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Surfacing Design for Access Roads to the
Saskatchewan Metals Processing Plant
Prepared by
for
M2112-2840010
July 2010
Released December 22, 2010
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
R2112-2840010 Page i
TABLE OF CONTENTS
1.0 Introduction .............................................................................................................................................. 12.0 Background Information ......................................................................................................................... 1
2.1 Project Location .................................................................................................................................... 12.2 Existing Roadways ................................................................................................................................ 1
3.0 Traffic Analysis ........................................................................................................................................ 33.1 Introduction ........................................................................................................................................... 33.2 ESAL Calculation .................................................................................................................................. 3
3.2.1 Equivalency Factor ........................................................................................................................... 33.2.2 ESAL Calculations ............................................................................................................................ 43.2.3 Traffic Information for Highway No. 305 ........................................................................................... 43.2.4 Traffic Information for Shultz Road ................................................................................................... 5
4.0 Surfacing Design Considerations .......................................................................................................... 55.0 Surfacing Thickness and Geometric Upgrade ...................................................................................... 5
5.1 Saskatchewan Method .......................................................................................................................... 55.2 Highway No. 305 Rehabilitation and Upgrade....................................................................................... 65.3 Shultz Road Upgrade ............................................................................................................................ 75.4 Geometric Considerations ..................................................................................................................... 7
6.0 Cost Estimate ........................................................................................................................................... 77.0 Conclusions and Recommendations ..................................................................................................... 88.0 Closure .................................................................................................................................................... 10
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
R2112-2840010 Page i
TABLE OF CONTENTS
1.0 Introduction .............................................................................................................................................. 12.0 Background Information ......................................................................................................................... 1
2.1 Project Location .................................................................................................................................... 12.2 Existing Roadways ................................................................................................................................ 1
3.0 Traffic Analysis ........................................................................................................................................ 33.1 Introduction ........................................................................................................................................... 33.2 ESAL Calculation .................................................................................................................................. 3
3.2.1 Equivalency Factor ........................................................................................................................... 33.2.2 ESAL Calculations ............................................................................................................................ 43.2.3 Traffic Information for Highway No. 305 ........................................................................................... 43.2.4 Traffic Information for Shultz Road ................................................................................................... 5
4.0 Surfacing Design Considerations .......................................................................................................... 55.0 Surfacing Thickness and Geometric Upgrade ...................................................................................... 5
5.1 Saskatchewan Method .......................................................................................................................... 55.2 Highway No. 305 Rehabilitation and Upgrade....................................................................................... 65.3 Shultz Road Upgrade ............................................................................................................................ 75.4 Geometric Considerations ..................................................................................................................... 7
6.0 Cost Estimate ........................................................................................................................................... 77.0 Conclusions and Recommendations ..................................................................................................... 88.0 Closure .................................................................................................................................................... 10
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
R2112-2840010 Page ii
LIST OF TABLES
Table 1 Estimated equivalency factors. ................................................................................................................. 3Table 2 Traffic data and design traffic ESALs. ...................................................................................................... 4Table 3 Required surfacing thicknesses on Highway No. 305. ............................................................................. 6Table 4 Required surfacing structure on Shultz Road. .......................................................................................... 7
APPENDICES
Appendix A General Location and Site Plans
Appendix B Typical Surfacing Design Cross-Sections
Appendix C Traffic Analysis Calculations
Appendix D Thickness Determination Using the Saskatchewan Method
Appendix E Detailed Cost Estimates
Appendix F Traffic Information Provided by Fortune Minerals and SMHI
Appendix G Intersection Warrant Calculations
Appendix H Highway No. 305 Construction History
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Page 1
1.0 Introduction
Fortune Minerals Limited (Fortune Minerals) is proposing to construct a Metals Processing Plant in Saskatchewan. The site will be located near a secondary highway, which may require upgrading to accommodate the increased number of trucks and cars that will be accessing this facility. MDH Engineered Solutions Corp. (MDH) was commissioned to determine the surfacing structure required to accommodate the anticipated traffic loading for the access roads to the plant facility. MDH also completed a preliminary investigation to determine if turning lanes would be required to provide an adequate level of safety for vehicles turning on any provincial highways to access this facility.
MDH utilized the Saskatchewan Ministry of Highways and Infrastructure (SMHI) Surfacing Manual to develop the required surfacing designs, specifically the Saskatchewan Method. The SMHI Design Manual was used to determine if turning lanes were warranted to improve safety.
2.0 Background Information
2.1 Project Location
This project is located near Langham, Saskatchewan in the Rural Municipality (RM) of Corman Park. A project location map and a detailed site plan are provided in Appendix A.
