Big Digs - Site Development & Underground Solutions for Mining

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© 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. Eng

Manager International Sales

Armtec Drainage Solutions

Glenn Smith, CET

Sales Supervisor, Atlantic


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SITE DEVLOPEMENT AND UNDERGROUND


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

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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]

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• 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

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Bridge MaterialsDrainage Solutions

and Water Treatment

Landscaping

Products

and Amenities

Noise Control

Road and

Highway Safety Soil RetentionUnderground

and Utilities

Precast Concrete

Buildings and

Venues

Precast Concrete

Garages and

Parkades

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YOUR SPEAKERS

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Armtec Drainage [email protected]

Doug Leitch, P. Eng



[email protected]

Glenn Smith, CET

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Webinar - Nov 14, 2014

BIG DIGS

Nov 14, 2014

SITE DEVELOPMENT AND UNDERGROUND


Doug Leitch, P. Eng



Glenn Smith, CET



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WORK SAFE !!

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Jacioeta Stream Crossing

MOA Nickel

• JV Cuba

• Sherritt International

Cuba, West Indies

Conveyor Wildlife Crossing

Cortez Mine

Barrick Gold

Nevada, USA

Portal Tunnel Entrance

Tafts Quarry

Tafts Well Limestone

Wales, UK

RECENT BIG DIGS

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Mine Portal

Buyanhula Gold Mine

Barrick Gold

Tanzania, West Africa

Mine Portal

Kumtor

Centerra Gold

Kyrgystan, Asia

Haul Road

Minera Cerre Verde

Freeport , McMoron

Peru, South America

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STRUCTURAL PLATE

CORRUGATED STEEL PIPE

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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

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Given the versatility of structural plate

products, a wide variety of shapes

and sizes can be manufactured to

meet your needs.


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Ship to the Site

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Bolts the Plates together

Per Assembly Drawings

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And this ….. Becomes this


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EVOLUTION OF STRUCTURAL

PLATE

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EVOLUTION OF STRUCTURAL PLATE

1896 - CORRUGATED STEEL PIPE PATENTED

CONSTRAINTSLarge dia. pipe fabrication

Available gauges

Transportability

Demand for larger diameter

SEGMENTAL PLATE CONSTRUCTION

Heavy gauge corrugated plate

Bolted connections

Assembled on site

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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 time

Bridge Plate became

the strongest such

Product available


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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.

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FLEXIBLE STEEL PIPE DESIGN

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The Handbook of Steel Drainage and

Highway Construction

Published By

Corrugated Steel Pipe Institute

652 Bishop Street North

Cambridge Ontario , Canada

N3H 4V6

Ray Wilcock

+1 519-650-8080

www.cspi.ca

CANADIAN HANDBOOK of STEEL DRAINAGE AND HIGHWAY CONSTRUCTION

http://www.cspi.ca/

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SUPPORTFROMBACKFILL

SUPPORT FROM

BACKFILL

Live load applied

Dead load applied Structure deflectstowards fill

RING COMPRESSION THEORY

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Net Result:

An economical buried

structure capable of

supporting significant loads

FLEXIBLE SOIL – STEEL STRUCTURES

Steel Component:

Corrugated thin wall flexible pipe

Corrugated shell is highly efficient

member to support axial

compressive loads

Soil Component:

Engineered granular

Backfill envelope with

materials of known

properties

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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, reducing

the support provided from the

surrounding fill.

