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By T. Bajpayee, L. Prosser, A. Iannacchione

Reducing the number of roof fall injuries is a goal of the NIOSH mine safety research program. Central to this effort is the development of assessment techniques that will help to identify the nature of the risks associated with working under potentially hazardous roof conditions. This paper discusses a method to determine the roof fall risk using a qualitative risk analysis technique. The ability to determine roof fall risk has been a long-standing goal of safety professionals and can provide the kind of information, needed by on-site personnel responsible for worker safety, to mitigate roof fall injuries.

Jan 1, 2007

By J. K. Atherton

If the metals sector is to contribute successfully to sustainable consumption we must adopt principles and practices which address the entire life cycle of the materials we produce. Progress must be founded on a sense of shared responsibility for the resources we utilize and the materials we create - it is this integrated approach which lies at the heart of materials stewardship. Materials stewardship means mining and metals companies producing materials in a responsible manner and then working with others, beyond their site, to ensure that the downstream material flows and applications are managed properly to create maximum societal value. In September 2006 ICMM published 'Maximizing Value: Guidance on implementing materials stewardship in the minerals and metals value chain'. This document takes a practical view presenting structured guidance as well as good practice case studies. In the publication, materials stewardship is described in terms of the range of activities that can be undertaken to ensure that all parties work collectively toward the responsible use of metal and mineral resources. This paper introduces the materials stewardship concept as set out in `Maximizing Value' and describes the business case for implementation as well as the ICMM framework for promoting materials stewardship.

Jan 1, 2007

By W. Miles

Introduction From a historical perspective, bentonite is the common rock term for various uses and applications. Its name originates from water-based muds near Fort Benton used for lubrication of wagon wheels during the 19th century migration to western territories (which are presently part of the United States) when the pioneers ran out of axle grease. From a clay mineralogy perspective, bentonite is composed primarily of montmorillonite, an expandable magnesium aluminum silicate clay mineral. When magnesium occupies an octahedral structural site that usually contains an aluminum atom, a negative charge is created. In order to neutralize negative charges, cations are drawn to the interlayer surfaces between clay mineral sheet structures. Modern applications for bentonite depend on the sodium or calcium cation populations and other characteristics of the clay mineral. When sodium is the dominant cation, the material is also called sodium bentonite, also known as swelling bentonite, western bentonite or Wyoming bentonite. When calcium or magnesium is the dominant cation, the material is called calcium bentonite, also known as nonswelling bentonite or southern bentonite. Swelling bentonite is recognized for its rapid hydration of interlayer sodium and subsequent dramatic expansion up to more than 20 times its original volume. Low shear can then disperse the hydrated sodium bentonite to form suspensions that increase viscosity and suspend solids. However, when shear is subsequently eliminated a sodium bentonite slurry gels. Characteristically, nonswelling calcium bentonite has relatively poor hydration properties and thus low expansion of the clay mineral. When subjected to low shear, calcium bentonite exhibits very little viscosity and poor suspension. Additionally, when shear is subsequently eliminated no more than minimal gelling takes place. The domestic and export markets related to both swelling and nonswelling bentonite are discussed below.

Jan 1, 2007

By A. Davis, C. Webb, J. Sorensen

The abandoned Belle Eldridge Mine near Deadwood, South Dakota, is on land controlled by the U.S. Bureau of Land Management (BLM). The mine produced lead and zinc during the first half of the 1900s. Because of acidic drainage and elevated levels of metals in tailings and waste rock, the site was evaluated in 1998 and 1999. After evaluation, the mine was remediated during 1999-2001 by the BLM. Since remediation, values of pH in water samples have been nearly neutral and specific conductance values have been much lower than before remediation. The Grizzly Gulch forest fire of July, 2002, consumed much of the Belle Eldridge site and resulted in greater than normal erosion and sediment flushing during the months following the wildfire. Had the site not been remediated and the tailings emplaced within a capped repository, generation of acidity and off-site migration of heavy metals within sediments could have been severe at downstream locations.

Jan 1, 2007

By C. Liu

Corrosion behavior of the stir zone in a friction stir weld of dissimilar A12024/AZ31 alloys was investigated in the immersion test in distilled water (pH=6) for different times. Microstructures and the distribution of chemical elements were analyzed by scanning electron microscopy (SEM) and energy dispersive X-ray spectroscopy (EDS). Due to the difference in the corrosion potentials between A12024 and AZ31, the AZ31 alloy constituent in the stir zone was susceptible to the corrosion attack in the distilled water. The corrosion attack was found to occur in the narrow region of the AZ31 alloy adjoining the A12024 region, where there was a low ratio of anode-to-cathode surface area. The corrosion attack became more severe in the AZ31 alloy regions with increasing immersion time. The A12024 alloy region in the stir zone of the weld was protected by cathodic reactivity due to sacrificial anode AZ31 alloy.