2.2 Existing Roadways
Primary access to the plant facility will be on Highway No. 16 and Highway No. 305. Highway No. 16 is part of the Yellowhead Highway, which is a major interprovincial highway corridor. Highway No. 16 is designated as a primary weight highway, which allows trucks to haul primary weights. Highway No. 16 is designed to accommodate the anticipated truck volumes as long as the trucks meet the current regulations for vehicle weights and dimensions. Oversize and/or overweight trucks may still be used on Highway No. 16 as long as a permit is obtained from SMHI. The amount of additional truck traffic generated by this facility is very small compared to the total number of trucks already on Highway No. 16. As a result, there should be no requirement for Fortune Minerals to consider upgrading the structural capacity of Highway No. 16.
Highway No. 305 will provide access to the plant facility from Highway No. 16. Highway No. 305 is considered a regional or local road, which primarily services local traffic patterns. Highway No. 305 is designated as a secondary weight highway, which means that vehicles can only operate at secondary weights that are lower than primary weights. This reduces transportation efficiency, but protects the road infrastructure. It is important to
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Page 2
note that Section 12(1)(kk) of The Vehicle Weight and Dimension Regulations, 1999 of the Province of Saskatchewan states primary highway means the following highways, or a portion of the following highways, a maximum distance of 15 kilometres on any secondary provincial highway or any provincial road or a maximum cumulative distance of 15 kilometres on any number of secondary highways from the point of intersection of the first secondary provincial highway with a highway mentioned in clauses (a) to (ii), except Provincial Highway No. 364. While Highway No. 305 is designated as a secondary weight highway, Fortune Minerals will legally be able to haul primary weights to their facility because it is within 15 km of a primary weight highway.
Highway No. 305 has a minimal pavement structure that will likely not handle the increased truck traffic associated with the construction and operation of the Fortune Minerals facility. However, there is no legal obligation for Fortune Minerals to pay for improvements to Highway No. 305 as long as the vehicles are hauling legal loads. Since SMHI is responsible for the ongoing maintenance and upgrading of all provincial highways, they would have to maintain the road in a condition that allows safe travel at a basic level of service. At some point, the road will require further maintenance and SMHI would be forced to upgrade the road. However, these improvements would be prioritized with all other provincial highway upgrading priorities and could take several years to be completed. If Fortune Minerals wanted to accelerate these improvements, SMHI increases the priority of highway improvements when a third party is willing to cost share on the improvements, whether they are structural road capacity improvements (surfacing or resurfacing) or traffic safety improvements (turning lanes). SMHI negotiates the terms and conditions of these cost shared agreements on a case by case basis.
Range Road 3071, also known as Shultz Road, connects Highway No. 305 and the in-plant access road. Shultz Road is a main farm access road that is maintained and operated by the RM of Corman Park. The segment of Shultz Road to access the plant facility from Highway No. 305 is approximately 800 m long. This segment will likely need to be upgraded to handle the increased traffic. Primary weights are only allowed on the municipal road system by a permit obtained from the RM. Although Fortune Minerals can haul primary weights on Highway No. 305, primary weights cannot be hauled on Shultz Road unless a permit is obtained from the RM.
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Page 3
3.0 Traffic Analysis
3.1 Introduction
Traffic information for the surfacing design including types of trucks and the anticipated traffic volumes were provided by Fortune Minerals. This information is included in Appendix F. MDH used the information to determine the axle group configurations and to estimate Equivalency Factor (EF) for each type of truck. The Equivalent Single Axle Load (ESAL) in 15 years was calculated using the EF and the anticipated annual peak traffic volumes after the plant is built. SMHI provided existing traffic information on Highway No. 305, which is also included in Appendix F.
3.2 ESAL Calculation
3.2.1 Equivalency Factor
The SMHI Surfacing Manual assigns an equivalency factor (EF) to different truck configurations when they are loaded to maximum allowable primary weights on each axle. The SMHI Surfacing Manual was used to assign the EF to each type of vehicle and truck configuration having access to the site. Since the residue trucks will not be travelling on the off-site RM roads or highways they were not considered in the ESAL calculations. Fortune Minerals provided information that MDH used to determine the types of trucks that would be used. The EF for the various truck configurations are provided in Table 1.
Table 1 Estimated equivalency factors.
