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By A Jurg, F Leclercq

The total drill and blast concept is widely known in the mining industry. On the contrary, the quarry industry rarely adopts such working methods. Based on the experience of the CBS quarry in the North of France, this paper shows how up-to-date blasting technology and simple control methods can significantly improve the overall Mine to Mill efficiency of a quarry. The CBS quarry, in partnership with the EPC group and Nitro- Bickford Company, adopted a new working process three years ago aimed at increasing blast performance and related productivity of the downstream process (loading, hauling and crushing). The pattern geometry of each blast is controlled and explosive charging is carried out following the æconstant specific energyÆ CSE concept. This method provides a homogeneous fragmentation distribution and reduces vibration peak-particle-velocities. The impact on downstream productivity is controlled by means of a simple information management system, which collects and measures key parameters of the production process such as; hauling cycles, crusher throughput, secondary breaking and vibration peak particle velocity. This information system has clearly proved over time that consistent blast quality could be achieved, leading to a 30 per cent improvement in quarry productivity. Improved energy control of blasting through optimisation with electronic detonators, allowed a significant reduction in vibration impact on the environment. Improvement in blasting security, reduction in the environmental impact and productivity enhancement are major benefits that quarries can obtain from these CSE optimisation blasting methods.

Jan 1, 2007

By Werner Burger

The last decade has witnessed a rapid development and application of slurry and EPB type tunnel boring machines. Both soft ground types are able to excavate tunnels in unstable ground conditions below the water table with positive face support. The most significant component of the excavation process is the cutterhead and tool con-figuration were the excavation and face support meets the geological challenge. The TBM downstream processes cannot take place unless the cutterhead and tools effectively do their job. This paper will review the current state of the art design for both slurry and EPB cutterheads and highlight both common as well as geological specific design features.

Jan 1, 2007

By J L. Mauk

The Favona adularia-sericite epithermal Au-Ag deposit is located at the southern end of the Hauraki Goldfield, about one kilometre southeast of the world-class Martha deposit. The deposit occurs in Late Miocene andesitic lava flows and local dacitic tuffs of the Waipupu Formation. In some places, post-mineralisation ash fall and ignimbrite, up to 50 m thick, cover mineralised rocks and andesite. We collected soils samples from 110 sites along eight traverses over Favona, and from three regional lines: two south of Favona, and one north of Favona.   Analyses of soils identify prominent enhanced concentrations of Au, Ag, and Hg, and lower enrichments of Sb and As. At Favona, Au and Ag appear to be highly anomalous in areas over mineralisation with Au concentrations greater than 100 ppb and Ag concentrations greater than 1000 ppb, whereas background concentrations are approximately 5 ppb and 50 ppb respectively. The background concentrations of Hg in soils are approximately 100 - 200 ppb, but in mineralised areas, Hg generally exceeds 200 ppb, and some soils contain greater than 600 ppb. Antimony shows enrichments, although weak, above known veins and As locally shows some enrichment above areas of known mineralisation. Therefore, soil sampling at Favona defines geochemical anomalies that correlate with the position of known mineralisation at depth. Thus, there is strong empirical support for the use of Au, Ag and Hg, and possibly Sb and As geochemistry to identify mineralised trends associated with buried deposits at other epithermal prospects.

Jan 1, 2007

By M Wortley, O Gu, D La Rosa, J McMaster

Metso Minerals Cisa have developed VisiofrothÖ û a system which calculates parameters of the froth surface using vision from remote cameras mounted about individual flotation cells. The parameters calculated from this system can be utilised within process control strategies to achieve stabilisation or optimisation of the flotation process. As part of a JKMRC AMIRA P9 field campaign, froth vision was collected from various cells operated at different air rates and froth depths within Rio TintoÆs Northparkes copper roughing and scavenging circuit. At the same time, samples were collected to determine the cell metallurgical performance at each operating condition. These froth images have been processed using the VisiofrothÖ system with froth velocity, bubble size, froth collapse rate and various froth colour parameters calculated. These parameters have been compared to the measured concentrate flow and concentrate grade produced at each condition. This analysis shows that the concentrate tonnage flow is strongly correlated with froth velocity whereas the concentrate grade is best correlated using froth velocity in combination with a bubble stability parameter which affects the bubble size distribution on the top surface of the froth. This paper summarises the results from this analysis as well as an overview of the VisiofrothÖ system and the parameters that are measured by the software.

