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By K. van Warmerdam, M. Pearson, C. Kember, D. McMullen, M. Thayer, C. Ugarenko

In July 2012, Hatch Ltd. and Air Products & Chemicals Inc. completed construction and commissioning of a 4000 tpd O2 cryogenic air separation unit (ASU) for Barrick Gold’s Pueblo Viejo Project located in central Dominican Republic. The ASU produces high pressure gaseous oxygen, which is used for the oxidation of refractory sulphide ore within the pressure oxidation (POX) circuit. As a result of the project’s remote location and tropical climate, many challenges were faced over the course of construction, commissioning and start-up of the ASU. These challenges included adequate preservation of equipment due to dusty and humid site conditions, final assembly and erection of the cryogenic distillation columns on site, limited spare parts inventory/availability, and an unfinished power source for plant commissioning. This paper discusses the steps taken by Hatch and Air Products to successfully design, construct, commission and start up the largest stand-alone ASU plant for a POX application in the metallurgical industry.

Jan 1, 2014

By Kyle Kershaw

Micropiles are routinely used in the United States for foundation support and stabilization of slopes. In recent years, several retaining walls have been constructed using micropiles in an A-frame type configuration to support temporary and permanent excavations at sites with limited access and limited right-of-way. Typical A-frame micropile walls consist of a row of vertical micropiles at the face of the wall and a row of battered micropiles extending into the soil or rock to be retained. The two rows are then tied together with a pile cap such that the front pile acts primarily in bending and the back pile acts primarily in tension. Because of tight right-of-way constraints at a residential site in Aspen, Colorado, it was not possible to construct the wall using conventional shoring systems or micropiles in the typical A-frame configuration. Rather, the wall was designed such that the row of battered piles was installed at the wall face and the row of vertical piles was installed adjacent to the property line behind the wall. As a result of the reverse configuration of the A-frame wall, FLAC, a two-dimensional, finite difference software program, was used to model the soil-structure interaction. The final wall design consisted of both temporary and permanent retaining wall sections with maximum heights of 26 feet. Inclinometers were installed in several piles to monitor the behavior of the retaining walls during and after excavation. This paper presents an overview of the design method, a discussion of construction techniques, and a comparison between the FLAC model and the measured behavior of the wall in the field.

Jan 1, 2007

By Cheng Lin, Guoming Lin

"This paper presents a case history for the design, construction and long-term performance monitoring of a driven prestressed concrete (PSC) piled foundation supporting a large liquefied natural gas (LNG) tank in Savannah, Georgia, USA. Following a geotechnical investigation, a design stage pile test program was performed with three objectives: to study the densification effect from pile driving on the liquefaction resistance, to test axial and lateral pile capacities, and pile behavior under lateral loads. The test program comprised five piles driven on a test pad constructed adjacent to the tank foundation. Cone penetration testing (CPT) was performed before and after pile installation to test soil densification effects from the pile driving and liquefaction potential was re-evaluated based on the soil densities after pile installation. The axial load tests involved static load testing, high strain dynamic testing, and Statnamic testing. This paper presents the findings of the densification effects, compares results from different axial testing methods and discusses the procedures to use the load test results in the pile design. The paper also comments on the construction issues and presents performance data with 10 years of monitoring.1. IntroductionThe project site is located at the Kinder Morgan’s Elba Island LNG Terminal on the Savannah River which is three miles downstream of the downtown Savannah, Georgia. This LNG terminal was initially developed in the 1970s as an LNG import terminal. The facility includes five LNG storage tanks with two larger tanks which were constructed in 2003 and 2006, respectively. The terminal is currently being converted into a liquefaction and export facility. This paper discusses pile foundations for Tank D4 which is a double walled insulated steel tank built to hold one million barrels of LNG in 2003. This tank has an outer tank diameter of 258 feet, an inner diameter of 252 feet, and liquid height of 113 feet. A number of geotechnical challenges were present in the foundation design and construction.??The site is a typical coastal deposit site featuring a thick layer of very soft under-consolidated clay (up to 40 feet in thickness);??The bedrock is a couple of thousand feet deep;??There is a sand layer that is liquefiable under a high seismic design category (0.5% possibility of exceedance in 50 years)."

