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DESIGN CRITERIA
24017-DC-001
FOR
CIVIL/STRUCTURAL
TABLE OF CONTENTS
1.0 INTRODUCTION 3
1.0 INTRODUCTION
These criteria shall govern the design of structures and facilities. These criteria shall
be applied in conjunction with civil/structural specifications governing specific
elements of the project.
Insure that critical facilities have a design margin appropriate for the risk
involved
Maximize safety
2.1 GENERAL
Unless specifically stated otherwise, the design of all structures and facilities
shall be based on the applicable portions of the following codes,
specifications, industry standards, regulations, and other referenced
documents, based on the latest revision or edition thereof.
In addition to the codes and regulations listed below, the design shall comply
with any laws or regulations of the local authorities. In the event of
conflicting requirements between codes and standards, the most stringent
shall apply.
2.3 REGULATIONS
3.1 LOCATION
The mine-site facilities for the Escondida expansion project are located at the
Minera Escondida Limitada (MEL) facilities in the Atacama Desert of
northern Chile at 3200 metres above mean sea level. The site is surrounded
by a mountainous area known as Cordillera de Domeyko and it is adjacent to
the Salar de Hamburgo, 180 kilometres southeast of the port of Antofagasta,
Chile.
3.2 TOPOGRAPHY
The mine-site facilities are on the western slope of a basin formed by the
Cerro Colorado Chico and the Cordillera de Domeyko. Topographical
features are barren, rock-covered hillsides sloping downward to a shallow
salt flat or salar. Extremes in temperatures have weathered the surface rock
extensively and covered the mine-site area with talus material. The higher
elevation of the Cerro Colorado Chico region receive rain and snow that
drain down through the barren soil and is collected in nearby basins. These
basins are evaporation ponds and form dry salt beds.
The surface soils at the plant site are composed of weathered volcanic ash,
underlain by gravel layers intermixed with sandy material. The surface
material in the concentrator area may have a high salt content and will be
removed to expose the unweathered surface below. The specific
characteristics, thickness and depth of the soil strata are defined in the
Project Geotechnical Investigation Report.
The plant site is at approximately 3200 metres above mean sea level.
Wells for fresh water will be located at Salar Punta Negra (approximately 25
kilometres southeast of the site) and at Salar Monturaqui (approximately 70
kilometres northeast of the site).
3.3 ACCESS
The geotechnical report by E.C. Rowe & Asociados, titled Mine Site
Facilities Geotechnical Report dated March 1989, was issued for the existing
mine-site facilities. For the Phase IV Expansion Project the Geotechnical
Report by E.C. Rowe & Asociados, issued in December 1998, shall be used.
3.5.1 HORIZONTAL
The Plant coordinate system shall be used exclusively in the PDS and
in all the design drawings for the Phase IV Plant Area, excluding off-
site drawings
3.5.2 VERTICAL
3.6 PRECIPITATION
Minesite Coloso
Rainfall average annual mm 7.2 12.5
Rainfall maximum for 24 hour period mm 55.8
Snowfall design load mm 500 0
3.7 EVAPORATION
3.11 WIND
3.12 EARTHQUAKE
Minesite:
The design shall be based on the requirements of NCh 433, NCh 2369 and
UBC codes (see 4.7).
Seismic Zone 2, with soil Type II and importance coefficient I=1 shall be
used for NCh codes.
Seismic Zone 4, with site coefficient S factor = 1.2 and seismic importance
factor I=1 shall be used for UBC.
For equipment suppliers outside Chile, the design shall be based on UBC
code.
1
Coloso:
The design shall be based on the requirements of NCh 433, NCh 2369 and
UBC codes (see 4.7).
Seismic Zone 3, with soil Type I and importance coefficient I=1 shall be used
for NCh codes.
Seismic Zone 4, with site coefficient S factor = 1.2 and seismic importance
factor I=1 shall be used for UBC.
For equipment suppliers outside Chile, the design shall be based on UBC
code.