Jan 1, 2007

By Monique Nykamp

"INTRODUCTIONTerminal 46 is located just south of downtown Seattle, and is one of the Port of Seattle’s busiest container terminals. The Terminal 46 Redevelopment Project was undertaken to replace the existing 15-m-wide (50 ft) cranes along the apron with 30-m-wide (100 ft) cranes, which can unload larger, post- Panamax ships. The project included upgrading the existing waterside crane rail with new piles and constructing a new land-side rail behind the sheetpile bulkhead. The new piles had to be installed adjacent to the existing apron without causing damage, which was a signifi cant geotechnical challenge due to the soft soil conditions at the site. An instrumentation program performed during the test pile program evaluated this challenge and allowed for the development of specifi c production pile installation procedures that had the least possible effect on construction costs and schedule.SITE HISTORYThe site lies along the west side of Elliott Bay, north of the mouth of the Duwamish Waterway. Prior to development, this area was part of the tide fl ats where the Duwamish River drained into Elliott Bay. Prior to 1970, there were several existing timber piers and structures in the area. In the 1970s, the Port of Seattle constructed a 900-m-long (3,000 ft), 30- m-wide (100 ft) apron to support fi ve, 15-m-wide (50 ft) container cranes. The contained backland area was then fi lled with dredged spoils (sand and silt with organics) and the upper 5 to 20 m (16 to 65 ft) backfi lled with sand and gravel.The existing apron was constructed using 0.4 m (16 in) octagonal prestressed concrete piles to support the precast concrete deck and crane rails. The pile-supported bents were spaced at 6.1 m (20 ft), center-to-center, along the longitudinal direction. Pile lengths typically varied from about 20 to 40 m (65 to 130 ft) with 15 to 26 m penetration below mudline (50 to 85 ft penetration). The slope below the apron was constructed at about 1.75 horizontal to 1 vertical to allow for suffi cient water depth for cargo ships. In most areas, a riprap buttress was placed at the toe of the slope. A typical cross section of the apron is shown on Figure 2.Several stability, settlement and pile driving issues arose during the original construction of T-46 (Pita, 1983). Reportedly, movement of the submarine slope occurred during pile driving, resulting in settlement behind the bulkhead. Pile driving reportedly caused settlement of adjacent piles. In addition, some piles were “running” (dropping quickly under one hammer blow) during installation."

Jan 1, 2007

By Brian Fulcher

While tunneling in Europe has been a tradition for centuries, many companies and countries have embraced tunnel innovation with considerable vigor and creativity. Indeed, local needs and site conditions have provided the initiative for improved means, methods, materials and equipment to complete progressively more challenging projects. Many recently completed tunnels have expanded tunneling technology and contributed to the development of highly specialized and productive equipment ? such as the mixed-mode tunnel boring ma-chine (TBM) presently in operation at the SOCATOP A- [ ] 86 road tunnel and the high-pressure slurry TBMs for the Westerschelde Tunnel in the Netherlands and Hollandsas near Malmo, Sweden. This paper describes some of the key technologies employed by European tunnel builders and designers including the New Austrian Tunneling Method (NATM), advanced earth pressure-balanced (EPB) machines, pres-sure-faced (slurry) tunneling machines as well as ?hybrid? or mixed-mode TBMs. While these tunneling methods and equipment generally involve significant equipment investment, they may also involve highly trained, experienced and specialized tunneling and support crews as well as materials and tools specifically developed to supplement or complement tunneling performance. For example, mechanized pipe arch placement substantially improves ground support measures and NATM advance and on larger tunnel cross-sections.