Jan 1, 1900

By Joel B. Dellaria, Justin R. Lewis

"No. 9 Walton is a new high-rise condominium building located in the Gold Coast area of Chicago. The adjacent building, Walton on the Park, featured 4 levels of below grade parking and utilized a secant pile wall with integral drilled shafts to support the exterior columns. The earth retention system (ERS) for No. 9 Walton also employed a secant pile wall in combination with drilled shafts. The excavation into the soft Chicago clays varied in depth from 9.75 m to 12.5 m (32 feet to 41 feet) below grade. The temporary excavation support used internal braces from the new secant piles to the existing foundation system of Walton on the Park to provide earth retention. Engineering teams for both projects worked together to design the bracing scheme and connections to ensure that the new excavation and internal bracing would not overstress any elements of the existing structure. Further complicating the project, immediately to the west of the project was a historic church founded on shallow spread footings which required underpinning to minimize movements.The project involved three different building owners, small values for acceptable wall movement, an extensive monitoring program and the challenges of merging two earth retention systems. The subsurface conditions at the site, the adjacent structures, the excavation, and the performance are described. A summary of the design methods and the expected movements of the ERS are discussed, and the performance monitoring system is described. Overall, the ERS performed better than expected with less than 1 inch of measured lateral wall movement during and after the excavation was completed. Measured performance of the ERS is compared to the predicted performance and to the performance requirements for the project.INTRODUCTIONNo. 9 Walton is a new high-rise condominium building in Chicago located in the Gold Coast. The building has 3 levels of below grade parking and 36 levels of living space above grade. Developers originally slated the project to be Phase 2 of the Walton on the Park development built in the mid 2000’s, using portions of the existing foundation system for development of the new structure. However, the housing market crash in 2007 prompted cancellation of Phase 2 of the Walton on the Park development. The property sat undeveloped until 2015 when design and construction for No. 9 Walton began under a new development and design team. The project team completed foundation excavation and below grade structures in 2016 with the first units of the building turned over to new homeowners in 2017.The structural design for No. 9 Walton consisted of reinforced concrete columns and slabs, supported laterally by a heavily reinforced concrete central core. Drilled shafts to rock supported the interior columns and core with the exterior columns and foundations integrally included in the earth retention system. The structure had a below-grade footprint of approximately 1,490 m2 (16,000 ft2). The general excavation extended 9.75 m to 12.5 m (32 feet to 41 feet) below street level with the deepest portions at the central building core mat foundation."

Jan 1, 2017

By P. Lefebvre, J. Sargent, K. Major, B. Darnton

"Stillwater Mining commenced mining operations at Nye, Montana in 1987 for the recovery of platinum and palladium. Exploration identified that the J-M Reef extended for 43 km. In 1998 Stillwater Mining made the decision to develop the East Boulder mine complex, located approximately 13 miles from the Stillwater mine complex at Nye, to increase production. This paper describes the design, construction, and start-up of the East Boulder process plant.INTRODUCTIONStillwater Mining Company have been producing Platinum and Palladium from their Nye, Montana operations since 1987. The mine production from Nye had been increased in stages with mine production being delivered through several portals and one vertical shaft.The deposit is narrow veined which prevents the application of bulk mining methods and thus limits the production capabilities.In order to increase the production of platinum (Pt) and palladium (Pd) Stillwater made the decision to access the ore from the J-M Reef from the East Boulder site. The East Boulder mine site is located about 21 km (13 miles) from Nye, however as shown in Figure 1, the travel distance is closer to 188 km (114 miles). Distance, on strike, and space availability at Nye precluded the expansion of the Nye concentrator to handle the increased mining rate and supported the decision to install a new concentrator at East Boulder."

