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
webinars@armtec.com
Will send certificate

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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 Materials
Drainage Solutions
and Water Treatment
Landscaping
Products
and Amenities
Noise Control
Road and
Highway Safety Soil Retention
Underground
and Utilities
Precast Concrete
Buildings and
Venues
Precast Concrete
Garages and
Parkades

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YOUR SPEAKERS
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Glenn.Smith@armtec.com
Doug Leitch, P. Eng
Doug.Leitch@armtec.com
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
CONSTRAINTS
Large 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

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SUPPORT
FROM
BACKFILL
SUPPORT
FROM
BACKFILL
Live load applied
Dead load applied Structure deflects
towards 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 compact
backfill
Assemble
Safety space
Plate Assembly
Start 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 is
installed
“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

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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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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

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88www.cspi.ca

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Contact Your Local Rep:
www.armtec.com/contact-us
Today’s Speakers:
Doug Leitch
Doug.Leitch@armtec.com
Glenn Smith
Glenn.Smith@armtec.com

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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!

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