The structure carries more load

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FLEXIBLE –RIDGID LOAD RESPONSE

12.0 m span x 4.0 m rise arch

Bending Moments and Thrust

Flexible Soil Steel

Ridgid Concrete Arch

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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

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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

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DEEP CORRUGATED/

STANDARD CORRUGATED

DIFFERENCES

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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

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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 of

Thickness Section of Inertia Modulus Gyration

mm mm2/mm mm4/mm mm3/mm mm

4 5.351 14944 252.66 52.85

5 6.811 19060 322.05 52.85

6 8.26 23154 391.01 52.85

7 9.64 27071 456.91 52.85

8 10.94 30759 518.88 52.85

Table 2 - Section Properties of Armtec Multi-Plate

Nominal Area of Moment Section Radius of

Thickness Section of Inertia Modulus Gyration

mm mm2/mm mm4/mm mm3/mm mm

3 3.522 1057.25 39.42 17.327

4 4.828 1457.56 53.3 17.327

5 6.15 1867.16 66.98 17.327

6 7.461 2278.31 80.22 17.327

7 8.712 2675.11 92.56 17.327

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WHAT TEN TIMES STIFF REALLY MEANS

Multi-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

•

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APPLICATIONS IN MINING

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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

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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

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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

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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

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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

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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.

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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

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MINE PORTALS

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MINE PORTALS

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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 vehicles

2. Manpower

3. Ventilation pipes

4. Utility lines

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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

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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

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PORTAL DESIGN - SHAPE

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PORTAL DESIGN-FOOTING

Footing design by Consultant

15% gradient –maximum

7.5 degree vertical elbow

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PORTAL DESIGN - INTERFACE

Portal – Interface Connection

• Flexible meshing

• Shotcrete grout

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PORTAL - CONSTRUCTION

Backfill and compact

box cut

Room to compactbackfill

Assemble Safety space

Plate AssemblyStart at the face

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Consultant provides:

• Alignment & Clearance Box

• Rock / Portal Interface

• Footing Design

Armtec 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

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MINE TUNNELS

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MINE TUNNELS

Multi-Plate, Bridge-Plate and Tunnel Liner Plate

• Reclaim Tunnels

• Escape tunnels

• Conveyor Tunnels

• Process and Utility Tunnels

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500mm wide sections

Thickness = 3, 4, 5, 6 mm

Plate weights = 15 kg - 42 kg

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TUNNEL LINER PLATE

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Loading

• Live load

• Dead Load

• Varying Load

• Earthquake Load

Use

• Shape

• Size

• What goes through?

Access

• Emergency

• Maintenance

• Hopper openings

TUNNEL DESIGN CONSIDERATIONS

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ESCAPE TUNNELS

Versatility of Multi-Plate provides wide range of options

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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

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CONVEYOR AND STOCKPILE TUNNELS

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

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PROCESS TUNNELS

Fittings can be designed and constructed to match needs

of raw ore processes.

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ROCKFALL PROTECTION

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RAISEBORE TUNNELS

Raisebore liners protect

vertical shafts between

Underground drifts.

Plates are bolted together

and lowered down the

shaft prior to connecting to

the rock wall. The space

is then grouted to provide

protection from falling

Rock.

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GROUNDFALL TUNNELS

Underground utilities and conveyors can

be afforded protection from roof falls using

liner plate or structural plate

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MINE ACCESS CROSSINGS

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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

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ON-SITE INSTALLATION

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TWO CREEKS – BRIDGE PLATE ARCH

11.34 m

6.545 m

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ASSEMBLY EQUIPMENT

1 small crane + 2 man lifts

1 large crane

2 - 4.0 ft. bars

Drift pins

Air wrenches

Hand wrenches

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PLATES ARRANGED & SET ON-SITE

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-Footing channel

FOOTINGS

8.9 Deg.

Re-Entry

Angle

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

INSTALLATION

Lifting the first pre-assembled “ring”

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INSTALLATION

The next ring isinstalled “plate-by-plate”

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Set Footing PlatesINSTALLATION

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INSTALLATION

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INSTALLATION

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INSTALLATION

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Longitudinal seam

Circumferential.

seam

1200 mm wide per ring

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STRUCTURE READY FOR BACKFILL

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LIFE CYCLE DESIGN

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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

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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

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

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Hand Spray guns

THE COATING PROCESS

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Plates coming out of the spray booth and entering the oven

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Ready for shipment

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EnvironmentalParameter

Suggested Limits Galvanized Steel

Suggested Limits for Polymer Coated Steel

50 year EMSL

75 yearEMSL

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

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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]

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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