Jan 1, 2003

By E Villaescusa, C Drover, I Onederra

Development face destress blasting is a construction technique in deep mining, which aims to prevent, reduce the frequency, or manipulate the timing of violent, stress-driven rock mass instability at the face. This paper presents a destress blasting design concept that was optimised for the specific rock mass conditions of a deep mine using the Hybrid Stress Blasting Model (HSBM) software. The design was then implemented in an area of the mine where stress-driven instability of the face regularly occurred during development. An adjacent tunnel was constructed in parallel without destressing, within the same rock mass conditions, as a control. The rock mass response to each excavation was quantitatively compared using high-resolution local seismic monitoring. Visual observations of the fractures created by destress blasting were also made. The analysis indicated that destressing reduced both seismicity and the rock mass stiffness ahead of the face. This was inferred from the spatial broadening of the development seismogenic zone and the typically significant reduction in the spatial density of seismic events. Seismic source mechanism analysis also indicated that destress blasting generated a much wider variety of failure modes than conventional blasting. Most seismic source mechanisms following destressing were associated with natural joint structures. A relatively small portion were consistent with newly created blast-induced fractures. The greater diversity of rock mass failure modes associated with destressing implied a lower potential for stain-energy accumulation within the rock mass at the face, and thus a lower risk of hazardous instability. Observations of visible rock fracturing indicated that the major principal stress influenced the damage intensity on natural geological structures within the destressed zone, and that numerical predictions of radial fracturing limits made by HSBM analysis were realistic representations of the real blasting performance.

Nov 29, 2022

By S. A. H Tyrrell, R. Rotzinger

"Taseko Mines Limited recommenced operation of the Gibraltar copper-molybdenum mine in 2004 and embarked on series of development projects to modernize the mine and increase throughput capacity. The Gibraltar Development Plan 3 (GDP3) project included a second stand-alone copper-molybdenum concentrator, a stand-alone molybdenum separation plant and associated services. Ausenco was contracted to commence the detailed design in 2Q2011, commissioning commenced in 4Q2012 and first ore was processed in 1Q2013. This paper discusses the design, implementation and commissioning of the GDP3 Concentrator.INTRODUCTION The Gibraltar Mine (Gibraltar) property is located in the Cariboo Region of south central British Columbia, approximately 360 kilometers northeast of Vancouver. The site is accessed via an 18 kilometer paved road from the town of McLeese Lake, which is located on the province’s main north-south highway between the cities of Williams Lake and Quesnel. Gibraltar was originally developed by Placer Development and commenced production in 1972. Gibraltar was acquired, while on care and maintenance, by Taseko Mines Limited (Taseko) in 1999 during a period of unusually low metal prices. Taseko recommenced operations at Gibraltar in 2004, and embarked on series of development projects to modernize the mine and increase throughput capacity. The 1972 Gibraltar process flowsheet incorporated two-stage crushing followed by rod and ball milling and flotation. In 2008 Gibraltar completed their first development stage that included the installation of a SAG mill, converting the existing rod mills to ball mills and adding additional flotation capacity. Gibraltar continued development with the installation of an in-pit primary crusher, expansion of the bulk regrind circuit, expansion of the cleaner flotation circuit, replacement of the tailings pumping system and replacement of the concentrate filters and dryer."

