Big Digs - Site Development & Underground Solutions for Mining

1© 2013 Armtec Infrastructure Inc. • Confidential & Proprietary

Webinar - Nov 14, 2014

BIG DIGS

Nov 14, 2014

SITE DEVELOPMENT AND UNDERGROUND SOLUTIONS FOR MINING

Doug Leitch, P. EngManager International SalesArmtec Drainage Solutions

Glenn Smith, CET Sales Supervisor, AtlanticArmtec Drainage Solutions


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SITE DEVLOPEMENT AND UNDERGROUND SOLUTIONS FOR MINING

Review and use of SPCSP in Mining Applications

Design , Corrosion , Earthquake Considerations

Q & A

Armtec Introduction

Portals, Haul Roads, Tunnels, Raise Bores

Onsite Assembly, Corrosion - Life Expectancy


JOIN THE DISCUSSION

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CPD CREDIT CERTIFICATES

• Qualifies in Most Jurisdictions in Canada & USA for 1 Hour Technical Informal

• Formal completion certificates are emailed within one week of attending• Check your local guidelines if unsure of your requirements

Email Your Attendance List:

• Full Name• Title• Email

[email protected]

Will send certificate

mailto:[email protected]


• 43 locations in Canada• Approximately 2,000 employees• Exceptional product range for:

Armtec is a leading global infrastructure and construction materials company.

– Mine Portals– Reclaim Tunnels– Stockpile Tunnels– Heavy Haul Road Bridges


Bridge Materials Drainage Solutions and Water Treatment

Landscaping Products

and Amenities

Noise Control

Road and Highway Safety Soil Retention

Undergroundand Utilities

Precast ConcreteBuildings and

Venues

Precast ConcreteGarages and

Parkades


YOUR SPEAKERS

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Sales Supervisor, AtlanticArmtec Drainage [email protected]

Doug Leitch, P. Eng Manager International SalesArmtec Drainage [email protected]

Glenn Smith, CET


Webinar - Nov 14, 2014

BIG DIGS

Nov 14, 2014

SITE DEVELOPMENT AND UNDERGROUND SOLUTIONS FOR MINING

Doug Leitch, P. EngManager International SalesArmtec Drainage Solutions

Glenn Smith, CET Sales Supervisor, AtlanticArmtec Drainage Solutions


WORK SAFE !!


Jacioeta Stream CrossingMOA Nickel• JV Cuba• Sherritt InternationalCuba, West Indies

Conveyor Wildlife CrossingCortez MineBarrick GoldNevada, USA

Portal Tunnel EntranceTafts QuarryTafts Well LimestoneWales, UK

RECENT BIG DIGS


Mine PortalBuyanhula Gold MineBarrick GoldTanzania, West Africa

Mine PortalKumtor Centerra GoldKyrgystan, Asia

Haul Road Minera Cerre VerdeFreeport , McMoron Peru, South America


STRUCTURAL PLATE CORRUGATED STEEL PIPE


Multi-Plate(SPCSP)(152 mm x 51 mm)

Bridge-Plate (DCSP)(400 mm x 150 mm)

CORRUGATED STRUCTURAL PLATE

Two Corrugation Profiles

Corrugate and Punch Plates


Given the versatility of structural plate products, a wide variety of shapes and sizes can be manufactured to meet your needs.




Ship to the Site


1.2m


Bolts the Plates together Per Assembly Drawings


And this ….. Becomes this



EVOLUTION OF STRUCTURAL PLATE



1896 - CORRUGATED STEEL PIPE PATENTED CONSTRAINTS

Large dia. pipe fabricationAvailable gaugesTransportabilityDemand for larger diameter

SEGMENTAL PLATE CONSTRUCTIONHeavy gauge corrugated plateBolted connectionsAssembled on site


Multi-Plate (SPCSP)(152 mm x 51 mm)

Bridge-Plate (DCSP) (400 mm x 150 mm)

Late 1990’s Armtec introduced a Deep Corrugated Structural Plate and at the timeBridge Plate becamethe strongest suchProduct available




Click icon to add picture


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Bridge Plate 400 mmx 150 mm corrugation

• is 3 times stronger • 10 times stiffer.

It extended structure spans over 20 meters and brought expanded use of SPCSP in demanding mining applications.


