1. Design Criteria for
Civil Engineering
Document No:
140189-1000-41EC-0001
Ol'Jilllll VJ~
+))
BARI~UNING LTD.
SNC•LAVALIN
Australia
Rev
00
JABAL SAVIO HCIS PROJECT
CIVIL DESIGN CRITERIA
Date: Page
05/10/12 1 of 18
This document has been prepared by, and remains the sole property of, SNC-Lavalin Australia Ply Ltd (SNCL). It is provided
solely for use of the Jabal Sayid HCIS Project. The recipient agrees by receipt and/or use of this document to return it to SNCL
upon request, and not to reproduce, copy, lend or otherwise disclose or dispose of the contents, directly or indirectly, and not to
use them for any purpose other than that for which they are specifically furnished.
Revision Date Issued for Prepared By Reviewed By Approved By Client Rev/App.
PA 18/09/12 Internal and B. Samson V. Toh J. Matijevic
Client Review
00 05/10/12 Issued for B. Samson V. Toh J. Matijevic
Design ,---y--) [1. ~//
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Civil Engineering 140189-1000-41EC-0001 00 05/10/12 2 of 18
REVISION CONTROL
Issued for Internal Review
Issued for Client Review
Issued for Design
REVISION HISTORY
Revision Pages Revised Remarks
PA NA
00 11 Added design criteria for cuts greater
than 6m height.
Jabal Sayid HCIS Project- Civil Engineering Design Criteria
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Design Criteria for
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1 GENERAL
The purpose of the Jabal Sayid HCIS Project is to:
D Reconstruct civil infrastructure components of existing security access gates in
the project site to satisfy the Saudi Arabian and other relevant design
standards.
D Construct new security access gates in the Jabal Sayid site facilities as
identified in Section 1.1 of this document.
1.1 Scope
This design criteria covers the basic criteria for the design of all civil engineering
works for the following site areas of the Jabal Sayid Project in the Kingdom of Saudi
Arabia.
D Area 1: Upgrade of Pre-Inspection Checkpoint
D Area 2: New Main Entrance Gate
D Area 3: Upgrade of Permanent Village Access Gate
D Area 4: New Explosive Magazine Main Gate and Pre-inspection Checkpoint
D Area 5: New Process Plant Access Gate and Road Upgrade to Explosive
Magazine
D Area 6: New Process Plant Security Control Building
The design criteria is related, but not limited, to the following:
D Earthworks;
D Stormwater Drainage;
D Road Geometry and Pavement;
D Signages, Linemarkings and Road Furnitures;
1.2 Jabai-Sayid Location
The proposed Jabal Sayid HCIS Project is situated in an area referred to as Jabal
Sayid, in the West of Saudi Arabia. The mine is located on Latitude 23°51 'N and
Longitude 40°56'E and at an elevation of approximately 960 m above sea level.
The site lies 150 km to the South East of the Holy City of Madinah and
approximately 31 0 km to the North East of Jeddah and approximately 350km by
road from the port city of Yanbu AI Bahr. The site is situated within the Municipality
of Medinah.
Jabal Sayid HCIS Project - Civil Engineering Design Criteria
6. ~ Design Criteria for
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Date:
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The nearest sizeable town is Mahd adh Dhahab, which is situated some 35 km to
the south of the Jabal Sayid site. Mahd adh Dhahab has developed around the gold
mining operations of Ma'aden, Saudi Arabia's national mining entity.
1.3 Quality Certifications and Requirements
Quality assurance and quality control requirements shall be in accordance with the
requirements of the Project Quality Management Plan, document
140073-38AG-I-0001 .
1.4 Occupational Health and Safety
Bariq's Representative's commitment to health and safety is the primary focus on
this project and its principles shall be applied to all design and construction works.
The guiding principal is sharing values relating to caring - for the health and safety of
our colleagues; for sustainable environment and for the communities in which we
live and work.
2 REFERENCED DOCUMENTS
All works covered by this Design Criteria shall be in accordance with the applicable
Saudi Arabian, American and International Standards and Codes and Statutory Acts
and associated Regulations applicable to the project site.