Jan 1, 2014

By Douglas R. Hardin, Stanley L. Worst, Joanna Mason

A challenging earth retention project presented itself in Washington, DC in the backyard of the historic House of the Temple (The Scottish Rite of Freemasonry, Supreme Council 33°). Located at 15th St NW and S St NW, a forty-foot-deep underground basement was to be installed adjacent to the existing Temple, a historic Carriage House structure dating back to the 1800’s and across a narrow alley from a four-story brick apartment building. The unique geology of the site included typical urban fill overlying a mixture of loose alluvial soils underlaid by dense marine deposits of the Potomac Formation. The clay, sand and gravel of the Potomac included nested boulders up to three feet in diameter. Design of the earth retention system accounted for ground conditions, installation methods and estimated movement of the system and adjacent structures. Anticipated ground water and unanticipated water from leaky sewers also proved obstacles to overcome during construction. Soldier beams were installed using a variable momentvibratory hammer to minimize disturbance to the historic and sensitive structures. Monitoring of the existing structures included both seismograph and optical targets during installation of soldier beams and as the excavation progressed. Micropiles drilled into the Potomac Formation were a part of the permanent foundation for the new structure. This local case history will delve into the details of the successful design, installation, and performance of an earth retention system and micropiles in a historic and highly congested urban environment.

Oct 1, 2022

By Marco D. Boscardin, Kenneth A. Pidgeon, Adriane G. Boscardin

"Hollow bar tiebacks can offer an economical alternative to conventional solid bar and strand tieback systems for use in temporary excavation support construction. However, the limitations associated with the installation of hollow bar tiebacks require special attention during design, construction and load testing to verify conformance with conventional performance and proof testing criteria (PTI, 2014). In particular, providing a reliable free length is complicated by the 10-foot (3-m) -long, segmental, couplingto- coupling nature of the free length sheath in the hollow bar system, and addressing the fully grouted annulus of the bond zone and the free length zone at the end of installation are key concerns. In addition, it is often more convenient to install a greater number of more closely spaced, lower capacity tiebacks with the hollow bar system, compared to conventional tiebacks. This paper examines how these issues were addressed for a project involving a 60-foot (18-m) -deep sheet pile excavation through a highway embankment and a 70-foot-deep sheet pile and soldier pile and lagging excavation through a railroad embankment, both supported by a hybrid system of hollow bar tiebacks and hollow bar soil nails. The project involved approximately 300 tiebacks and 400 soil nails.INTRODUCTIONEngineers Construction, Inc. (ECI), constructed a pair of 32-foot (9.8-m) -wide (clear span), 30-foot (9- m) -high (21 feet (6.4 m) above the stream bed), cast-in-place concrete arch culverts as a design-build project for the Vermont Agency of Transportation (VTrans) in East Ryegate, Vermont. The new culverts replaced an existing 8-foot (2.4-m) -wide by 6-foot (1.8-m) -high cast-in-place concrete culvert under US Route 5 (RTE5), and twin, 2-foot (0.6-m) -wide by 5-foot (1.5-m) -high granite block culverts under the Washington County Railroad (WACR) alignment. The culverts convey Manchester Brook eastward, through the embankments for RTE5 and the WACR, on its way to the Connecticut River. The Connecticut River is located approximately 100 feet (30 m) east of the WACR embankment. The existing structures were undersized and backed up water behind the embankments during high flow events; and often trapped debris that flowed down the brook and became clogged. The existing culverts also had cracks and openings that have resulted in the loss of ground into the culverts and the formation of sinkholes in the sides of the embankments. Moreover, the reason for the large cross-sectional dimensions of the culverts was to make them of sufficient size and openness to encourage the migration of fish up the stream to spawn. The culvert through the RTE5 embankment is 144 feet (44 m) long, and the culvert through the WACR embankment is 128 feet (39 m) long, with a 57-foot (17.4-m) -long by 32–foot (9.8- m) -wide by 17-foot (5.2-m) -deep 10 feet (3 m) deep above the stream bed) open channel section between the two culverts. A plan view of the culvert alignment is presented in Figure 1."