For soils data for civil/structural design refer to the Project Geotechnical
Report.
4.1 The Concentrator building, Flotation/Regrind building, and the Coarse Ore
Stockpile building shall be steel frame structures with metal roofing and
siding, as defined on the design drawings.
4.2 The ore storage reclaim tunnel shall be constructed of reinforced concrete.
4.3 Grade slabs and sump bottoms shall be constructed of reinforced concrete
placed on native competent material or on compacted fill.
4.4 Operating floors and other floors indicated on drawings shall be constructed
of reinforced concrete. The elevated concrete floors shall use noncomposite
steel deck as the formwork
4.5 Elevated floors and access platforms shall be constructed of metal grating,
except where noted on drawings or in areas with potential for crushed ore
spillage.
4.7 The seismic requirements per NCh 433 and NCh 2369 and those per UBC
may be in some respects more severe than each other in terms of ductile
details and redundant force transfer systems, and the factors used to arrive at
the design spectrum. The most severe requirements out of those Codes shall
prevail, and the design engineer must be fully cognizant of such differences
and incorporate them into the design.
5.1 EARTHWORK
Cuts in original soils - Vertical, for temporary cutting when cut not
exceed 1meter in vertical measurement.
5.2.1 Yard finish grading shall be a minimum of 150 millimetres below the
adjacent floor slabs.
5.2.2 Yard grading shall have a finish grade slope of two percent minimum
away from structures and toward the storm drainage.
Allowable bearing values for mat foundations and spread footings shall be in
accordance with the Project Geotechnical Report.
5.4 ROADS
Principal roads 6%
Secondary roads 10 %
Principal roads 50 m
Secondary roads 25 m
Maintenance roads and pond inspection roads 25 m
Principal roads 30 m
5.5.2 Storm runoff quantities for small areas in the plant site shall be
determined by the Rational Method using a minimum time of
concentration of 10 minutes.
Facility Criteria
a) 150 litres per person per day for treatment system operation,
and maintenance with a design flow rate of four times the
average for pipe sizing
5.6.2 All sanitary sewers shall be at least 150 millimetres in diameter. The
minimum velocity shall be 0.5 meters per second flowing half full.
Maximum velocity shall not exceed 1.5 meters per second to prevent
the water from leaving floating solids behind thus forming dune or
which subsequent flows catch and eventually plug the pipe.
5.6.3 The top of all sanitary sewer line must be 200 mm below the bottom
of any water line.
5.6.4 Spacing between manholes shall not exceed 90 meters.
5.7.1 The yard fire main shall be a minimum of 200 millimetres in diameter.
The minimum depth of cover for the yard pipe shall be 1 meter below
grade.
5.7.2 The yard pipe for fire protection shall be complete with hydrants,
gate valves, and post indicator valves as required.
5.7.3 Fire hydrants shall be placed at a spacing of not more than 90 meters.
The minimum depth of cover for the fresh water pipe will be 0.7 meters
below grade.
The minimum depth of cover for the potable water pipe will be 0.7 meters
below grade.
6.1 LOADS
The dead loads (DL) shall include the weight of framing, roofs,
floors, walls, partitions, platforms and all permanent equipment and
materials (see Section 6.1.7.a). The static vertical and lateral 1
pressures of liquids shall also be treated as dead load (in accordance
with Section 9.2.5 of ACI 318-95).
The live loads (LL) shall include floor area loads, laydown loads,
equipment handling loads, active earth pressure and truck wheel loads.
The floor area live load shall be omitted from areas occupied by
equipment whose weight is specifically included in the dead load.