Each specification (refer Table 2-1) shall be reviewed during detailed design
engineering for compliance with statutory requirements and technical content.
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Where the stipulations of these standard specifications and drawings do not comply
with the minimum requirements of the Statutory Regulations and Code Standards,
the latter shall prevail.
Where the stipulations of these standard specifications and drawings are more
exacting than the minimum requirements of the Statutory Regulations and Code
Standards, the former shall prevail in the following order:
1. Data Sheets and Design drawings;
2. Standard specifications and standard drawings.
The following list of Acts and Regulations, design criteria (other design disciplines)
and engineering specifications are applicable to this design criteria. The American
Standards listed are specifically referenced by this document.
2.1 Design Criteria
Document Number
1 140189-1000-43EC-0001
1 140189-1000-45EC-0001
Table 2-1 - Design Criteria
Title
IStructural Design Criteria
I Mechanical Design Criteria
2.2 Engineering Specifications
Table 2-2 - Engineering Specifications
-- - - -
Document Number
1 140189-1000-41EF-0001
1 140189-1000-41 EF-0002
1 140189-1000-41 EF-0003
1 140189-1000-41EF-0004
Title
I Bulk Earthworks
ITrenching
I Stormwater Drainage
IRoad Pavements and Surfacing
2.3 Codes and Standards
Table 2-3 -Codes and Standards
-~
- - - - - - -
Code/Standard Title
IAASHTO HDG-3 Vol IV Guidelines for Hydraulic Design of Culverts
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Code/Standard
IASTM C131
IASTM C136
ASTM C14
ASTM C443
ASTM C76M
ASTM D1140
ASTM D1556
ASTM D1557
ASTM D1883
ASTM D2167
ASTM D2216
ASTM D2419
ASTM D2487
ASTM D6938
ASTM D2937
IASTM D422-63
IASTM D425-88
Title
Test Method for Resistance to Degradation of Small Size
Course Aggregate by Abrasion and Impact in the Los
Angeles Machine.
Sieve Analysis of Fine and Course Aggregates
Standard Specification for Concrete Sewer, Storm Drain
and Culvert pipe
Joints for Circular Sewer and Culvert Pipe, using Rubber
Gaskets
Reinforced Concrete Culvert, Storm Drain and Sewer
Pipe
Standard Test Methods for Amount of Material in Soils
finer than the No. 200 (75-um) Sieve
Standard Test method for Density and Unit Weight of Soil
in place by the Sand-Cone Method.
Test Method for laboratory Compaction Characteristics of
Soil using Modified Effort {2,700 KN-mlm
California Bearing Ratio of Laboratory Compacted Soils
(CBR)
Standard Test Method for Density and Unit Weight of Soil
in Place by the Rubber Balloon Method.
Standard Test Method for Laboratory Determination of
Water (Moisture) Content of Soil and Rock by Mass
Sand Equivalent Value of Soils and Fine Aggregate
Test Method for Classification of Soils for Engineering
Purposes.
Test Method for In-Place Density and Water Content of
Soil and Soil-Aggregate by Nuclear Methods (Shallow
Depth).
Standard Test Method for Density of Soil in Place by the
Drive-Cylinder Method
Standard Method for Particle Size Analysis of Soils.
Test Method for Centrifuge Moisture Equivalent of Soils
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Code/Standard Title
IASTM 04253 Maximum Index Density and Unit Weight of Soils using a
Vibratory Table.
IASTM 04254 Minimum Index Density and Unit Weight of Soils and
Calculation of Relative Density.
IASTM 04318 Test Method for Liquid Limit, Plastic Limit, and Plasticity
Index of Soils.
I ASTM D4318 Liquid Limit, Plastic Limit and Plasticity Index of Soils
IASTM 0698-12 Test Method for Laboratory Compaction Characteristics
of Soil using Standard Effort
2.4 Design Guides
The following design guides will be used in conjunction with the relevant Codes and
Standards to carry out investigation and civil engineering design for this Project. The
requirements of the Codes and Standards shall take precedence over the content of
the Design Guides.