Truck Type Axle Combinations Tare Weight (tonne)Load
(tonne) GVWLoad Distribution
(tonne)Estimated
EF
Oxygen Truck 5 axles (steering - tandem - tandem)
19.5 22 41.5 5.5 - 18 -18 7.5
Soda Ash and Lime Trucks8 axles A train
(steering - tandem - tandem - single - tandem) 16.6 35.4 525.5 - 13.8 - 13.8 -
5.5 - 13.8 6.1
Caustic and Sulphuric Acid Trucks 8 axles B train (steering - tandem - tridem - tandem)
22.5 40 62.5 5.5 - 17 - 23 - 17 8.4
Covered Transport trucks 5 axles (steering - tandem - tandem)
19.5 22 41.5 5.5 - 18 - 18 7.5
Residue Trucks 3 axles (steering - tandem)
21 20 41 13 - 28 155.8
Metal Shipment Trucks 8 axles B train (steering - tandem - tridem - tandem)
22.5 40 62.5 5.5 - 17 - 23 - 17 8.4
Maintenance Crane * 8 axles B train (steering - tandem - tridem - tandem)
22.5 40 62.5 5.5 - 17 - 23 - 17 8.4
Armoured Car 2 axles (steering - single)
5.5 5.9 11.4 5.5 - 5.9 1.8
* Assuming transported to site using an 8-axle B train
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Page 4
3.2.2 ESAL Calculations
According to the SMHI Surfacing Manual, full traffic loading should be considered for the complete design of the roadways. To determine the thickness of the surfacing structure using the Saskatchewan Method, the ESALs must be calculated for the entire design life of the roadway.
The traffic parameters for the surfacing design and ESAL calculations for each separate part of the facility are summarized in Table 2 and the traffic analysis calculations are found in Appendix C. As requested by Fortune Minerals, the ESALs were calculated based on both nominal traffic and peak traffic volumes. At this time, Fortune Minerals is planning for all product shipments leaving the plant and reagent deliveries to the plant via CN Rail. The nominal traffic shows the remaining estimated traffic. The peak traffic shows the unlikely worst case scenario if no rail service was available. It is assumed that the residue trucks will be only operated in the plant facility.
Table 2 Traffic data and design traffic ESALs.
3.2.3 Traffic Information for Highway No. 305
Traffic information for Control Section 305-02 was provided by the SMHI Senior Traffic Engineer and is summarized in Appendix C. Current traffic on the highway segment of interest provides total ESALs of
Vehicle Type Estimated EFWeekly Traffic
Weeks Per Year
Annual ESALs
ESALs in 15 Years
Covered Transport trucks 7.5 3 52 1.17E+03 1.76E+04
Armoured Car 1.8 1 52 9.57E+01 1.44E+03
Total 1.27E+03 1.90E+04
Vehicle Type Estimated EFWeekly Traffic
Weeks Per Year
Annual ESALs
ESALs in 15 Years
Oxygen Truck 7.5 35 2 5.25E+02 7.88E+03
Soda Ash and Lime Trucks 6.1 11 52 3.50E+03 5.25E+04
Caustic and Sulphuric Acid Trucks 8.4 3 52 1.31E+03 1.96E+04
Covered Transport trucks 7.5 5 52 1.95E+03 2.93E+04
Metal Shipment Trucks 8.4 3 52 1.31E+03 1.96E+04
Maintenance Crane 8.4 1 2 1.67E+01 2.51E+02
Armoured Car 1.8 1 52 9.57E+01 1.44E+03
Total 8.70E+03 1.30E+05
ESAL Calculation - Peak Traffic
ESAL Calculation - Nominal Traffic
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Page 5
3.25 x 105. Adding the traffic generated by the plant facility, the total design ESALs will be 3.44 x 105 for nominal traffic and 4.55 x 105 for peak traffic.
3.2.4 Traffic Information for Shultz Road
No existing traffic information is available for the Shultz Road, so the calculated ESALs shown in Table 2 are used to determine the required surfacing structure.
4.0 Surfacing Design Considerations
Highway No. 305 should be rehabilitated to accommodate the anticipated truck traffic and loading. In addition to a structural upgrade, a left turn intersection treatment should be constructed to provide safe access to the plant site. Shultz Road should be upgraded to accommodate the anticipated truck traffic and loading. In the absence of any geotechnical information on the existing subgrade of Highway No. 305 and Shultz Road, the rehabilitation of Highway No. 305 and upgrade of Shultz Road were evaluated using a design subgrade CBR value of 2.5. This is the lowest CBR value used in the SMHI Surfacing Manual and should provide conservative results.
For the surfacing structure materials, it was assumed that suitable material for subbase course, base course, and asphalt concrete (AC) course would be available within a 50 km radius from facility.
5.0 Surfacing Thickness and Geometric Upgrade
5.1 Saskatchewan Method
In accordance with SM 1100 in the SMHI Surfacing Manual, the Saskatchewan Method, developed specifically for Saskatchewan conditions, was used for the surfacing thickness design. Based on the Saskatchewan method, three alternative thicknesses can be obtained for a given subgrade CBR value producing the following three scenarios:
Scenario 1 Full depth of asphalt concrete (AC); Scenario 2 Full depth of granular base and subbase; or Scenario 3 A combination of AC, granular base and subbase.
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Page 6
The Scenario 1 is only used in special circumstances where the subgrade is a granular material. Scenario 2 is applied to upgrading Shultz Road and Scenario 3 is applied to rehabilitating Highway No. 305.