FLEXIBLE STEEL PIPE DESIGN


The Handbook of Steel Drainage and Highway Construction

Published By

Corrugated Steel Pipe Institute652 Bishop Street NorthCambridge Ontario , CanadaN3H 4V6

Ray Wilcock+1 519-650-8080www.cspi.ca

CANADIAN HANDBOOK of STEEL DRAINAGE AND HIGHWAY CONSTRUCTION

http://www.cspi.ca/


SUPPORTFROMBACKFILL

SUPPORT FROM BACKFILL

Live load applied

Dead load applied Structure deflectstowards fill

RING COMPRESSION THEORY


Net Result:An economical buried structure capable of supporting significant loads

FLEXIBLE SOIL – STEEL STRUCTURES

Steel Component: Corrugated thin wall flexible pipeCorrugated shell is highly efficient member to support axial compressive loads

Soil Component:Engineered granular Backfill envelope withmaterials of known properties


FLEXIBLE VS RIDGID STRUCTURE

Flexible Structures deflect outward toward the soil mobilizing passive support from surrounding fill, distributing the load into the surrounding fill.

The load is distributed into the soil

Rigid structures are designed for limited deflection, reducingthe support provided from thesurrounding fill.

The structure carries more load


FLEXIBLE –RIDGID LOAD RESPONSE

12.0 m span x 4.0 m rise archBending Moments and Thrust

Flexible Soil Steel

Ridgid Concrete Arch


DESIGN CODES

• Handbook of Steel Drainage and Highway Construction Products

• basis is AISI (American Iron and Steel Institute) AISI design – historical procedure based on semi-empirical equations

• AISI generally gives less conservative design

• CHBDC – ( Canadian Highway Bridge Design Code) and AASHTO LRFD methods provide more modern approach to thrust and buckling resistance and are based on Ultimate Strength Principles.

• CHBDC and AASHTObetter address Deep Cor structures and constructability


FLEXIBLE STEEL PIPE DESIGN

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Mining presents unique situations which often require the use of Finite Element Analysis in combination with codes to extend the design scope


DEEP CORRUGATED/ STANDARD CORRUGATED DIFFERENCES


BRIDGE PLATE – MULTI-PLATE


Bridge Plate• Corrugation 400 mm x 150 mm• Steel thickness 4.3 mm – 8.0 mm• Plate length 1.2 m• Sizes 6 m – 20+ m• Low cover, high live load applications• Wide span arches and Box Culverts• Easier constructability in large sizes

Multi-Plate• Corrugation 150 mm 50 mm• Steel thickness 3.0 mm – 7.0 mm• Plate length 3.0 – 3.6 m• Sizes 1.5 m – 17.0 m• High cover applications with soil arch• Wide range of shapes• More conducive to fittings, curving

1.2 m

3.6 m


What it means on paper

BRIDGE PLATE MULTI-PLATE 7MM COMPARISON

Bridge Plate – What three times as strong and ten times as stiff really means –

Table 1 - Section Properties of Armtec Bridge Plate

Nominal Area of Moment Section Radius ofThickness Section of Inertia Modulus Gyration

mm mm2/mm mm4/mm mm3/mm mm

4 5.351 14944 252.66 52.855 6.811 19060 322.05 52.856 8.26 23154 391.01 52.857 9.64 27071 456.91 52.858 10.94 30759 518.88 52.85

Table 2 - Section Properties of Armtec Multi-Plate

Nominal Area of Moment Section Radius ofThickness Section of Inertia Modulus Gyration

mm mm2/mm mm4/mm mm3/mm mm

3 3.522 1057.25 39.42 17.3274 4.828 1457.56 53.3 17.3275 6.15 1867.16 66.98 17.3276 7.461 2278.31 80.22 17.3277 8.712 2675.11 92.56 17.327


WHAT TEN TIMES STIFF REALLY MEANS

Click icon to add pictureMulti-Plate requires• Cables or struts to hold in place• Is more susceptible to peaking

during backfill procedures• Is more prone to arch flattening• Additional costs for shape control

Bridge Plate • Is much stiffer• Allows faster assembly of plates• In most cases no additional shape

control

•


APPLICATIONS IN MINING


Afton Mines

MINE HAUL ROADS

Considerations for design• Live load• Dead load • Width of Structure• Cover height• Backfill material• Span • Stream crossing or grade crossing• Earthquake load


Vehicle weight• Todays mining trucks can

weight up to 600 metric tonnes or more

• Is the design for payload included ( truck loaded ) or no payload

• Two way traffic

Vehicle Weight Distribution• Live loads are distributed

through the soil cover and it essential to know how front and rear wheel loads are disbursed