Jan 1, 2007

By Adrian Coombs, Paul Magowan, Derek Zoldy

Continued development and intensification are fuelling the urgent need for new trunk infrastructure within The Regional Municipality of York and throughout the Greater Toronto Area. Permitting of these projects is increasingly subject to public scrutiny to severely restrict dewatering through construction technologies and the requirement for a comprehensive and effective Environmental Management Plan. Three current projects: one on the York Durham Sewage System and two in the City of Toronto 1.Conventional Design, Tender, Award: 4,150m (13,600 ft.) 2.7m (9 ft.) finished interior diameter soft ground tunnel for York Region’s YDSS Interceptor Trunk Sewer 2.Negotiated Contract: 3,800m (12,500 ft.) 3.5m diameter (11.5 ft.) rock tunnels for Enwave’s environmentally sustainable and innovative chilled water system in downtown Toronto 3.Conventional Design, Tender, Award: 2,200m (7,200 ft.) 3.3m diameter (10.8 ft.) rock tunnel for reinforcement of Hydro One’s primary hydro feed in the downtown core of Toronto These projects exemplify issues such as: EPB tunnel and sealed shaft technologies Substantial permitting requirements associated with dewatering Mitigation of rock creep Congested downtown rights-of-way Deep shafts and confined working compounds Unique scheduling and cost benefits when Owner, Contractor and Consultant can work together cooperatively.

Jan 1, 2007

By John J. Sammarco

Abstract- Emergency shutdown systems (ESDs) for mining machinery provide critical functions to safeguard miners. Traditionally, ESDs were realized with simple hardwired circuits; today, there is a growing trend to use programmable electronic technology such as programmable logic controllers (PLCs). This paper describes an analytical study to quantify the safety integrity of a PLC-based ESD and a hardwired ESD. The safety integrity level of each design approach was determined by quantifying the average probability of failure on demand (PFDavg) as described by the recommendations for programmable electronic mining systems published by NIOSH and the IEC 61508 international standard. The safety analyses addressed system architecture, hardware failure probability, proof test interval, diagnostic coverage, and human error probability. The results indicated that a same level of safety, safety integrity level 3 (SIL 3), could be attained when evaluating random hardware failures. Neither approach could attain SIL 3 if manual activation was used. Human error was the limiting factor where, using human reliability analysis, PFDavg < 1 x 10-1; thus, the ESD does not meet SIL 1. It is apparent that automatic verses human¬activation of the ESD is a very important safety consideration. Manually actuated ESDs can only achieve SIL 1 regardless of the technology; therefore, additional independent safety layers of protection are needed to exceed SIL 1. Secondly, it is apparent that the technology choice is very important. The PLC-based ESD was much simpler to design and to validate safety1.