5.2 Highway No. 305 Rehabilitation and Upgrade
The segment of Highway No. 305 between the Fortune Minerals access road and Highway No. 16 is approximately 3.5 km long. It is on the Control Section 305-02 between km 17.33 and km 20.64. MDH obtained the construction logs of Control Section 305-02 from SMHI. A summary of the construction history on the highway segment of interest is provided in Appendix H. It is determined from the construction logs that a total surfacing thickness of 132 mm (including 76 mm of AC) was placed from km 17.33 to km 20.09 and a total thickness of 450 mm (including 50 mm of AC) was placed from km 20.09 to km 20.64. To be conservative and facilitate the cost estimate, MDH used a surfacing granular structure of 130 mm for the rehabilitation design of the highway segment with a subgrade CBR value of 2.5.
Using the Saskatchewan Method, a surfacing structure including 520 mm of granular base and subbase and 90 mm of AC will be required for the existing ESALs of 3.25 x 105. Adding the nominal traffic generated by the plant facility will not change the required surfacing thicknesses. With additional peak traffic generated by the plant facility, the required surfacing structure will include 530 mm of granular base and subbase and 90 mm of AC. The required surfacing thicknesses over the existing 130 mm structure on Highway No. 305 are summarized in Table 3. Typical cross-sections are provided in Appendix B. The detailed thickness determination using the Saskatchewan Method is provided in Appendix D.
It is noted that the rehabilitation surfacing thicknesses shown in Table 3 are only for a preliminary cost estimate. A final surfacing rehabilitation design for Highway No. 305 would need to be completed based on information from a geotechnical investigation.
Table 3 Required surfacing thicknesses on Highway No. 305.
Subgrade Existing ESALs Total ESALs (Nominal Traffic)Total ESALs
(Peak Traffic)
CBR 2.5 3.3E+05 3.4E+05 4.6E+05
AC (mm) 90 90 90
Base Course (mm) 160 160 160
Subbase Course (mm) 230 230 240
Existing Structure (mm) 130 130 130
Total Structure (mm) 610 610 620
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Page 7
5.3 Shultz Road Upgrade
Using the Saskatchewan Method, a surfacing structure including 470 mm of granular base and subbase is required for the design ESALs of 1.90 x 104, which is the nominal traffic. A surfacing structure including 590 mm of granular base and subbase is required for the design ESALs of 1.3 x 105 (peak traffic). The required surfacing thicknesses for the 800 m of Shultz Road are summarized in Table 4. Typical cross-sections are provided in Appendix B. The detailed thickness determination using the Saskatchewan Method is provided in Appendix D.
It is noted that the rehabilitation surfacing thicknesses shown in Table 4 are only for a preliminary cost estimate. A final surfacing rehabilitation design for Shultz Road would need to be completed based on information from a geotechnical investigation.
Table 4 Required surfacing structure on Shultz Road.
5.4 Geometric Considerations
MDH also evaluated the requirement to provide turning lanes to safely accommodate the increased traffic on Highway No. 305. Based on the SMHI Design Manual and limited traffic information, MDH expects that a left turn lane is required for eastbound traffic on Highway No. 305 to access the plant. MDH recommends constructing a flared intersection at the intersection of Highway No. 305 and Shultz Road. The recommendation for the flared intersection treatment would be consistent with the Industrial Access Road Specification for Two-Lane Rural Highways from the SMHI Design Manual. The detailed warrant calculations are provided in Appendix G.
6.0 Cost Estimate
MDH developed cost estimates for Highway No. 305 rehabilitation and Shultz Road upgrade based on current bid price trends obtained from SMHI. Total cost is approximately $2,986,705. Assuming no third party contributions, the RM of Corman Park and SMHI would need to invest $1.1 M and $1.9 M respectively to complete the upgrades. The detailed cost estimates are provided in Appendix E.
Subgrade Total ESALs (Nominal Traffic)Total ESALs
(Peak Traffic)
CBR 2.5 1.9E+04 1.3E+05
Base Course (mm) 170 250
Subbase Course (mm) 300 340
Total Structure (mm) 470 590
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Page 8
7.0 Conclusions and Recommendations
Fortune Minerals is proposing to construct the Saskatchewan Metals Processing Plant near Langham, Saskatchewan. The primary access to the plant facility will be on Highway No. 16 and Highway No. 305. An 800 m existing gravel road (Shultz Road) will also be used to access the plant access road from Highway No. 305.
Highway No. 16 is a primary highway that does not produce any concerns regarding to the anticipated truck traffic for the plant. Highway No. 305 is a secondary highway within 15 km of the plant site. Fortune Minerals will legally be able to haul primary weights on Highway No. 305 as long as the distance is less than 15 km from Highway 16. Information of the existing surfacing structure on Highway No. 305 was obtained from SMHI construction logs. Additional surfacing structure is required to support the existing truck traffic. As estimated by MDH using the Saskatchewan Method, 90 mm of AC and approximately 400 mm of granular materials are required to accommodate the current traffic. The truck traffic produced by Fortune Minerals plant will result in virtually no change to the required surfacing thicknesses.
