth operation

Test Part Drilling ​

Drill a test part to verify machine capability:

Test part acceptance criteria:

Acceptance Documentation ​

Complete the following documentation for the machine record:

• Foundation drawing and as-built verification
• Leveling report (all positions before and after grouting)
• Alignment verification (spindle-to-guideway, tailstock, guideway straightness)
• Coolant system test results (pressure, flow, filtration)
• Electrical and control system verification
• Test part inspection report
• Machine serial number and installation date
• Warranty registration

Periodic Re-Leveling ​

Deep hole drilling machines require periodic re-leveling because foundations settle, particularly in the first year:

Signs that re-leveling is needed: Increasing bore straightness variation, inconsistent surface finish, growing tool wear, or visible coolant leaks at machine joints.

Summary Table ​

FAQ ​

How long does concrete foundation curing take before installing a deep hole drilling machine? ​

For Group II machines (typical BTA/gun drilling machines up to 25 tons), minimum 14 days of curing before machine placement is standard, with 28 days recommended for full cure before final grouting. For Group III machines (25+ tons), 28 days minimum is required. The concrete must reach at least 70% of its design compressive strength before machine loading. Rushing the curing process risks foundation cracking and alignment loss.

What leveling method is best for deep hole drilling machines? ​

Two-piece or three-piece leveling wedges are the recommended method for most deep hole drilling machines. They provide rigid support, allow precise adjustment (0.005–0.01 mm), and — unlike shims — can be re-adjusted after grouting. Leveling screws are acceptable for smaller machines but can creep under heavy dynamic loads. Steel shims are not recommended for permanent installation because they cannot be adjusted if the foundation settles.

How often should a deep hole drilling machine be re-leveled? ​

Monthly for the first three months after installation, quarterly for the remainder of the first year, and annually thereafter. The first year requires more frequent checks because the foundation undergoes initial settlement under the machine's weight. After the first year, annual re-leveling is sufficient for normal operation. Additional re-leveling is needed if there is any nearby excavation, construction, or if bore quality metrics show a declining trend.