Jan 1, 2007

By L Terrusi

The Bungaroo Valley hosts a concealed Tertiary channel iron deposit (CID) along a 17 km stretch of its length. Bungaroo Valley is approximately 0.5 km wide upstream at its easternmost extent, and 3.5 km wide downstream where it joins the Jimmawarrada Creek. The valley follows the axial trace of an anticline that plunges gently to the southeast, and the CID infills the valley. Mineralisation extends to a depth of 230 m below the surface, and almost the entire deposit occurs below the water table. Bungaroo Valley cuts through the Buckland Hills and is bounded to the north and south by steep scarps capped with the resistant Dales Gorge Member of the Brockman Iron Formation. Basement rocks are believed to be mostly Wittenoom Formation shales and dolomites, with Mount McRae Shale and Mount Sylvia Formation also present. Deep, localised depressions appear at the base of the CID sequence towards the north edge of the upstream section of the valley, while downstream the basal CID contact is relatively flat and shallow. In both cases the profile of the CID surface closely mirrors that of the basal contact. The localised depressions seen in the upstream basal CID contact produce significant variations in CID thickness of up to 100 m over short strike distances. This uneven palaeotopography is most likely due to eddying and waterfalls forming within the riverbed prior to CID deposition during a time when the water table was much lower than at present. It may also be associated with possible karsting in an underlying dolomite unit and subsequent syn- or post-depositional collapse of the overlying CID. The irregular basal contact of the Bungaroo CID sequence has implications for mining in terms of pit design and resource accessibility.

Jan 1, 2007

By Michael Cianchetti, Nadir Ansari, Matthew Janes

"PROJECT DESCRIPTIONThe R C Harris Filtration Plant underwent an expansion to install an underground sludge treatment capability consisting of a series of underground tanks within stepped excavations 12m (39 ft) and 10m (33 ft) deep into compact, wet sands over stiff clays and clayey silts.Concerns regarding the original structure influenced designers to set the lateral deflection limit for the proximal front footing at 4mm (1/6 in), (0.03% excavation depth). The design-build team indicated at the time of tender that the movement criteria was unattainable using the tender design. Through extensive Fast Lagrangian Analysis on Continua (FLAC) and a novel construction geometry the design-build team crafted an alternative that produced significant savings over the original concept and met deflection concerns.GEOTECHNIQUEThe hillside site drops 14.5m (47.6 ft) over a distance of 53m (174 ft) between the existing Filter Building on the north and the Services Building on the south. The soils adjacent to the Filter Building consist of 6m (20 ft) of sandy fills, to the footing elevation, over compact sands and layered dense sands and silts to a depth of 10m (33 ft) below existing footing. Beneath the silts lies a 10m (33 ft) thick stiff clayey silt, 2m (6.6 ft) of sandy silt till (containing cobbles and boulders) and an artesian gravelly sand at a total depth of 30m (98.5 ft).The tender information was deemed inadequate to accurately determine soil parameters for a finite element analysis. As a result, the design-build team performed pre-tender Cone Penetrometer Testing (CPT), including dynamic analysis. The CPT data indicated stratigraphy consistent with the conventional bore hole exploration (SPT results) however, the CPT data provided consistently superior soil strengths. The CPT data indicated the sands and silts were dense to very dense throughout their full thickness. The clayey silts below the sands were found to have shear strengths in the 100 to 200 kPa (14.5 to 29 psi) range with an Over-Consolidation Ratio (OCR) ratio of 1.5 to 2. The dynamic analysis, while low strain, indicated very competent behavior with Young’s Modulus values in the 200 to 350 MPa (29,000 psi to 51,000 psi) range. The CPT derived shear moduli and OCR values were vital in determining the soil engineering parameters used for the FLAC analyses."