Table 2-4- Design Guides
Document
Security Directives for Industrial
Facilities
Safety and Fire Protection Directives for
Industrial Facilities
Highway Design Manual (Volumes 1, 2
and 4), Highway Development
Work Zone Traffic Control Handbook,
Ministry of Communications, The
Kingdom of Saudi Arabia
Manual on Uniform Traffic Control
Devices for Streets and Highways
(2003) - Part 1 and Part 3
AASHTO Guidelines for Hydraulic
Design
I
Source
Ministry of Interior High Commission
for Industrial Security, The Kingdom
of Saudi Arabia
Ministry of Interior High Commission
for Industrial Security, The Kingdom
of Saudi Arabia
Ministry of Communications, The
Kingdom of Saudi Arabia
Ministry of Communications, The
Kingdom of Saudi Arabia
U.S. Department of Transportation,
Federal Highway Administration
IAASHTO
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- -
Document Source
IAustroads Pavement Design Manual IAustroads
3 CIVIL DESIGN REQUIREMENTS
3.1 Pavement Design Life
The road pavement shall be designed for a nominal life of 20 years.
3.2 Units
Sl units are to be used for the design calculations and drawings.
3.3 Survey
SNC-Lavalin has prepared the Field Ground Survey Scope of Work (Document No.
140189-1000-41 EW-0001) for the project. The data received in response to this
scope of works is to be utilised as part of the design.
The coordinate system to be adopted shall be based on Jabal Sayid Plane Mine
Grid (PMG).
3.4 Geotechnical Investigation
Bariq Mining Ltd. has commissioned Fugro-Suhaimi Ltd. to conduct the geotechnical
investigation (using test pits) and testing of materials. The Geotechnical Report will
be produced to provide site geotechnical information such as soil bearing capacity
and in-situ material CBR value for structural design and pavement design
respectively.
3.5 Earthworks
Earthworks designs shall incorporate the findings and recommendations of all
geotechnical reports prepared for the Project. The geotechnical engineer shall
approve any variations in proposed fill material or placement techniques.
The design of bulk earthworks shall consider the finished geometry of the facilities,
roads, hardstanding or other works to be constructed over the site. The location of
required services is to be considered in the earthworks design.
Unless otherwise indicated in a geotechnical report, the following maximum batter
slopes shall be used for batters up to 6 m in height.
General cut and fill
Culvert headwalls
Rock batters
1v to 2h
1v to 1.5h (erosion protection required)
1v to 1h
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Slope heights greater then 6m can be used with the advice of a specialised
geotechnical engineer upon carrying out a detailed slope stability analysis.
Otherwise, benching will be required on cuts greater than 6m height with 4m
benching width and 1% bench gradient.
The minimum grade for hardstand areas shall be 0.5 %. The following minimum
compaction standards shall apply:
0 general fill below lightly loaded structures and sub-grade for roads;
• cohesive soils: 90% of the maximum Modified Proctor density as
determined by ASTM 01557;
• cohesionless free draining soils: 70% relative density as determined by
ASTM 04253 and ASTM 04254.
0 fill below heavily loaded structures and road pavement;
• cohesive soils: 95% of the maximum Modified Proctor density as
determined by ASTM 01557;
• cohesionless free draining soils: 80% relative density as determined by
ASTM 04253 and ASTM 04254.
3.6 Roadworks
3.6.1 General
Roads shall be designed in accordance with minimum standards set by Bariq with
respect to access type and pavement formation.
Three standard types of access have been nominated for this Project. These are:-
0 Standard Vehicle Access
0 Haul Truck Access
0 Parking Area
The design criteria for each of the type of access are summarised in Tables 3-1, 3-2,
and 3-3. Below are the general requirements for all types of road.
0 Safe sight distances shall be applied for all roads in accordance with standard
guidelines. Where sight distance is restricted, design speed shall be reduced
together with the use of appropriate signage.