Jan 1, 2016

By B Nielsen, H Lehto, B Musuku

"The demand for fine and ultra-fine grinding associated with the processing of more challenging, finer grained orebodies and the global driver of minimising energy consumption has been an increased focus in our industry. Outotec’s stirred milling technology, the high intensity grinding mill (HIGmill™), was launched in 2012 in response to this industry need. First Quantum Minerals Ltd selected HIGmill™ technology for its Kevitsa mine in Northern Finland. The 700 kW mill is grinding copper rougher concentrate to improve copper/nickel separation and copper recovery. Selection of the HIGmill™ followed mineralogy analysis and laboratory and pilot testing for HIG milling in parallel with flotation tests to determine optimum grind size and energy input.The paper discusses the challenges and successes of the test work, manufacture, installation, commissioning and subsequent operation of the mill. Grinding performance is presented and a comparison between predicted and operating energy efficiency is made. In addition, the various steps to optimise wear rate and minimise maintenance and downtime are made, with particular reference to internal geometry of the mill.Citation:Nielsen, B, Lehto, H and Musuku, B, 2016. Design, Installation, Commissioning and Operation of Fine Grinding Technology at the Kevitsa Mine, in Proceedings 13th AusIMM Mill Operators’ Conference 2016, pp 59–66 (The Australasian Institute of Mining and Metallurgy: Melbourne)."

Oct 10, 2016

By Fallins J

THE John Darling Colliery, owned by The Broken Hill Proprietary Company Limited, is situated 12 miles south of Neweastle, NSW and about 1 mile from the ocean. The area of the holding is approximately 10,000 acres, about half of which underlies the Pacific Ocean. The area was proved to be coal bearing by diamond drill boring: this method not only proved the coal to exist, but gave the depths from which could be calculated. It also proved the existence or otherwise of heavy faulting, which is a very important factor in the design of the underground lay-out of a mine. The location of shafts had to be carefuIly studied, and, before final selection, the following salient points had to be considered:Railway communications.Flood waters.Boiler feed water.Surface buildings.Probability of coal washing.Underground haulage arrangements.Lengths of roadways from a ventilating viewpoint.Before the shaft sites were finally selected, an underground design was prepared to determine the direction of the main drives in relation to the boundaries of the holding, and the of the coal seam: the latter, being an important factor in this particular locality, was ascertained by a geological survey of rock outcrops in the neighbourhood. Size of shafts was the next subject for consideration. This was determined by output, number of seams to be worked, amount of ventilation required, and, on...

Jan 1, 1930

By Stephen Buttling

The construction of a water treatment plant in Dandenong, Victoria, required detention tanks and a pumping well. The design provided by the Engineer used conventional rectangular cast-in-situ reinforced concrete walls within a sheet piled cofferdam. It was decided to construct the tank and shaft using the diaphragm walling technique as an alternative and, for the shaft in particular, this involved a “circular wall”. Except where cutters are used, joints in diaphragm walls have to be made between colinear panels, with waterproofing provided by dumb-bell water stops held within trapezoidal forms. This means that the circle has to be approximated by a number of straight sides, which in this case was twelve. The requirement was to design the reinforcement for the strange shaped panels. Finite element analysis was used, in the first stage using an axisymmetric model to determine the profile of lateral earth pressures with depth. In the second stage a horizontal slice was modelled, without gravity which normally operates from the top to the bottom of the page. By considering appropriate possible earth pressures at different depths, a range of bending moments was calculated, which was used by the structural engineers to design the rebar. The tanks were successfully constructed, and inclinometers were installed in both the tank and the shaft. Measured deflection profiles show that the design was moderately conservative.