Jan 1, 2007

By J. E. Nesset, S. R. Rao, J. A. Finch

"For base metal sulphides, iron rejection starts in mineral processing. This review focuses on changes in plant practice specifically to improve iron sulphide rejection by control of contaminant ion effects and discusses selected general innovations in mineral processing that can be expected to play a role. One group of changes to control contaminant ions is in size reduction (the use of stage grinding and inert stirred milling) and another is in system chemistry (order of reagent addition and exploitation of the flexibility of sulphoxy reagents). Plant examples illustrate the successes, indicating that there are several options available. The general innovations start by considering the new tools for measuring gas dispersion properties and quantifying froth characteristics by imaging. Examples of their application to improve concentrate quality illustrate the potential. Other innovations stress adapting geostatistics to model variation in milling and flotation response to provide feed forward control and rigorous application of statistical experimental methodology in plant test work. An example from one concentrator shows improvements in concentrate quality from application of basic principles can be impressive.INTRODUCTIONThe more iron control (rejection) that can be accomplished in mineral processing the lower the subsequent metal extraction costs and environmental implications of iron disposal, particularly in hydrometallurgical processes. Iron rejection has been a contributing target to periodic attempts to apply mineral processing to nickel laterites and bauxites but the prime application is control of pyrite and pyrrhotite (iron sulphides) in the treatment of sulphide ores by flotation. In this paper some new concepts and innovations introduced in sulphide flotation plants over the past ten years or so (i.e., since a previous review [1]) will be outlined with examples of how they have contributed to improved “iron control”.To increase rejection of iron minerals, first the recovery mechanism should be understood. There are four principal ones, two physical in origin: 1, via locked particles (i.e., flotation of composite particles due to insufficient size reduction to liberate the minerals) and 2, through entrainment in the water reporting to the float product (an unselective process); and two originating from a response to the system chemistry: 1, true flotation (i.e., iron sulphides becoming hydrophobic) and 2, as a result of iron sulphides forming aggregates with hydrophobic particles (e.g., ”slime” coatings). There has been considerable effort to diagnose which of these dominates iron sulphide recovery; in many cases it is due to “chemistry”, in particular true flotation. The flotation effect often appears related to contamination by metal ions [1]. This can reduce selectivity in two ways: 1, metal ion species may activate iron sulphides, or 2, cause general depression which demands more vigorous flotation conditions (e.g., additional collector) with consequent loss of selectivity. This is where the review will start, by considering ways to control contaminant ions."

Jan 1, 2007

By K Buda, W Staunton, M Hill, V Tjandrawan

One of the challenges facing the gold industry in the 21st century is the continuing need to identify new reserves of economically treatable ores. Discoveries of large, metallurgically simple orebodies are becoming increasingly rarer, forcing companies to investigate options for the processing of ores which may present recovery, economic and/or environmental issues, requiring innovative approaches to their treatment. Ores which contain naturally occurring carbonaceous material (æpreg-robbing oresÆ) are an example of one such ore type. NewmontÆs Jundee operation contains zones of carbonaceous ore within the oxidised orebody. A program consisting of detailed laboratory work and extensive plant trials has been undertaken to assess the options of the processing of this material. Laboratory tests demonstrated the advantage of carbon-in-leach (CIL) over direct cyanide leaching and carbon-in-pulp (CIP) for treatment of these ores. The laboratory program identified several factors which would enhance overall gold recoveries where preg-robbing ore was being processed, including: keeping preg-robbing ore separate from non-graphitic ore; maximising gravity recovery; and ensuring the plant operates in æpureÆ CIL mode, ie no leaching prior to first adsorption tank. Several plant trials were undertaken to assess the economic sustainability of treating moderate preg-robbing ores through a modified gravity/leach/adsorption circuit. Results indicated that where good operational control of the circuit was maintained to ensure high gravity recovery, minimal leaching prior to carbon contact, and maintenance of good, active carbon inventory, then acceptable and sustainable overall gold recoveries could be obtained. Using these relatively simple plant modifications potentially allows a plant to treat ores with preg-robbing index (PRI) values up to one. When PRI values rise to 1.3 - 1.6, leach recoveries can drop from >85 per cent to

Jan 1, 2007

When it comes to structuring major mining contracts, the two most widely adopted formats are æmeasure and valueÆ and æcost-plusÆ. A problem with both of these formats is the difficultly of aligning the objectives of the mining company with those of the contractor to achieve mutually beneficial outcomes. An alternative contractual arrangement is for the mining company to enter into an Alliance arrangement with the contractor, linking remuneration to mine performance across a range of targets. These targets can change over time as operational requirements change. &nbsp; The aims of this paper are to: +&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; outline alternative types of mining contracts, as well as their strengths and pitfalls; +&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; describe the philosophy behind the Alliance contract at Newmont Waihi GoldÆs Favona underground mine; and +&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp;&nbsp; identify some of the keys to success and pitfalls to avoid when implementing an Alliance.