0 Minimum vertical grade shall be 0%. The maximum vertical grade is as noted
in the tables.
0 Generally, a minimum cross fall of 1.5% shall be provided for all pavements,
unless vendor equipment requires a level surface.
0 If superelevation is required on any road horizontal curve, it shall extend for
the full length of the curve. The transition from crown to superelevation and
vice versa shall be not less than 30m.
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3.6.2 Standard Vehicle Access
Design criteria for this type of access is summarised in Table 3-1.
Table 3-1 -Standard Vehicle Access
- - - - - - - - - - - - - - - - - - - - - - - - - - -
Design Element Design Criteria
I Design Traffic Loading IRefer Section 3-7
~------------~============~
J Road Classification / Local
r---------------------------------~
Design Vehicle 13.87m Long WB-40 Semi-trailer
(Village Only)
20.88 Long WB-62 Semi-trailer (all
other access)
Design Speed /so kph
·~ -S-urf_a_c_e_T_y_p_e_____=--~------'---_c:_=-- 1 Sealed
~---------------======
Lane Width 4.0 m (Standard Minimum)
8.0 m (Large Loads Access)
4.0 m minimum (Bus Parking/ Turning
Lane)
I
~inimum Vertical Curve ISag: K =12
Crest K =11
~-------------=~====~~
IMaximum Vertical Grade
Minimum Vertical Clearance to Obstruction (i.e.
overhead structure, power lines)
7% (Desirable)
11% (Absolute)
r-M-in_i_m_u_m__H_o-riz_o_n-ta_I_R_a_d-iu_s_w--ith_o_u_t_w_id_e_n-in_g__----,
1
, 125 m
IMinimum Sight Distance '16_5__m_________________________
.-------------------------------------,
Minimum Taper Length on Added Lane or Lane Refer Figure 1.05.15, Highway
Widening Design Manual (Vol. 2)
ICurb Type/ Minimum Curb Radius IType A1/ R3 m
~, -R-a-is_e_d-ls_l_a-nd--M-in_i_m_u_m__W_id_t_h____~======~~ 1 m
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3.6.3 Haul Truck Access
Design criteria for this type of access is summarised in Table 3-2.
Table 3-2 - Haul Truck Access
Design Element Design Criteria
IDesign Traffic Loading Refer Section 3.7
IDesign Vehicle Caterpillar 740 Articulated Truck
ISurface Type
ILane Width
Minimum Vertical Clearance to Obstruction (i.e.
overhead structure, power lines)
3.6.4 Parking Area
Sealed
6.5m
5.5m
Design criteria for this type of access is summarised in Table 3-3.
Table 3-3 - Parking Area
Design Element Design Criteria
I Design Traffic Loading IRefer Section 3.7
~------------~============~
ISurface Type Sealed
IParking Bay Width x Length 3.0 m x 5.5 m
·IAisle Width 8.0m
IMaximum Vertical Grade 2.5%
ICurb Type/ Minimum Curb Radius Type A1/ R3 m
3.6.5 Signages, Linemarkings and Road Furnitures
The design of signs and linemarkings on roads, parking area and security access
gate houses shall be designed based on Manual on Uniform Traffic Control Devices
for Streets and Highways (2003) - Part 1and Part 3.
All speed bumps shall be designed based on Standard Drawing No. TCD-2,
Highway Design Manual (Volume 4).
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Standard road blocker and gate equipments will be designed by the Mechanical and
Structural Engineers but ensure that the proposed equipments are suitable on the
proposed access widths and grades.
3.7 Pavement
The Operational and Construction Traffic shall be determined from Bariq. The initial
information secured from the Client is as follows:
D Process Plant: Tailings Truck will pass every 6 min with 18 min turnaround.
All pavement design shall be based upon 4-day soaked subgrade CBR value
according to the specifications outlined in the Geotechnical Report.
3.8 Stormwater Drainage
3.8.1 General
All stormwater drainage for the Project site shall be analysed and designed using
accepted hydrologic and hydraulic principals in AASHTO Standards
Stormwater run-off from the Project site shall be controlled via a system of open
drains and culverts.