• Often wheel loads overlap

Unbalanced Loading• Low cover , can generate

unbalanced loads must be evaluated

• Finite Element Analysis required for these applications

LIVE LOAD


Number of trucks• One or two vehicles on

structure• Are both loaded, both

unloaded or fully loaded

Load Distribution• Axle spacing• Wheel Spacing• Tire Imprint

Traffic Conditions• What Live load is • Rail, standard highway or

special mine load on top• Yandi Mine, Hamersley

Iron, Western Austraila

LIVE LOAD


Soil Properties• Bulk density• best estimate of the dead

load soil weight • AASHTO / CHBDC have

default values• Testing – remote mine

sites may use non standard soils

Geometry• Span requirements• Hydraulic requirements• Rise requirements• Cardinal River Coals, Teck

Minerals, Alberta Canada

Roadway or Rail Grade• Sets the cover height• Most mine vehicles

operate at maximum 15% gradient

• Railways typically want 2% gradients

• Toromocho – Chinalco Copper, Peru

DEAD LOAD



Roadway width• Single or double lane

traffic through the tunnel –define the clearance box

• Use of side berms for haul trucks defines length of structure

• Pueblo Viejo, Barrick Gold, Dominican Republic

Site Accessibility• Bridge Plates are fully

nestable and easy to deliver to site

• Bridges over a standard two lane highway can be delivered on as few as two flatbeds.

• Quintette Coal, Teck Resources, BC Canada

High Cover Applications• The ability of flexible

structures to distribute loads into the soil are ideal for high load applications

• Walker Brothers Quarry, Ontario, Canada

OTHER CONSIDERATIONS


DESIGNING FOR SEISMIC EVENTS

Canadian code requires buried structures be designed to resist inertial forces based on seismic event with a10% chance of being exceeded in 50 years.

CHBDC defines zonal acceleration ratios for seismic regions in Canada. The earthquake load on the structure is defined as 2/3 of the horizontal ground acceleration times the unfactored dead load thrust. In haul road design height of cover are often minimized and the additional thrust is generally not significant.

AASHTO evaluates earthquake loads for known fault areas.


HAUL ROADS – BENEFITS OF SPCSP

Benefits of Buried Metal Structures for Haul Roads• Low maintenance • Easy to extend length to accommodate

future road widening• Safer travel for large haul trucks- no

bridge deck freezing issues• Design can accommodate a wide

range of Mining vehicles• Cost efficient -Life expectancy can

match mine life.• Easy to deliver and assemble in

remote locations• Wide range of sizes for all applications


MINE PORTALS


MINE PORTALS

Click icon to add picture Click icon to add picture Click icon to add picture


MINE PORTALS

Mine Portals • Prevent surface water from entering

the mine• Provide ground support and safe

passage of surface roadways over the mine entrance

• Egress from ground level to the underground mine face for

1. Equipment and mine vehicles2. Manpower3. Ventilation pipes4. Utility lines


Egress requirements• One/two lane traffic• Pedestrian traffic• Utility Lines• Combination of all

Location of the mine face• Sets depth and cover • Sets ramp grade • Defines tunnel length• Defines solid rock

above the entrance

Constructability• Amount of rock

removal• Mine face portal

connection• Constructed with or

without the free flow of traffic into the mine

PORTAL DESIGN CONSIDERATIONS


End Treatment• Vertical Pre-Cut• Vertical Elbow

Safety• Include Safe Chamber• Chamber Spacing• Vertical Riser Access

Size of Rock Cut• Rock removal costs• Amount of Backfill

Required

PORTAL DESIGN CONSIDERATIONS


PORTAL DESIGN - SHAPE


PORTAL DESIGN-FOOTING

Footing design by Consultant15% gradient –maximum7.5 degree vertical elbow


PORTAL DESIGN - INTERFACE

Portal – Interface Connection• Flexible meshing• Shotcrete grout


PORTAL - CONSTRUCTION

Backfill and compact box cut

Room to compactbackfill

Assemble Safety space

Plate AssemblyStart at the face


Consultant provides:• Alignment & Clearance Box• Rock / Portal Interface• Footing DesignArmtec provides:• Cross-section Shape• Footing Reactions• Assembly & Backfill Specifications• Sealed Drawings*• Continuous On-site Daily Supervision*• Construction Certification Package*

* Dependent on jurisdiction

MINE PORTALS

Design to Construction Support


MINE TUNNELS


MINE TUNNELS

Multi-Plate, Bridge-Plate and Tunnel Liner Plate • Reclaim Tunnels• Escape tunnels• Conveyor Tunnels• Process and Utility Tunnels


500mm wide sectionsThickness = 3, 4, 5, 6 mmPlate weights = 15 kg - 42 kg

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TUNNEL LINER PLATE


Loading• Live load• Dead Load• Varying Load• Earthquake Load

Use• Shape• Size• What goes through?