Jan 1, 2007

By Dean Brox, Jason Morrison, Peter Procter

The Galore Creek Mine project is one of the newest major mining projects underdevelopment in Canada. The project is located in a very remote area of northwester British Columbia and is being developed by Nova Gold Resources of Vancouver. The mine project comprises one of the largest and highest grade undeveloped porphyry-related gold-silver-copper deposits in North America. In order to access the mine site anew 120 km road is planned to be constructed including a 4.4 km mine access road tunnel. Glaciers with heavy snow pack cover approximately two-thirds of the tunnel alignment with a maximum cover of 1,200 m. The size of the access road tunnel is about 50 m2 and has been designed as a large single lane road tunnel to accommodate the transport of large size mining equipment for mine start up and ongoing operations. The rock conditions along the tunnel alignment comprise very strong volcanic rocks. Key services for mining operations will be incorporated into the tunnel comprising diesel and power as well as the concentrate pipeline. Structural portal canopies have been incorporated into the tunnel design due to the risk of rockfalls and avalanches in the portal areas. The mine access road tunnel is a significant and critical-path component to the overall project to provide vehicular access to allow construction of the mine site. In order to meet the expected mine start up date the construction of the tunnel works are to commence prior to any other works at the mine site and will be constructed entirely by helicopter support. Geotechnical investigations commenced in the summer of 2006 with the removal of the overburden materials at the portals to assess bedrock conditions. Tunnel construction from both portals is expected to commence in the spring of 2007. The construction of the mine project is subject to and awaiting environmental approval in the spring of 2007. The mine access road tunnel will be the longest private road tunnel in North America. The key design and constructability issues for the mine access road tunnel project are presented and discussed.

Jan 1, 2007

By E. M. Abraham

The establishment and survival of different grass species and cultivars on various phytotechnic treatments at a limestone quarry was studied. The treatments applied were: a) bare soil, b) bentonite, c) bentonite-straw and d) asphalt-straw. According to the results, significant differences were found among species and cultivars, growing on different treatments as far as plant growth and survival are concerned. The seed germination was higher on bentonite -straw and asphaltic-straw than on bentonite but the plants survival were higher on bentonite. Lolium perenne had higher seed germination rate and better establishment than the other tested species at all treatments. However, the survival rate of Agropyron desertorum and of the cultivars palestina and chrysopigi of Dactylis glomerata was higher than of the other species.

Jan 1, 2007

By R Dimitrakopoulos

The development of mineral resources is based on a spatial model of the orebody that is only partly known from exploration drilling and associated geological interpretations. As a result, orebody models generated from the available information are uncertain and may require the use of stochastic conditional simulation techniques. Multiple-point methods have been developed for petroleum reservoir modelling, enabling reproduction of complex geological geometries. This paper considers a multiple-point approach to capture the uncertainty of the lithological model. The implementation of the method at the Yandi channel iron ore deposit in Western Australia and performance characteristics are discussed. The uncertain lithological model translates into considerable grade-tonnage uncertainty.

Jan 1, 2007

By D Craw

Otago Schist and Klondike Schist are two Paleozoic-Mesozoic metamorphic belts on the circum-Pacific margin in which there has been a long history of abundant alluvial gold mining, but only minor hard-rock gold mining. &nbsp; Modern exploration for hard-rock gold is ongoing in both belts, and the active Macraes mine in Otago (&gt;2 Moz production) highlights the hard-rock potential of the geological setting of these belts. Hard-rock gold mineralisation in both belts formed in the latter stages of schist exhumation, after rocks were subjected to major regional ductile folding and then uplifted through the brittle-ductile transition. The majority of known hard-rock gold-bearing systems in both belts consist of well-defined, but generally discontinuous, vein swarms. Most Otago veins are hosted in steeply dipping post-metamorphic normal faults and fractures. However, the Macraes mine is hosted by a late-metamorphic shear zone, and much ore is sulphide-impregnated auriferous schist. Goldbearing veins in the Klondike schist are hosted primarily in extensional sites associated with post-metamorphic compressional structures. Some disseminated sulphide mineralisation is associated with Klondike veins and this is important as it extends the exploration target for these veins. No foliation-parallel late metamorphic mineralisation has been identified in the Klondike but exposure is relatively poor compared with Otago and both schist belts are highly prospective for deposits of this type.