Drainage systems within the plant area shall be designed to cater for the worse case
of either deluge water or storm water runoff.
The drain system shall provide for the segregation of contaminated and
uncontaminated runoff. All potentially contaminated runoff shall be considered
contaminated.
All open channel drains shall be trapezoidal or V drains.
Drains carrying contaminated runoff shall be open channels lined with an impervious
membrane and shall be designed to inhibit flooding out of containment areas. The
contaminated runoff shall be impounded, collected and recycled.
Open Channel lining shall be concrete unless there is potential for significant acid
spills. In these areas HOPE shall be utilised and the spill impounded and prevented
from entering the main drainage system until neutralised.
3.8.2 Design Rainfall Intensity
Design rainfall intensity is based upon the Intensity I Frequency I Duration (IFD)
information derived from the Steel Formula [I =K I (t + b)] as detailed in the Saudi
Aramco Desktop Standard SAES-A-112.
The IFD information derived from this formula is shown in Table 3-5 below:
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Table 3-1 - Design Rainfall Intensity
-
Time of
Concentration in
Minutes
Rainfall Intensity in mm I hr
- - - - - - - - ~
- - - - - -
5 Year 10 year 25 Year
5 119.2
6 115.2
10 65.1 101.5
15 57.5 88.4
20 51.4
25 46.5
30 42.5
40 36.2
50 31 .5
60 27.9 40.9
23.8 34.7
90 20.8 30.1
105 18.4 26.6
120 16.6 23.8
3.8.3 Runoff Calculations
3.8.3.1 Average Recurrence Interval (ARI)
Page
15 of 18
-
- - - - -
50 Year
146.5
141.1
122.9
105.8
62.5
53.7
47.0
39.7
27.0
All areas of the Project site shall be designed for an Average Recurrence Interval of
10 years.
Overland drainage paths for the 50-year Average Recurrence Interval storm event
are to be identified and checked for extent of inundation. Overland flow paths shall
be included in the design to divert major overland flows directly to downstream
sedimentation dams and watercourses.
3.8.3.2 Run-off Coefficients
Run-off coefficients shall be determined from an assessment of expected catchment
conditions and from information contained in the following Table 3.6:
Table 3-2 - Run-off Coefficients
- - - - - - - - - - - - - -
Character of Drainage Area c
IPavement, roads and parking lots 0.9
I Compacted marl or open rocky areas 0.8
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Character of Drainage Area
Commercial or Community Services areas
I Residential areas 0.6
ISchool sites 0.5
IParks and open sandy areas 0.3
3.8.3.3 Time of Concentration
The initial Time of Concentration for drainage design shall be determined from
Bransby Williams Formula:
Where
Tc =(F XL) I (A0
"
1
XSe0
"
2
)
Tc =Time of Concentration for Catchment (minutes)
F = 58.5 when A is km2 and 92.7 when A is hectares (ha)
L = length of mainstream (km) from the outlet to the
Catchment divide
A= area of catchment (either km2 or hectares)
Se = equal area slope (ml km) where distance is in km and
height above catchment outlet is in m.
The initial Time of Concentration shall not be less than 10 minutes for the purpose of
calculating rainfall intensities.
3.8.3.4 Discharge Estimation
The peak discharge for each element of the drainage system shall be calculated
using the Rational Method in accordance with the formula below:
Q =0.002755 * C * I *A
Where Q = the Peak Discharge for the Catchment (m3
I sec)
C =the Runoff Coefficient from the above Table 3-6.
I =the Rainfall Intensity from the IFD information in Table 3-5 (mm/hr)
A =the Catchment Area (ha)
3.8.4 Drainage Channel Design
The Drainage Channel design shall be comprised of the following items:
D The minimum freeboard required shall be 150mm. The freeboard within the
site drainage channels can be utilised to accommodate the overland flow
requirements.