Nov 1, 2022

By John S. Pack

The application of square shaft helical piers in expansive soils is a standard of practice in many areas of the United States. Over 20 years of performance monitoring show exceptional performance and economy will result if proper design procedures, specification requirements and installation procedures are followed. This is true for new foundations and the repair of existing foundations, including lightly loaded wood-frame structures on expansive soils. Proper design includes: 1) site geotechnical characterization, 2) pier layout such that each pier is loaded to its maximum design capacity, 3) maximize spans between piers, 4) minimize the number of piers, 5) isolate the structure from the expansive soil with an appropriate void zone below all grade beams, slabs or other components that would otherwise be in soil contact and 6) utilize only single helix piers. Proper specification employs a performance specification that specifies: 1) the design load on each pier with a suitable safety factor, 2) the minimum installation torque, typically 4,000 ft-lbs (5.4 kN-m), or refusal, 3) a minimum pier shaft steel Fy = 70 to 90 ksi (483 to 621 Mpa) and pier helix steel Fy = 80 ksi (552 Mpa), 4) 1.5 to 1.75 inch (38.1 to 44.5 mm) square shafts, 5) smooth shaft surface, 6) the ICC Evaluation Report (ER) number of the manufacturer and 7) the manufacturer ISO 9001 certification for material quality control. Proper installation requires: 1) equipment with sufficient axial compression force (crowd) on the pier shaft so the helix engages the soil and advances to the specified minimum installation torque or refusal, 2) additional specialized techniques for expansive soils and 3) qualified specialty helical pier installation contractors experienced in expansive soils who submit and utilize pier configurations, techniques and equipment that will most effectively and economically meet the specified performance.

Jan 1, 2007

By Lyne Côté, Jose Adante

"The Caribou underground mine, 50 km west of Bathurst, the Restigouche open-pit mine, another 30 km west and the concentrator located at the Caribou mine site resumed operations in July 2007 after a nine year shutdown. The Caribou operations achieved commercial production on Jan 1. By June, 2008, all metallurgical targets had been achieved or surpassed with the production of lead and zinc concentrates assaying approximately 50% Zn and 45% Pb respectively with recoveries exceeding 80% for Zn and 70% for Pb.The deposit features very fine-grained massive sulphide mineralization, which in the past has proven difficult to process. ISA Mill Ultra Fine Grinding Technology in combination with conventional flotation technology is used to process these complex oresSeveral modifications arising from experience gained from past operations, an extensive research project at Lakefield Research and post startup flow sheet and reagent alterations have been employed to achieve this break through performanceThis paper describes the design, start up and optimization of the Caribou operations including the many challenges faced including the flotation of mineral particles with K80s ranging from 35µm to 8µm.HISTORICAL BACKGROUNDThe Caribou massive sulphide deposit was discovered by Anaconda geologist Cam Cheriton in 1959. Anaconda initiated an extensive underground exploration and discovered a super gene copper blanket which was developed into a small open-pit mine-mill operation that ran from 1970 until the depletion of the copper ore in 1974. East West Minerals, an Australian public company, purchased the mine in 1986 and operated for only seven months producing a single bulk lead-zinc concentrate. In 1995, Breakwater acquired the Restigouche Open pit and Caribou underground deposits. Breakwater began milling operations in July 1997 but Caribou Mine failed to commercialize production, and the company decided to shut it down in August 1998, because of declining metal prices. The mill was plagued by mechanical and design problems, but deficiencies in metal recoveries prevented the operation from reaching desired levels."

Jan 1, 2009

By Robin Dill, Julian Prada, Kathryn Kelly, Brian Hann, Todd Moline

Narragansett Bay Commission’s (NBC) Pawtucket Tunnel Project includes construction of the 11,600-ft long, 30-ft ID, deep rock tunnel. This paper presents insight into the features and benefits of lump-sum, design-build that led NBC to select it as the project delivery method. The use of a design-build contracting process that included proprietary meetings to discuss and obtain feedback on Alternative Technical Concepts as well as to facilitate reaching consensus on modifications to the GBR-B is also described. The discussion includes features and benefits of design-build process that not only addressed NBC’s desired outcomes, but also allowed the Design-Builder to propose several innovative changes to the Base Technical Concepts included in the bid documents, and to develop a GBR-C that was compatible with their proposed means and methods of construction and addressed what they believed to be the more significant subsurface risks on the project.

