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Since 2010, one miner was killed when a storage bin collapsed. These deaths and several near misses are alarming. Careful examination and prompt correction of hazards are essential.
Since 2010, one miner was killed when a storage bin collapsed. These deaths and several near misses are alarming. Careful examination and prompt correction of hazards are essential.
Since 2010, one miner was killed when a storage bin collapsed. These deaths and several near misses are alarming. Careful examination and prompt correction of hazards are essential.
Recent failures of storage bins, silos and other structures highlight the need to increase awareness of hazards associated with these structures. Since 2010, one miner was killed when a storage bin collapsed; another miner was killed when the concrete silo he was standing on collapsed. These deaths and several near misses are alarming. Careful examination and prompt correction of hazards are essential to maintaining these structures. These occurrences can be greatly reduced by utilizing the following best practices.
Examine structures for indications of damaged, weakened or displaced structural elements, bulging or deformed bin sides or tops, gapped joints, cracked or broken concrete, corroded or fatigue-cracked metal, bent or buckling columns, beams or braces, loose or missing connectors, cracked, broken or inadequate welds, etc. Inspect structural elements for reduced load-carrying capacity, thinned or missing sections of beam and column webs or flanges, corroded rusted or flaked metal surfaces, delaminated plywood or water-weakened wooden structures. Clean accumulations of material from around the base of structures and flanges of horizontal beams. Carefully inspect for damaged support columns, braces, anchor bolts and eroded foundations. Report all areas where indications of structural weakness are found. Protect lower level structural elements from collision damage by mobile equipment. Minimize spillage and eliminate the source promptly. New structures should be designed and certified as appropriate by a registered professional engineer in accordance with local building codes and in conformance with accepted engineering practices. Significant modifications to existing structures should be undertaken only after consultation with an engineer. Structures should be constructed according to plans and specifications by trained workers using good materials and employing generally accepted construction methods.
Report Structural Damage or Deterioration To Your Supervisor
PowerPoint prepared by Terry Taylor, P.E., Senior Civil Engineer, PSHTC 1 2 St r uc t ur al Condi t i on Assessment s 3 Structural Materials Steel Concrete (plain, reinforced, pre-stressed) Timber Other - Masonry, Aluminum, Fiber- Reinforced Polymer (FRP), etc. 4 Inspecting Structural Steel Corrosion (holes,delamination & loss of cross section) Cracking (overload & fatigue) Overloads (buckling & deflection) Member Impact Damage
5 Cor r osi on hol es & del ami nat i on 6 Reinforced Concrete Concrete is strong in compression but weak in tension. Rebar is introduced so that steel, which is strong in tension, can carry the tensile load while concrete carries the compressive load. 7 Inspecting Concrete Structures Cracking Delamination (Internal Splitting - Silos) Spalling Rebar Corrosion Crushing Impact Damage 8 Spalling & Corrosion from Exposure to Chemicals 9 Inspecting Timber Structures Cracking Deflection / Sag Crushing Fungi - molds, rot, dry rot Wood Boring Insect Damage
11 MNM Surface - 56.11001 MNM Underground 57.11001 Safe Access Safe means of access shall be provided and maintained to all working places. 12 MNM Surface - 56.14100 MNM Underground 57.14100 Machinery & Equipment Safety Defects b) Defects on any equipment, machinery, and tools that affect safety shall be corrected in a timely manner to prevent the creation of a hazard to persons. 13 MNM Surface -56.14205 MNM Underground -57.14205 Machinery, Equipment, & Tools Machinery, equipment, and tools shall not be used beyond the design capacity intended by the manufacturer where such use may create a hazard to persons. 14 Inspection of Processing Plants 15 Beams - Bending & Shear Resistance Beams and girders are common members used to resist bending moments and shearing forces. Bending is resisted by flanges; shear is resisted by web. 16 Bending Moment 17 Shear Force Equal (magnitude) but opposite (direction) forces which tend to slide one section of a member past an adjacent section. 18 Cor r oded web of w i de f l ange beam 19 Long corrosion hole at web to flange interface 20 Thi s beam was st i l l st andi ng (?) 21 Cor r osi on hol e i n web of beam (hi dden by pi pi ng) 22 Cor r osi on hol es i n web of beam 23 Cor r oded web @end of beam 24 Cor r osi on hol e i n web & buck l ed t op f l ange 25 Heavy del ami nat i on of bot t om f l ange 26 Buck l ed web 27 Buc k l ed webs of c or r oded c hannel s 28 Beam modifications need engineered! 29 Columns Buc k l ed c ol umn f l anges @web c or r osi on hol e 30 Cor r osi on hol e i n web of c ol umn 31 Buc k l ed f l anges at bot t om of c ol umn @c or r osi on hol e 32 Repai r ed c ol umn base (appear s good) 33 Bad Repair At Column Base 34 Another Bad Column Repair (base) 35 a few feet up from base 36 Rot t ed t i mber c ol umn 37 An equi pment mi shap t hese t ypes of r epai r s c an be eval uat ed by an engi neer 38 Crooked Column (creation of moment) 39 Severe equipment damage 40 Replacement time! 41 I nspec t t he c ol umn f oundat i ons 42 Dont take the bracings out! 43 Cor r oded di agonal br ac e 44 Cor r oded di agonal and gusset pl at e 45 Cor r oded di agonal 46 Cor r oded c hannel s/gi r t s suppor t i ng t he si di ng 47 Check equipment supports! Corrosion hole in channel post for a magnetic separator 48 Cor r oded c hannel post suppor t f or a magnet i c separ at or 49 Cr ac k i n a suppor t beam f or a shaker sc r een 50 Fr ac t ur ed spr i ng suppor t f or vi br at i ng equi pment 51 Det er i or at ed c onc r et e f l oor i ng 52 Fl oor sl ab c r ack s - a pot ent i al sour c e of r ebar c or r osi on 53 Look at f l oor gr at i ng - c or r osi on @suppor t s 54 Corrosion at support edge of grating 55 56 Cor r oded st ai r c hannel s 57 Corroded angle supporting stair tread 58 Dont f or get t o c heck t he handr ai l s! 59 Cor r osi on hol es i n handr ai l suppor t post 60 Heavy Roof Loadi ng 61 Roof Collapse Due to Clinker Buildup and Snow Load 62 Inside of Failed Structure 63 Collapsing Roof Support Purlins 64 Cor r osi on of bot t om f l ange of r oof suppor t c hannel 65 Buckled Vertical Roof Truss Member 66 Check tightness Look for missing bolts sheared bolts elongated bolts excessive corrosion Bolted Connections 67 I nspec t c onnec t i ons! Cor r oded bol t heads 68 cracked welds poor quality - irregular surface corrosion in connected parts Always use qualified welders Welded Connections 69 Fr ac t ur ed wel d @c onnec t i on 70 Vi br at i ng equi pment - f r ac t ur e & poor qual i t y wel d 71 Irregular weld surface w/porosity 72 Ex posed r ebar on t he si de of a c onc r et e set t l i ng t ank 73 Collapsed floor Avoid this! 74 Pl ant c ol l apses c an be c ost l y. 75 Recap - Inspection of Processing Plants Check the beams, columns, diagonal braces Examine members for buckling, corrosion, damage, excessive sag, holes, local buckling, and cracking. Examine connections for corrosion, missing or cracked elements Examine floors, roofs, walls, & foundation Examine equipment supports, stairways, & handrails