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0 Channel shape shall be vee or trapezoidal with O.Sm minimum base width;
0 Maximum channel side slope is 1V:2H
0 Minimum channel longitudinal gradient is 0.3% (absolute minimum) and 0.5%
(desirable minimum).
0 Minimum channel non silting velocity shall be 0.5 m/s;
0 Channellining:
o Bare Earth for flow velocities less than 1.0m/s (assuming non-dispersive
soil)
o Grass lined for flow velocities greater than 1.0m/s but not more than 1.8m/s.
o Riprap for flow velocities greater than 1.8m/s
• Sharp curves must be avoided. In general, curves should be such that the
minimum radius at the centre line is equal to about three times the width of the
top of the design flow.
3.8.5 Pipe and Box Culverts
Pipe and box culverts shall be designed to incorporate the following criteria:
0 1 in 50 year average recurrence interval flows;
0 maximum outlet velocity: 3 m/s;
0 minimum self-cleansing velocity: 0.7m/s;
0 minimum pipe diameter: 600 mm; minimum box culvert dimension: 600 mm x
375 mm;
0 minimum pipe cover: 600mm for standard vehicle load, 750mm for haul truck
load ; minimum box culvert cover: 300mm;
0 assume full pipe flow, with no allowance made for loss of capacity from
possible sediment build up;
0 ensure that inlets cannot fail due to buoyancy uplift during design floods;
0 maximum road and rail vehicle loads applied in structural design;
0 avoid skewed culverts, where possible. Maximum culvert skew: 30°;
0 items located a distance of 1OOOmm from the face of an embankment, shall be
backfilled with cement-stabilised backfill, specified from 100 mm below the
pipes and culverts to a level 300 mm above the top of the culverts;
0 rip rap or rock mattress erosion protection shall be provided downstream of
drainage structures in accordance with the relevant standards and shall be
included at culvert outlets where the outlet velocity exceeds 1.0 m/s;
0 where Corrugated Steel Pipes (CSPs) are utilised, the manufacture and
design shall be in accordance with ASTM A770 I A760 M and shall specify
wrapping of the CSPs with an impermeable membrane;
0 Standard headwall and wingwall shall be specified for all culverts.
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3.8.6 Pipe Flow
The flow in pipes and channels shall be determined by the Manning Formula and
the Continuity Equation as follows:
Where
Where
Where
Q = A*V
Q = Flow in the Pipe or Channel Section (m3
I sec)
A = Area of Flow ( m2
)
V = Average Velocity of Flow ( m I sec)
V =(R213
* S112
) In
R = Hydraulic Radius of Pipe or Channel Section ( m )
R = AlP
P = Wetted Perimeter at the Pipe or Channel Section ( m )
S = Slope of the Pipe or Channel Section ( m I m )
n = Manning's Roughness Coefficient for the Pipe or Channel (see
Table 3-3 below.
Table 3-3 - Manning's Roughness Coefficient
Pipe or Channel Surface
IVitrified Clay or RTR Pipe I0.013
~--------------~==================~-
1 Concrete or Steel Pipe I 0.015
~~ -Pa_v_e_d_S_t_re_e-ts- w--ith__K_e-rb_a_n_d_G--ut_re_r_____________________ l 0.015
~----===~
Concrete lined Open Channels and Box Culverts I0.016
~~C--on_s_t-ru-c-te_d_O_p_e_n_C_h_a_n_n_e_ls_w_i-th_C_o_n_c_re_t_e_s-id_e_s_lo_p_e_s________ l0.019
~----======
Constructed Open Channels with Earth side slopes I 0.023
.--C-o-ns-t-ru-c-te_d_O_p_e_n_C__ha_n_n_e-ls- w--ith--R-ip--r-a_p_s-id_e_s_lo_p_e_s_________ l 0.027
~----=====--
1 Smooth natural stream Channels I 0.040
~~-R-o-ug_h_o_r_R_o_c_k_y_n_a-tu-ra_l_s-tr_e_a_m_C_h_a_n_n_e_ls----------------- ~ 0.050
Jabal Sayid HCIS Project- Civil Engineering Design Criteria