Based on the SMHI Design Manual and limited traffic information, MDH expects that a left turn lane is required for eastbound traffic on Highway No. 305 to access the plant. MDH recommends constructing a flared intersection at the intersection of Highway No. 305 and Shultz Road.
The segment of Shultz Road between the Highway No. 305 and plant access road should be upgraded. There is no existing traffic information available for the road. Based on the nominal and peak traffic volumes anticipated from the plant site, 470 mm and 590 mm granular structure will be required, respectively. Geometric upgrades will likely be expected to improve traffic safety. Both structural and geometric information of the existing Shultz Road is required to refine the surfacing design and the cost estimate. Fortune Minerals will only be able to haul primary weights on Shultz Road if a permit is issued by the RM.
MDH recommends entering into negotiations with SMHI and the local RM for the structural and traffic safety improvements to Highway No. 305 and Shultz Road. MDH understands that Fortune Minerals will also discuss issues regarding hauling construction loads to the plant site with SMHI and the local RM once a gravel pit, construction contractor, etc. have been identified. It is anticipated that preliminary construction will begin in late 2011, full construction is set to be completed in 2012 and production start-up is likely to occur in late 2012 or early 2013.
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Page 9
The surfacing design is a preliminary design based on information available at the time of writing the report. A final surfacing rehabilitation design for both Highway No. 305 and Shultz Road will be performed based on information from a geotechnical investigation.
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Page 10
8.0 Closure
MDH Engineered Solutions Corp., hereinafter collectively referred to as MDH, has exercised reasonable skill, care and diligence in preparing this report. MDH will not be liable under any circumstances for the direct or indirect damages incurred by any individual or entity due to the contents of this report, omissions and/or errors within, or use thereof, including damages resulting from loss of data, loss of profits, loss of use, interruption of business, indirect, special, incidental or consequential damages, even if advised of the possibility of such damage. This limitation of liability will apply regardless of the form of action, whether in contract or tort, including negligence.
MDH has prepared this report for the exclusive use of Fortune Minerals Limited and does not accept any responsibility for the use of this report for any purpose other than intended. Any alternative use, reliance on, or decisions made based on this document are the responsibility of the alternative user or third party. MDH accepts no responsibility to any third party for the whole or part of the contents and exercise no duty of care in relation to this report. MDH accepts no responsibility for damages suffered by any third party as a result of decisions made or actions based on this report.
Should you have any questions or comments please contact the undersigned.
Regards,
MDH Engineered Solutions Corp. Association of Professional Engineers And Geoscientists of Saskatchewan Certificate of Authorization Number 662
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Appendix A
Appendix A
General Location and Site Plans
1:150,000PRODUCED BY
CLIENT TITLE
PROJECT No. FIG. No.DRAWING No.APPROVED BY
DRAWN BYSUPERVISED BYSCALE DATE
Path: \\ssasfs02\projects\Fortune Minerals Ltd\M2112-2840010 - Geotechnical, Hydrogeological and Environmental Assessments For Saskatchewan metals Processing Plant\3. GIS\2. Drawings\M2112-21-14 TASK 2 (Site Location).mxd
M2112-2840010S. LONG, GIS Cert.
LOCATION OF THE PROJECT AREAM2112-21-14
NO RTH SAS
KATCHE
WAN RIV
ERTP39-RG07-W3 TP39-RG06-W3
TP37-RG06-W3TP37-RG07-W3
TP38-RG06-W3TP38-RG07-W3
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LANGHAM
DALMENY
SASKATOONDUNFERMLINE
305
14
16
12
11
7 5
370,000
370,000
380,000
380,000
5,780,00
0
5,780,00
0
5,790,00
0
5,790,00
0
5,800,00
0
5,800,00
0
A1
LegendSITE LOCATIONMAJOR HIGHWAYRAILWAY
Note1. LOT PARCEL BOUNDARIES OBTAINED FROM INFORMATION SERVICES CORPORATION OF SASKATCHEWAN (ISC) AND ARE APPROXIMATE.2. LOT PARCELS ARE LABELED BY ISC SURFACE PARCEL NUMBER.
04-OCT-10
M. STURBY, P.Eng. 04-OCT-10
!
!
!
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!
!