Jan 1, 2007

By Terrence R. Udland, Russell D. Call

"Honored with a DFI 2006 Special Recognition Award, the Four Bears Bridge was constructed across Lake Sakakawea and opened to traffi c in September 2005. The very large lake size and severe winter conditions required an effi cient foundation design capable of resisting extreme ice loading and able to be effi ciently constructed in waters up to 90' deep (27.4m).DESIGNING FOR EFFICIENCYLocated in a remote area of North Dakota, the Four Bears Bridge replacement was a major undertaking for the North Dakota Department of Transportation, with dual goals of providing a new structure that would endure a severe environment, while enhancing the natural beauty of the area. Competing bids would achieve the best price for the owner, challenging the design team to creatively solve the engineering challenges unique to the site. Foundations for North Dakota’s new Four Bears Bridge had to accommodate water level fl uctuations of up to 40 feet (12m), along with extreme ice loading and be effi cient in order to be the low cost solution at the time of bidding. All three major criteria were achieved through the use of an effi cient ‘fl oating’ lost precast concrete cofferdam founded on steel pipe piles, which allowed the contractor to achieve the project schedule. The result is an award-winning bridge that is contextually sensitive to the environment. The bridge aesthetics pay tribute to the Three Affi liated Tribes, the Mandan, Arikara and Hidatsa, who reside on the Fort Berthold Indian Reservation, adjacent to the bridge site.The original Four Bears Bridge was located over the Missouri River near Elbowoods, the native grounds of the Three Affi liated Tribes. Construction of the Garrison Dam in the early 1950’s created Lake Sakakawea, a fl ood control project on the Missouri River, and resulted in the area being fl ooded. The bridge, along with many tribal members, was relocated to a site near New Town. The bridge provides the primary crossing of Lake Sakakawea and is a critically important transportation element for the residents of the Fort Berthold Indian Reservation. The relocated bridge had become functionally obsolete and not replacing it would require a detour of 170 miles (274km). The North Dakota Department of Transportation determined that it should be replaced. In order to achieve the most effective solution, the North Dakota Department of Transportation selected a design team responsible for the creation of competing steel and concrete designs that were competitively bid. The design team was led by Kadrmas Lee & Jackson, with FIGG responsible for the concrete bridge design, while Lichtenstein Consulting and Kadrmas Lee & Jackson completed the alternate steel bridge design."

Jan 1, 2007

By K. Delbeke

Within the framework of the EU Existing Substance (93/793/EEC) and REACH regulations EC/1907/2006), the copper industry initiated in 2000 a comprehensive Voluntary Risk Assessment of copper and several copper compounds. The Italian Government's Istituto Superiore di Sanità, reviewed the process and reports on behalf of the European Commission. Copper exposure levels to man and the environment from production of copper anodes and cathodes, copper powders and copper chemicals as well as fabrication and use of semi-fabrication products and down stream user products were collected across Europe. Environmental and human health effects data were obtained from literature as well as novel research programs and used to deduct safe threshold

Jan 1, 2007

By A. Deneys

This paper reviews industrial gases used in primary copper production. Copper smelting industrial gas demand has steadily increased since the first commercial oxygenconcentrate smelting in 1952 [1]. In copper production oxygen for smelting is the dominant industrial gas use followed by oxygen for converting. Nitrogen is finding increased use in copper smelters. Nitrogen is used for porous plugs for copper converting and anode refining [2-5]. Nitrogen can be used for concentrate drying [6,7] and is also used in some Ni-Cu smelters as a coolant in Peirce-Smith converting [8,9]. Industrial gas supply options of cryogenic or adsorbent based on-site plant or cryogenic liquid delivery are detailed.

Jan 1, 2007

By Theirry Bernard

The era of non-electric systems as an initiating system has revolutionised the blasting world by introducing a very safe initiating system that is reliable, with initiation sequence possibilities that are superior to those of purely pyrotechnical or electric systems. Electronic initiation has brought with it accuracy, programming and controls that were lacking in the non-electric systems. However, it has also led to a certain degree of complexity, which works against user-friendliness, sometimes introducing a few constraints that are balancing out the intrinsic performance of electronic detonators. The introduction of a hybrid initiation system, Electronic and Non Electric, offers accuracy, and flexibility that were lacking in non-electric systems, whilst removing the inherent complexity of electronic systems. This paper endeavours to summarise the advantages and disadvantages of non-electric and electronic initiation systems that have been recorded after years of experience on site. The paper will then describe how a hybrid system only keeps the advantages whilst eradicating the disadvantages, via a case study.

Jan 1, 2007

By C. Laughton

Construction of a Deep Underground Science and Engineering Laboratory(DUSEL) is proposed under the auspices of the US National Science Foundation(NSF). DUSEL will provide scientists and engineers with a research facility capable of supporting a broad spectrum of fundamental and applied research deep in the earth’s crust. Research partners are physicists, biologists and geoscientists. DUSEL research calls for the construction of a network of shafts, tunnels and caverns that will provide laboratory facilities at depths of up to approximately 2 kilometers. The Project is still in the planning stages but, the initial experimental program is taking shape and conceptual designs have already been developed at two hard rock mine sites. This paper discusses the overall program and key engineering tasks being developed to support the construction of deep, large-span caverns. These caverns will house a new generation of physics experiments. As currently scoped, the experiments call for the excavation of permanent caverns with spans of up to 60 meters, sited at depths in excess of a kilometer.