Jan 1, 2007

By Richard W. Graeme, James J. Komadina

Gold Fields acquired an option to purchase the Cerro Corona project, located in Hualgayoc, Cajamarca Department, Peru, in December 2003. In January 2006, the option was taken up and the transaction closed. During the intervening months, project development occurred against the backdrop of a presidential election, increasing national social activism and environmental regulation, rapidly escalating operating and capital costs, as well as an unprecedented demand for engineering and technical skills. Project “Lessons Learned” are discussed in the context of an evolving strategy. The Cerro Corona project forms part of a porphyry copper-gold deposit situated within the Hualgayoc Mining District in northern Peru. It is located in the highest part of the Western Cordillera of the Andes, close to the headwaters of the Atlantic Continental Basin. It lies approximately 90 km (56 miles) by road north of the Department of Cajamarca’s capital city and near the village of Hualgayoc. Access to the Cerro Corona project from Cajamarca is by two roads, one from Cajamarca to the Yanacocha Mine 45 km (28 miles), and then from Yanacocha to the village of Hualgayoc and the town of Bambamarca 45 km (28 miles).

Jan 1, 2007

By M. Keevy, K. Hackney

Centrifugal slurry pump station and deposition sites are a common feature of many mines and mineral processing plants. Yanacocha Mine has completed the design of a pump station consisting of two trains of four pumps each. A number of trade-off studies was conducted to optimize the pump station design. The most significant of these was determining the drive types for the slurry pumps. The pump station duty can vary considerably due to the number of deposition points round the disposal site. The standard solution to this problem on a multi-stage pump train is to install one pump with a variable speed drive to control the pump station output by varying the speed of this pump and stopping and starting other stages. However, there are a number of negative impacts associated with this approach. These include head losses through pumps that are stationary or ?wind-milling?, different wear life on pumps that are running and pumps that are stationary, and slower response to the control system with the possibility of hunting. The use of variable speed drives on all the pumps was considered as an alternative to the standard solution. The factors considered in comparing these options were the control and operational differences, the pump efficiencies and absorbed power, the expected pump wear life, the impact on pump maintenance and the cost of the drive options. For this project the option of using all variable speed drives was selected. The paper presents the following aspects of the study: ?Description of the various options investigated. This includes a discussion on the required duty and the drive options. ?Technical comparison between the options. ?Description of the factors influencing pump performance and life.

Jan 1, 2007

Mineral sands mining for ilmenite, rutile, and zircon will disturb over 2,500 ha of prime agricultural farmland in Virginia and North Carolina (USA) over the next 20 years. Mining of the Virginia deposit was initiated in 1997 and approximately 750 ha have been disturbed to date with approximately 150 ha reclaimed to support a mix of agricultural post-mining land uses. While considerable university research and corporate effort were devoted to developing environmental management systems and reclamation protocols for these lands, specific indicators of sustainability and restoration success were lacking. By 2003, it became apparent to the mining operator (Iluka Resources), local land-owners/farmers, local government, and the regulatory authority that testable indicators of reclamation success were essential for long-term sustainability. Virginia Tech worked cooperatively with all stakeholders to review the pre-existing research base and to propose reasonable expectations of post-mining soil productivity levels. The state regulatory authority reinforced its position on a number of associated issues including necessity of topsoil return and specific comparative crop yield targets. Virginia Tech, Iluka Resources, and a local leaseholder (Carraway-Winn family) agreed to jointly manage a 45-ha research demonstration farm where the effects of alternative soil reconstruction practices are being rigorously monitored for both row crops (corn and wheat) and forage production. All mined land crop yields are also compared to an adjacent undisturbed exceptional quality prime farmland soil. Corn and wheat yields in 2005 and 2006 were significantly above county average yields (regulatory target level) and approximately 75% of undisturbed adjacent prime farmlands. This cooperative effort allows all clientele groups to objectively assess the post-mining productivity of these mined lands while providing an invaluable educational opportunity for the mining industry.