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LLODYMINSTER
REGINAYORKTON
WEYBURN
MELFORT
ESTEVAN
HUMBOLDTSASKATOON
MOOSE JAWSWIFT CURRENT
PRINCE ALBERTNORTH BATTLEFORD
SASKATCHEWAN MANITOBAALBERTA
MONTANA NORTH DAKOTA
DETAIL
PROVINCE SCALE: 1:6,000,000
F. ANTUNES, P.Eng. 04-OCT-10
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Appendix B
Appendix B
Typical Surfacing Design Cross-Sections
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Appendix C
Appendix C
Traffic Analysis Calculations
Vehicle Type Estimated EFWeekly Traffic
Weeks Per Year
Annual ESALs
ESALs in 15 Years
Oxygen Truck 7.5 35 2 5.25E+02 7.88E+03
Soda Ash and Lime Trucks 6.1 11 52 3.50E+03 5.25E+04
Caustic and Sulphuric Acid Trucks 8.4 3 52 1.31E+03 1.96E+04
Covered Transport trucks 7.5 5 52 1.95E+03 2.93E+04
Metal Shipment Trucks 8.4 3 52 1.31E+03 1.96E+04
Maintenance Crane 8.4 1 2 1.67E+01 2.51E+02
Personal cars and light trucks 125 52 1.26E+03 1.89E+04
Armoured Car 1.8 1 52 9.57E+01 1.44E+03
Total 9.96E+03 1.49E+05
Vehicle Type Estimated EFWeekly Traffic
Weeks Per Year
Annual ESALs
ESALs in 15 Years
Residue Trucks 155.8 225 52 1.82E+06 2.73E+07
Calculation Example for Metal Shipment Trucks:
Fortune Minerals - ESALs Calculation
Residue Trucking Route
Plant Access Road and Internal Gravel Roads
Calculation Example for Metal Shipment Trucks: Annual ESALs = 8.4 x 3 x 52 = 1,310
15 Year ESALs = 1310 x 15 = 19,650
Traffic Information
2009 TAADT (tpd) 20
Growth Factor 1.35
EF (ESALs per truck) 1.90
Dirctional Split 50/50
Design Life (year) 15
Year of Construction 2011
ESAL Calculation
2024 TAADT (tpd) 27
Yearly Increase (tpd) 0.47
2011 TAADT (tpd) 21
2026 TAADT (tpd) 28
Average TAADT (tpd) 24.5
15 Year Background ESALs per lane 1.30E+05
15 Year Incremental ESALs per lane
km 17.33 - km 20.64 1.95E+05
15 Year Fortune Mineral ESALs per lane 1.49E+05
15 Year Design ESALs per lane
km 17.33 - km 20.64 4.74E+05
Highway Control Section 305-02 ESALs Calculation
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Appendix D
Appendix D
Thickness Determination Using the Saskatchewan Method
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Appendix E
Appendix E
Detailed Cost Estimates
Contract No.: Project Number Estimated CostType of Work:Region:Prepared By:Date:
Total Total kmProject Description:
Remarks:
Item No. Spec. No. Description Unit Quantity Price Cost Price Cost Item Cost
Quantities and Cost Estimate Sheet
Highway 305 RehabM2112 To km Length
Fortune Minerals Ltd.
Control Section From kmProject Information
Highway No. 305 Rehabilitation, Shultz Road Upgrade, and Additional Turning Lane.
Contract Items SundriesPre-Tender At Award
Matt WeisbrodJune 3, 2010
p p y3000.19 3000 m2 49 200 $3.50 $172,200.00 Courtesy Signs3300.03 3300 t 25 500 $6.00 $153,000.00 SaskTel Relocates3505.05 3505 GRANULAR BASE COURSE IN PLACE t 19 600 $10.00 $196,000.00 SaskPower Relocates
SaskEnergy Relocates4000.03 4000 t 80 $100.00 $8,000.00 TransGas Relocates
Delineation (TRPMs/Marking Tape)4100.03 4100 t 8 460 $26.00 $219,960.00 Capital Road Loss
RR X-ing8400.01 8400 lump sum 1 $50,000.00 $50,000.00 Bridges8700.02 8700 lump sum 1 $100,000.00 $100,000.00
4300.19 4300 t 600 $8.00 $4,800.002200.41 2200 m3 12 800 $10.00 $128,000.00 Sundries Total
Item Quantity Price CostLime (t) 84.6 $235.00 $19,881.00
MC-30 (t)SS 1 (t) 80 $700 00 $56 000 00
Materials
SUBGRADE PREPARATION AND COMPACTION, 100 mm BELOW GRADE
ASPHALT CONCRETE IN PLACE
TRAFFIC ACCOMMODATIONMOBILIZATION & DEMOBILIZATION
SUB-BASE COURSE IN PLACE
TACK COAT
TRAFFIC GRAVEL IN PLACE ON THE ROADEARTH EXCAVATION INCLUDING HAULING, 100% MAXIMUM DENSITY REQ'D FOR
SS-1 (t) 80 $700.00 $56,000.00
150/200A (t) 423 $760.00 $321,480.00