Access• Emergency• Maintenance• Hopper openings

TUNNEL DESIGN CONSIDERATIONS


ESCAPE TUNNELS

Versatility of Multi-Plate provides wide range of options


CONVEYOR AND STOCKPILE TUNNELS

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Range of shapes and bolted plate construction allow for• Installation over live lines• Economical design for variable stockpile height• Maintenance access


CONVEYOR AND STOCKPILE TUNNELS

Reinforced Hopper Openings are designed by Armtec per ASTM A998/A


PROCESS TUNNELS

Fittings can be designed and constructed to match needs of raw ore processes.


ROCKFALL PROTECTION


RAISEBORE TUNNELS

Raisebore liners protect vertical shafts betweenUnderground drifts. Plates are bolted togetherand lowered down theshaft prior to connecting to the rock wall. The spaceis then grouted to provideprotection from fallingRock.


GROUNDFALL TUNNELS

Underground utilities and conveyors can be afforded protection from roof falls using liner plate or structural plate


MINE ACCESS CROSSINGS


Multiple structures make excellent low cover, wide stream crossings for both mine exploration and servicing.

Stream crossings under rail lines can be pre-assembled and set into place as the line is progressed forward.

Large low cover Bridge-Plate make excellent train crossings for rail lines servicing remote mine sites

ACCESS ROAD AND RAIL CROSSINGS


ON-SITE INSTALLATION


TWO CREEKS – BRIDGE PLATE ARCH

11.34 m

6.545 m


ASSEMBLY EQUIPMENT

1 small crane + 2 man lifts1 large crane2 - 4.0 ft. bars Drift pins Air wrenchesHand wrenches


PLATES ARRANGED & SET ON-SITE


-Footing channel

FOOTINGS

8.9 Deg.

Re-Entry

Angle


The first 2 rings are assembled on ground, then bolted to the footing channels

INSTALLATION

Lifting the first pre-assembled “ring”


INSTALLATION

The next ring isinstalled “plate-by-plate”


Set Footing PlatesINSTALLATION


INSTALLATION


INSTALLATION


INSTALLATION


Longitudinal seam

Circumferential.

seam

1200 mm wide per ring


STRUCTURE READY FOR BACKFILL




LIFE CYCLE DESIGN


STRUCTURAL PLATE COATINGS

STRATA CAT POLYMER COATING

• Additional barrier coating applied to the steel which eliminates or minimizes contact with environmental contaminants

• Dual coating systems will provide 2 levels of protection

• Broadens the allowable range of environmental parameters that are known to negatively influence the Estimated Material Service Life (EMSL) of buried steel products



STRATACAT POLYMER COATING - APPLICATION

• Process of coating fabricated steel by applying a Ethylene Acrylic Acid (EAA) copolymer over a zinc based layer – 4 step process

• Surface Preparation – 8 stage pre-treatment wash

• Zinc application – (minimum 1.5 mil per side)

• Copolymer application – spray applied and baked (10 mil thickness per side)• Inspection

• Each process ensures proper bonding of each coating layer



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CAT = Corrosion Arresting Technology

Download at www.armtec.com

http://files.armtec.com/Downloads/Categories/Bridge-Materials/Structural_Plate/PROD-C01-G07-P03_PG-2014-E.pdf


Hand Spray guns

THE COATING PROCESS


Plates coming out of the spray booth and entering the oven


Ready for shipment



Environmental Parameter

Suggested Limits Galvanized Steel

Suggested Limits for Polymer Coated Steel

50 year EMSL

75 year EMSL

100 year EMSL

pH preferred range 5 – 9 3 – 12 4 – 9 5 – 9

Resistivity 2,000 – 8,000 ohm-cm >100 ohm cm

>750 ohm cm

>1,500 ohm cm

Chlorides < 250 ppm NA NA NA

Sulfates < 600 ppm NA NA NA

Hardness > 80 ppm CaCO3 NA NA NA

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Table 21

Environmental Limits For Galvanized Steel and Polymer Coated Steel

1 Performance Guideline For Buried Steel Structures – Tech. Bulletin 13, CSPI Feb 2012



88www.cspi.ca




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Contact Your Local Rep: www.armtec.com/contact-us

Today’s Speakers:

Doug [email protected]

Glenn [email protected]


UPCOMING MONTHLY WEBINARS

www.armtec.com/webinars/

Dec 12 | Armtec’s Earth Retention Solutions - An Overview

Doug Lowry & Ron Prychitko

Many more to come in 2015!

http://www.armtec.com/webinars/


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BIG DIGS Mine Site Development & Underground Solutions

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Big Digs - Site Development & Underground Solutions for Mining