Jan 1, 2007

By J E. Everett

At BHP Billiton Iron Ore Newman Joint Venture (NJV) ore is railed from four separate mine operations in the Newman area to Port Hedland, where the ore is screened, crushed and blended to produce lump and fines NJV products. Each mineÆs grade varies separately, so it is important that a centralised system is in place to control the overall blend and ensure that the products meet customer expectations. It is important that grade- related decisions are built into the normal production process and have minimal impact on production rates. A continuous stockpile management system (CSMS) covering the whole NJV production process is used to generate the daily crushing schedule, taking into account all currently available ore sources. Innovative additions to the CSMS provide more accurate information to support decision making by the mine schedulers; for example, blasthole estimates are continually adjusted for bias compared to crusher and port rake grades; lump-fines (L-F) grade split and beneficiation plant upgrade algorithms are updated on a continuous basis, and the dilution effect, which impacts on reported port rake grades, is removed.

Jan 1, 2007

By Lon Santis, David Leidel, John Tatom, Meredith Hardwick

This paper describes the development and methodology of the Institute of Makers of Explosives’ Safety Analysis for Risk (IMESAFR), a risk analysis software program for commercial explosives operations. IME is a nonprofit safety and security association devoted to the safe and secure manufacture, transportation, storage, and use or disposal of commercial explosives in the US and Canada since 1913. The software methodology’s basis is the U.S. Department of Defense Risk Based Explosives Safety Criteria Team’s Safety Assessment for Explosives Risk (SAFER) software. A diverse group of industry and government experts contributed to modifications to SAFER that reflect commercial operations. IMESAFR is intended to supplement the American Table of Distances (ATD) and offer standardized methods of managing risk from a wide variety of commercial explosives operations where the ATD does not apply. The modifications made to SAFER primarily involved the addition of commercial activities and potential explosives sites (PES). A review of commercial explosives accidents and operations over the last 20 years served as the basis for establishing probability of event values. An industry survey of commercial PES types in the U.S. and Canada was conducted to identify and address critical differences in commercial structures as compared to the military structures in SAFER. The paper concludes with discussion of the potential uses for quantitative risk analysis (QRA) and a description of other explosion effects software

Jan 1, 2007

By A. M. Esteves

This paper addresses the question ?What constitutes the right level of investment in community goodwill?? Mining companies are still grappling with this subject even though the business case for community investment has been accepted at a general level, as a strategy for competitive differentiation, risk mitigation and a desire to deliver - and to be seen to deliver - a ?net benefit? to affected communities. Gaining senior management commitment to long term social projects, by definition characterized by uncertainty and complexity, is made easier if projects are shown to benefit the site?s strategic goals. Case study research amongst mining companies, including interviews with social investment decision-makers, has assisted in developing a SI-DAT (Social Investment Decision Analysis Tool), a decision model for evaluating social projects in order to create value for both the company and community. Multi-criteria decision analysis techniques integrating business planning processes with social impact assessment have proved useful in assisting mining companies think beyond seeking access to required lands and peaceful relations, to how they can meet their business goals and contribute to regional development.

Jan 1, 2007

By Issa S. Oweis

Two Towers are currently under construction in Central Moscow in the Russian Federation. Building A is a 96 story tower and Building B is a 65 story tower. The columns in both structures bear on a thick concrete mat that is supported on drilled shafts, 1.5 m in diameter. The shafts derive their capacity from weak limestone with layers of marl. Assigned allowable shaft loads were initially based on rock strengths that were later verified by load tests using the Osterberg Cell. One of the load tests was carried to near failure which allowed refining socket friction values that were later used in the design of Building A. All shafts were advanced using an auger and concrete placed in the dry. Grout tubes were placed with the reinforcing cage which allowed grouting of the limestone in contact with the shaft. Load sharing between the shafts and the mat was approximated using published methods as well as site specific finite element analysis. This paper covers the methodology of design, analysis of the Osterberg results to derive non-linear stiffness of the rock and differences between finite element analyses and results by approximate methods.