Base Course (t) 19600 $15.00 $294,000.00Subbase Course (t) 25500 $14.00 $357,000.00AC Course (t) 8460 $30.00 $253,800.00Traffic Gravel (t) 600 $8.00 $4,800.00
Grass Seed (Bg)
Contract Items Sub Total $1 031 960 00Contract Items Sub-Total $1,031,960.00Price Quantity Cost Quantity Cost
$1,306,961.00
Contract Items Total (For comparing bids for award) $1,031,960.00 $1,306,961.00
Pre-Tender At Award Cost CostPrev. Years 2008 2009 Total $1,131,960 $100,000.00
1. Internal Budget Target $50,0002. Pre-Tender Estimate $2,986,705 $1,306,961 $50,000.003. At Award Budget
$373,338$124,446
ItemOther Contract Items (OCI)
Materials Total
Material Sub-TotalFreight/Miscellaneous
Contract Items (Sub-Total(not inc. Site Occ.) + OCI)Force AccountMaterials
Des. Engineering
Region Forces
Difference ($) % Difference
Pre-tender Total Added Project Cost $1,954,745
Force AccountItem
Pit RehabFailure Repairs
Testing Services
Summary of Estimates Expenditure Category
ROW PropertyROW SurveysGeneral Services
Con. Engineering
Turning Lane General
Sundries
Budget ItemsYearBudget Type
Contract Items At Award vs. Pre-Tender $2,986,705 $100,000.00 $50,000.00($) % Difference
Force Account TotalOther Contract Items TotalTotal Cost
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Appendix F
Appendix F
Traffic Information Provided by Fortune Minerals and SMHI
FortuneMineralsAnticipatedTruck,VehicleandEquipmentAccessPostConstruction
Informationa) OxygenTruck22metrictonneload.Totalweightisunknown,22t
+truck.Informationontruckisunknown.MDHmayhaveinformationfromotherprojectsontypicalsizesofoxygendeliverytransporttrucks.
b) SodaAshTrucks&LimeTrucks35metrictonneload.Estimatedtotalweight=52t.
8axelRtactruck(Atrain),Max81feetlongtruckandtrailerbyCdnLaw,Gross:51,610kgs,Tare:16,556kgsweightoftruckandtrailerNet:35,054kgsSodaAshshipped(approx22MTonLeadtrailerand14MTonLagtrailer)
c) CausticandSulphuricAcidTrucks40metrictonneload.Estimatedtotalweight=62t
Thelargest,withapayloadof40,000KGhasagrossvehicleweightmaximumof62,500KGandhas8axles.
d) Regulardeliveriescoveredtransporttrucks. Regular18wheelerdeliverytruckstosite(palletsofsupplies,pipes,pumps,filtercloths,baggedreagents,etc)
e) ResidueTruckingtoResidueStorageFacility20metrictonneload.Totalweight=20t+truck.
SeeexampletruckfromPDFfile
f) MetalShipmentsout40metrictonneload. FlatdeckBTrains,40tofproduct.Weightoftruckunknown.8axeltruckwithleadandlagtrailers.
g) 80tonmaintenancecrane SeeexamplePDFfile.Veryinfrenquentuse,comingtositeonceortwiceperyear.
h) 85employeesaccessingsite.PersonalvehiclesviaHWY16andHWY305.
i) Armouredcar(ie.Brinks,GS4,etc) Nodata.Armouredcarcomestositeafewtimespermonth.
FortuneMineralsTypicalWeeklyCyclesPostConstruction
Weekly Peak CommentsaboutPeak Additionala) OxygenTruck 0 35 Fortunehasanoxygenplant,iftheoxygenplantgoesdownfor
maintenance,wemaychoosetotruckinoxygenforshortperiodsoftime(oneweekorless).
Typically,notrucks.
b) SodaAshTrucks&LimeTrucks 0 11 Sodaashandlimedeliveriestypicallybyrail.Ifrailcarswerenotavailable,wewouldusetrucks.
Typically,notrucks.
c) CausticandSulphuricAcidTrucks 0 3 CausticandSulphuricacidwillcomebyrailandtruckdeliveries.
d) Regulardeliveriescoveredtransporttrucks.
3 5 Regularwarehousedeliveries(MonWedFri)
e) ResidueTruckingtoResidueStorageFacility
175 225 25tripsdailyfromtheplanttotheresiduepile,maybehit30trucksperdayifwearemakingalotofresiduethatweek.
f) MetalProductShipmentsout 0 3 Typicallybyrail.Iftherearenorailboxcarsavailable,wewouldshipbytruck.
Typically,notrucks.
g) 80tonmaintenancecrane 0 Veryinfrequent.Largemaintenanceshutdowns.
h) 85employeesaccessingsite. 85 125 85regularemployees.Addanother4050peopleformaintenanceshutdowns.
i) Armouredcar(ie.Brinks,GS4,etc) 1 1 Regularhighvalueproductshipping.