Jan 1, 2007

By P. P. Sinha, D. N. Bhatia, B. R. Ghosh, R. K. Gupta

Medium carbon, low alloy, high-strength steels containing Ni, Cr, and Mo are used for the fabrication of various types of high-strength fasteners required for launch vehicle structures. Cold heading properties and response to hardening and tempering are the essential requirements of the material for fabrication and application, respectively. Combining these two requirements is essentially warranted in high-strength fastener-grade steels. Cold heading properties require ductility, which can be achieved through spheroidizing treatments. In the absence of a suitable spheroidizing cycle for medium carbon 3.8 Ni, 1.8 Cr, 0.3 Mo steel, experiments were carried out with a theoretical understanding of the alloy system. This paper presents the experiments and results obtained after a spheroidizing treatment, which was carried out to optimize the process. Hardness measurements were carried out and microstructural studies were conducted to assess the spheroidization process and to determine the optimal spheroidization parameters.

Jan 1, 2007

By Saieb Haddad, Henry Pate

"Building retaining walls in an urban area is becoming more diffi cult due to right-of-way restraints. Using standard concrete cantilever walls requires a construction easement behind the walls for installation, which for the most part is unavailable. To install these types of walls in a limited right-of-way requires extensive temporary walls to minimize the construction easement. Top-down construction walls utilizing tie-back anchors for support require either the purchase of the right-of-way or underground easements in the area of the anchors.These problems faced the Department on Interstate 75 widening in Knoxville, TN in an area of a large cut. A multi-story Insurance Building and a large commercial Retail Center were located at the top of the cut. To prevent any impact on the buildings, the walls had to be placed within a limited area. The option of buying the properties was prohibitively expensive. Due to the height of the two walls and the variability of the underling rock line, contiguous caisson pile cantilever walls were contemplated as the only wall type that would be appropriate. The cost of the two walls was estimated to be very close or even higher than the cost of purchasing the two buildings. The Department believed that there must be a better way to deal with the problem. A vertically tied-down pile frame wall constructed from the top-down with a concrete facing was developed. This allowed the construction of the walls to be restricted to the available limited area and provided substantial savings for the State. INTRODUCTIONThe widening of I-40/75 has been a major transportation project in the Knoxville area which is being constructed by the Tennessee Department of Transportation. The project includes 18 Retaining Walls and 13 Bridges. Two of the 18 Retaining Walls, refer to Figure 1, are to support two valuable properties, one being an insurance company housed in a multi-story offi ce building and the other a suburban shopping center which were appraised at $13.0 million and $5.0 million respectively. Due to the 31 ft. (9.5m) maximum height of each of the two Retaining Walls and the limited Right-of- Way of 15.0 feet (4.6m), a contiguous caisson pile cantilever wall was proposed for each of the two retaining wall sites with an estimated cost of $12.0 million each. The contiguous pile cantilever Wall is comprised of a line of caisson piles socketed into underlying competent bedrock. The design required that 4 ft. (1219mm) dia. piles be installed at 6 ft. (1.83m) centers, socketed into rock in order to provide lateral stability and restrict lateral wall movement to acceptable limits. The line of caissons would be fronted with a cast-in-place concrete face wall."

Jan 1, 2007