Jun 13, 2023

By Rick Deschamps

The Block 76 project includes the demolition and redevelopment of an entire city block for mixed use retail, office and residential properties directly adjacent to Historic Temple Square in Salt Lake City, Utah. Excavation was carried out 65 ft below street grade and by as much as 50 ft directly below adjacent buildings supported by shallow foundations. Movements of the earth retention system and adjacent buildings were monitored in real time using automated equipment which complemented traditional geotechnical instrumentation. In the areas immediately adjacent to the existing buildings 9 stories or greater, anchored diaphragm walls were employed. Areas of the site not supported by diaphragm walls employed a soil nail wall system. Jet grouting was used for water cutoff in lieu of dewatering along the north and east sides of project. In total, the earth retention scope included 45,000 sq. ft of diaphragm wall, 104,000 sq. ft of soil nail wall, and micropile underpinning of 3 buildings. This paper provides an overall description of the Block 76 project. A detailed account is provided of the technical and commercial lessons learned. The project provided a unique example of how an owner can receive best overall value by acceptance of some technical risk up front. Benefit was gained by allowing the contractor to reduce contingencies within the bid from unknowns on a fast-track project.

Jan 1, 2009

By David P. Sauls

Design-build contract delivery provides unique opportunities for efficiencies in pile foundation design and installation. The Louisiana Department of Transportation and Development (LADOTD) US Highway 90 at Louisiana State Highway 85 (US90/LA85) intersection was contracted under the design-build delivery system, in part to take advantage of these efficiencies. As one of five projects recognized by the Design Build Institute of America (DBIA) when it honored LADOTD as its 2011 Transportation Owner of the Year in the highway/bridges category, the design-build method provided a way for this project to be ?shovel-ready?, which enabled the LADOTD to secure American Recovery and Reinvestment Act (ARRA) funding. This paper describes the benefits this project gleaned from the design-build process, which included synergy, schedule, design and construction efficiencies, and team building. Interlaced with design and construction of precast prestressed concrete (PPC) piling in compressible southern Louisiana soils, the design-build process rapidly translated computations to cost and schedule savings. A robust quality assurance program using Pile Driving Analyzer (PDA) equipment to evaluate pile set-up provided expedited acceptance of bridge bents and advanced construction schedule. Data evaluation includes analyses of PDA data obtained from 1-hour, 24-hour, 7-day, 14-day and 6-month restrikes of the project test pile.

By T. Plikas, T. Porretta, M. Al-Dojayli, B. Pretorius, J. Woloshyn, H. Ghorbani

"Water-cooled ducts represent an integral part of high temperature off-gas systems in metallurgical processes. Typically, off-gas enters these ducts at significantly elevated temperatures; therefore, water cooling may be required to maintain the duct skin temperature within allowable design limits. These off-gases are typically of high mineral content that could lead to dust buildup, and there is a possibility of slag buildup / molten metal splashing. Therefore, dust cleaning provisions may be necessary in order to remove or minimize accretion on the duct wall, which could otherwise impact the water cooling and the system process efficiency. These ducts may have complex geometry and experience a wide range of loading, including gravity loads, water and gas pressures, cyclic thermal loading and dynamic impact forces. Consequently, the thermo-mechanical assessment of such water-cooled ducts is critical and requires consideration phenomena such as high temperature gradients, potential nucleate boiling, thermal ratcheting and fatigue failures. Such assessment is not comprehensively covered by design-by-rule design codes and guidelines due to its complexity. This paper presents a successful implementation example of design-by-analysis methodology to improve the design and extend the life of a water-cooled furnace transition duct using Computational Fluid Dynamics (CFD) and Finite Element Analysis (FEA).INTRODUCTION Water-cooling represents an important part of high temperature off-gas systems in metallurgical processes. Typical temperatures of the off-gas in the furnace uptake are in excess of 1400°C, and thus there is a need to maintain the water-cooled duct and jacket skin temperatures within their material allowable design limits. Water-cooled channels have been used effectively in arc furnace roof design (Sosonkin et al., 1972; Smolyarenko and Khainson, 1988) and other furnaces as well as in furnace fuming jackets (Scholey et al., 1994). The design of these systems was based on one-dimensional analysis to ensure sufficient cooling is available under extreme furnace conditions (Smolyarenko and Khainson, 1988; Scholey et al., 1994). With advancement in furnace and fuming system designs, water-cooled duct designs have become more complicated in geometry. Numerical techniques, such as three-dimensional fluid flow and heat transfer modeling, are therefore needed to more accurately calculate water velocity, temperature and convective heat transfer coefficients in the water-cooled channels (Haywood et al., 2002; Henning et al., 2010). This is of particular importance around geometric corners where stagnant water flow may lead to local nucleate boiling at the critical heat flux, causing hot spots (Bergman et al., 2011). High wall skin temperatures increase the risk of failures due to thermal stresses as well as increasing corrosion rates (Gelfi et al., 2012), leading to costly equipment downtime and potential safety risks."