1Frank Liu
From: Sarah HudsonSent: May-21-10 2:03 PMTo: Frank LiuSubject: FW: Traffic info for highway 305-02Attachments: Sarah Hudson MDH CS 305-02.xlsx
From: Anderson, Tom HI [mailto:[email protected]] Sent: Friday, May 21, 2010 1:39 PM To: Sarah Hudson Cc: Jaworski, Derek HI Subject: RE: Traffic info for highway 305-02 SarahThesurfacingdesigntrafficinformationyourequireforCS30502follows:CS30502km0to9.14TAADT0970tpdEAL1.9DirectionalSplit50/50Growthfactor1.35CS30502km9.14to20.64TAADT0920tpdEAL1.9DirectionalSplit50/50Growthfactor1.35TheincrementalgrainhaulloadingisestimatedatprimaryweightsbytheSaskatchewanGrainFlowModelasfollows:DirectionABCS30502km0to6.941,000ESALs/yr13,000ESALs/yrkm6.94to9.141,000ESALs/yr15,000ESALs/yrkm9.14to17.332,000ESALs/yr13,000ESALs/yrkm17.33to20.643,000ESALs/yr13,000ESALs/yrIhaveattachedaworkbookcontainingdetailedtrafficinformationanddataforyouruse.Shouldyourequiremoreinformationorassistancewiththeinformationprovidedpleasecall.//TomAndersonSr.TrafficEngineer3067878334
2From: Sarah Hudson [mailto:[email protected]] Sent: May 21, 2010 10:49 AM To: Anderson, Tom HI Subject: Traffic info for highway 305-02 HiTom,Howareyou?MynameisSarahHudson,IamasummercoopstudentworkingforMDHEngineeredSolutionsinRegina.IamcurrentlydoingsomeworkforalargedevelopmentprojectnearLangham,Saskatchewanandamlookingforsomebackgroundinformationonhighway305toaidusinanewsurfacedesign.Specifically,Iamlookingfortherecordedtrafficandtruckinformationforhighway30502.Wouldyoubeabletoprovidethisformeordoyouanybodywhocould?Iappreciateanyhelpyoucangive.Thanksforyourtime,Sarah
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Appendix G
Appendix G
Intersection Warrant Calculations
FortuneMineralsWarrantCalculationsforCS30502andCS1623:
Situation1:FlaredintersectionforaleftturnontoplantaccessroadfromCS30502
AADT=300+125(passengervehicles)+57(fortunemineralstrucks)=482 LeftturnAADT=125+57=182 Basedonthesetwovalues,aflaredintersectionforaleftturnoff30502iswarranted Thisisbasedontheindustrialaccessroadspecificationfor2laneruralhighways.
Situation2:RightturnoffofCS1623ontoCS30502
VR=VL=10.2
VA=Vo=360
R=VR/VA=10.2/360=0.028
Rightturninglanenotwarrantedbasedonthechartforruralhighways.
Situation3:AccelerationlaneonHighway1623forleftturnoff30502
Accelerationlanesarenottypicallyinstalledforthisvolumeoftraffic
Situation4:LeftturnlanefromCS1623(divided,4laneruralhighway)
Aleftturnlanealreadyexists(refertoattachedphotographs).
Situation5:AccelerationlaneonHighway1623forrightturnoff30502
Accelerationlanesarenottypicallyinstalledforthisvolumeoftraffic
Note:AllcalculationsarebasedonSaskatchewanMinistryofHighwaysDesignManualPart1.
Photograph1LookingwestalongHighwayNo.16(westboundlane)attheJunctionofHighwayNo.305
Photograph2LookingwestalongHighwayNo.16(eastboundlane)attheJunctionofHighwayNo.305
Surfacing Design for Access Roads to the Saskatchewan Metals Processing Plant July 2010
M2112-2840010 Appendix H
Appendix H
Highway No. 305 Construction History
km from km to Year of constructionSurfacing thickness
added (mm) Total (mm)
7.07 20.09 1931 10 (GRV) 10
10 (GRV)
76 (HBC)
0.00 20.09 1972 13 (GAS) 13
0.00 20.09 1976 10 (GAS) 10
6.94 20.09 1985 13 (GAS) 13
150 (GSB)
200 (GB)
50 (HBC)
132
400
Legend:GSB = Granular SubbaseGAS = Graded Agg. SealGRV = GravelHBC = Hot Bituminous ConcreteGB = Soil Stabilized Base
Totalexistingsurfacingthicknessfromkm17.33tokm20.09
Totalexistingsurfacingthicknessfromkm20.09tokm20.64
Highway Control Section 305-02 Construction History
86
400
7.07 20.09
20.09 20.64
1947
1991
p6-7.pdfAccess Roads Report V3_Final_w Appendices.pdfC1 - traffic analysis.pdfM2112 Appendix D1.pdfM2112 Appendix D2.pdf
F1 - traffic info.pdfM2112 Appendix G1.pdfM2112 Appendix G2.pdf