Jan 1, 2007

By R Shaw, R Williamson

Global iron ore demand, sparked by ChinaÆs rapid industrialisation and emergence as the worldÆs newest steel market, has seen iron ore groups investing heavily in production capacity as well as infrastructure. The success of these new projects depends heavily on reliability, competitiveness and quality control in an increasingly demanding trading environment. Furthermore, the iron ore industry continues to improve its competitiveness in mining practices, technology innovation and management processes. The continued fine tuning of these sectors will be critical to the success of the industry in the years ahead, and this mining sector will continue to demand process improvements from their service suppliers to maintain competitiveness. Automation offers a real solution to these demands. A crucial quality control element in mining, beneficiation, stockpiling and shipping stages is ensuring representative samples of ore are taken along each step of the process. When these samples reach the laboratory it is imperative that the sample is representative of the entire stream and that no induced errors occur. Examples of automation start with mechanical primary and secondary samplers in the run-of-mine processes through to sample tower and laboratory crushers, dividers and collectors. Automation is widely used in many forms to provide reliable and repeatable samples for analysis whilst providing a safer working environment. Laboratory automation systems in use today vary from simple linear systems to sophisticated robotic cells. Sample automation in the iron ore industry has resulted in many benefits for both producers and their customers. The most significant benefits have come in the form of higher safety standards whilst reducing sample error, sample handling and sample contamination during collection. These benefits have been further augmented by reliability and repeatability of automating the final sample preparation and analysis stage. Today these benefits are reflected in reduced costs of sampling and improvement in both turnaround time and quality of results, whilst complying with Australian safety and ISO sampling standards.

Jan 1, 2007

By R. Gurung, S. Asokan, Ch. V. G. K. Murty, R. Upadhyay

Tata Steel Limited which is Asia?s first and India?s largest integrated private sector steel company, as part of its vision to grow in related industries is also undertaking the Titania project. The project will involve mining, separation of ilmenite and other valuable minerals from the inland heavy mineral sands deposit in the Indian state of Tamil Nadu. The raw material will be beneficiated to synthetic rutile, titanium dioxide pigment and ultimately to titanium metal. The recently concluded feasibility study revealed that the deposit under consideration has 10.4%of total heavy mineral content and 15.2% slimes of the size below 63 µm, over an average sand thickness of 6.9 metres. The presence of about 15% slimes in ROM sand coupled with scarcity of water at the project site complicates the slimes handling/disposal system, requiring the development of an innovative, efficient and effective system for disposal of slimes. Mineral characteristics of slimes revealed the presence of kaolinite clay, which poses its own challenges in thickening/dewatering of slimes. This paper outlines the detailed studies conducted, including slime characterization, settling and thickening characteristics, and ge-technical studies to arrive at an efficient and effective slime handling/disposal system, with a view to plant saplings on the mined-out reclaimed land with species typically suitable to that environment.

Jan 1, 2007

By D. M. Aloi

In today's evolving and globalized world, mining companies are being pressured to move beyond compliance towards long-term sustainability and sustainable development. Companies are expected to "engage" with communities and measure the success of these engagements without a clear understanding of "how" to do this. This move, away from "Corporate" Social Responsibility (CSR) and compliance, develops more of a focus on "Community" Social Responsibility and sustainability. This shift in focus leads to the development of world-class projects that provide sustainable development for people, reduces the incidence of costly delays, and promotes good global citizenship for corporations. The process of "engaging" communities in mining project design and development leads to a stronger license to operate and sustainable development. To create this mutually beneficial relationship between communities and companies, communities must be "engaged" in the mining process as early as possible, preferably during the exploration or the concept phases. How to create this "engagement" remains elusive. How to measure the progress of this engagement is also problematic. The quantitative and qualitative metrics needed to measure both positive and negative impacts of the mining and community relationship will be discussed.

Jan 1, 2007

By D S. Scovira

The effect of blast vibration on highwall stability is a common concern for many open pit mines. Vibration in such a case is a typical near-field blast vibration situation. Vibration modelling in the near-field of a blast requires consideration of both the amplitude and frequency attenuation of waveforms with distance. Most existing blast vibration models are designed for far-field vibration and do not simulate the frequency attenuation and its effect on waveform shape. With the advent of electronic detonators it is desirable to quantify the effects of blast delay on the amplitude as well as the frequency of blast vibrations. A suitable modelling tool is proposed here. At present, a blast vibration model with double attenuations(amplitude and frequency) has been developed at Orica. The present model simulates the amplitude and frequency attenuations separately using different transfer functions. The amplitude attenuation is modelled according to the non-linear relation between the peak particle velocity (PPV) and the charge weight scaled distance established from the signature hole vibration. The frequency attenuation is modelled with the signal broadening based on KjartanssonÆs transfer function û a linear model for attenuation of waves. The model is capable of taking multiple sets of signature waveforms as input to improve the modelling accuracy of the wave propagation in the geology at a site. The screening effect of the earlier firing holes in the path of a later firing hole is taken into account on not only the amplitude, but also frequency attenuation. The present blast vibration model is suitable for modelling both near-field and far-field blast vibrations. It yields reasonable agreement with measured field data for the near-field vibration examples discussed.

Jan 1, 2007