Jan 1, 2017

By Russel Delmar, Rick Everdell, Harry Charalambu, John Tait

Award of the Design/Build Agreement for construction of Ontario Power Generation’s (OPG’s) Niagara Tunnel Project was made after an intensive 8-month international procurement process. The 14.4-m diameter × 10.4-km long rock tunnel will divert 500 m3/s of water from the Niagara River to the Sir Adam Beck hydroelectric generating complex. The procurement process and Design/Build Agreement included features to address the owner’s requirements regarding risk allocation and cost and schedule certainty, while encouraging innovative ideas from the industry, both technically and commercially. The process included an international expression of interest and prequalification, followed by an invitation for design/build proposals to qualified proponents, and comprehensive proposal evaluations and negotiations with several respondent proponents. An honorarium was provided to the unsuccessful participants in the proposal stage. The resultant negotiated Design/Build Agreement includes Owner’s Mandatory Requirements, negotiated contract terms and conditions, performanceincentive bonuses and liquidated damages for schedule and water delivery performance, a multistaged Geotechnical Baseline Report, joint risk management, references to preexisting community impact agreements and measures to reduce impact on tourism. It also addresses regulatory approvals and permits, an owner controlled insurance policy that required reference to the International Tunneling Insurance Group (ITIG) Code of Practice for Risk Management as a condition of coverage, site specific safety, security and environmental plans, formal team building, a dispute review board, and escrow documentation.

Jan 1, 2007

By Cathy Aimone-Martin, Frank Achuff

The New Mexico Department of Transportation (NMDOT) and the Federal Highway Administration (FHWA) have let a contract to Sierra Blanca Constructors for a design / build contract along 38 miles US 70 in Lincoln County, New Mexico. The project will improve safety of travel along the corridor and facilitate the adopted economic development goals of the state. Proposed improvements include widening the existing highway from two lanes to four lanes, providing left turn lane options at selected locations, improving access for businesses and residences, aesthetically enhancing retaining walls, improving storm drainage and replacing the existing pavement with a 30 year mechanistic imperialistic perpetual pavement design. The US 70 Hondo Valley highway project is situated in a narrow valley with steep limestone walls, passes along a Scenic Byway and numerous historic ranching communities with structures that date back three centuries. The scope of work included requirements to monitor and mitigate blasting, noise, and vibrations. The contract was very presumptive with regard to blasting design and procedures. These included visual impact mitigation to treat and stabilize slope cuts, the Migratory Bird Treaty Act protecting roosting and nesting birds from airblast, and the protection of historic and cultural features such as acequias, wells, and structures. Public involvement affecting the rock blasting design has come from citizen task forces and committees concerned with highwall aesthetics and preserving the scenic byway and cultural resources. Constraints placed on the blasting program from agencies and the communities are often at odds. For instance, blasting must produce stable yet natural-looking walls to preserve aesthetics. Restrictions have been placed on pre-splitting and smooth-wall blasting yet safe slope are of the highest priority. This paper presents details of the design/build process undertaken by the contractors to conduct blast rock in an environmentally sensitive region. Blast designs consistent with good construction practices and used to comply with the many federal and state highway stipulations are described.

Jan 1, 2004