Live loads shall not be omitted under equipment where access is
provided, for instance under elevated tanks on four legs. In no case
shall the minimum design live loads be less than specified in Section
7.1.3. The equipment operating loads (LLo), upset operating loads
(LLu) and crane loads (CL) shall be included as described in Section
6.1.7.b, c and e. 1
The design live loads shall be shown both in the calculations and on
the design drawings for the corresponding floors.
b) For live loads greater than 500 kgf/m2, the following reductions
shall apply for columns, piers and walls supporting:
Roof =0%
Roof and 1 floor = 0 %
Roof and 2 floors = 10 %
1
6.1.5 WIND LOADS
b) The operating live load (LLo) shall include the contents of fixed
equipment, containers, conveyors, pipeways, etc., with
materials at normal operating densities.
c) The upset operating load (LLu) shall include dead loads plus
equipment filled to maximum capacities with materials of
maximum density, including scale buildup; e.g., plugged chutes
or screw conveyors, etc. These loads may be considered as
short-term loading conditions, with the special considerations
of Section 6.2.1, and shall be included as a special case of LLo
in the loading combinations per Section 7.2. 1
b) Conveyors
At transfer points:
Crushed Ore
Angle of repose:
Stacking degrees 37.5
Draw down degrees 70
Density for:
Weight t/m3 2.1
Volume t/m3 1.8
6.2.1 For wind, earthquake and temporary loads caused by upset conditions
or construction sequence, the allowable stress or load capacity may be
increased by a factor of 1.33.
6.2.2 The strength and deflection of the metal decking and support framing
shall be checked for the weight of wet concrete plus 150 kgf/m2
without the allowable stress increase.
6.3.1 GENERAL
Gyratory crushers
Cone crushers
Grinding mills
Flotation cells
Conveyors
Vibrating screens
7.1 GENERAL
All steel structures shall be designed by the working stress method. Soil-
bearing pressures for the actual loads shall be checked against the allowable
pressures. All reinforced concrete structures shall be designed by the ultimate
strength design method.
The minimum factor of safety provided for all structures shall be as shown
below for each loading condition:
For maximum uplift, sliding and overturning, the minimum dead load, which
may occur during construction or with equipment empty, shall be considered in
combination with the wind loads.
The loading combinations listed below shall be considered for the design of
structures and elements of structures. The footnotes list the reduction factors
that shall be applied to the individual loads to reflect the improbability of
simultaneous occurrence for infrequent or transient loads.
a) DL + LL + LLo + CL
NOTES
(1) Maximum crane loads need not be combined with more than 0.50 wind
(2) Crane hook load need not be considered for maintenance type cranes in
combination with wind or earthquake.
(3) For materials or designs where working stress procedures are used, dead
loads shall be multiplied by 0.85 to maximize the net uplift caused by
seismic loads
(4) In laydown areas the actual weight of the equipment as spread out on the
floor shall be considered
(5) When used in combination with seismic loads, (LL + LLo) shall be
multiplied by 0.7; this factor does not apply when using LLo alone (without
LL) in combination with seismic loads. The upset load LLU shall be
included as a special case of LLO.
7.3 DEFLECTIONS
Deflections due to live load and wind load or earthquake load shall not exceed
the following:
a) Roofs
b) Floors
Vertical Span/1000
Horizontal Span/500
e) Conveyors
Crane girders shall be designed in accordance with AISE Technical Report No.
13, 1991 - Guide for the Design and Construction of Mill Buildings.
Flat bottom tanks or other tanks with supported bottoms founded at or below
grade, shall be designed to resist the seismic forces calculated by using the
procedures in UBC Section 1632, for rigid structures, considering the entire
weight of the tank and its contents.
Braced frames and bracing members shall be designed in accordance with UBC
Section 2211.
8.1.1 Structural steel shapes, plates and bars shall conform to ASTM A36,
A42-27ES (NCh 203), or as approved.
8.3 GRATING
8.3.5Heavy duty grating shall be provided for areas with heavy vehicular traffic:
8.4.1 Checkered plate shall be A37-24ES (NCh 203) steel and shall have a
four-way safety pattern.
Anchor bolts and anchor plates shall conform to ASTM A36/A36M or A42-23
(NCh 206). Nuts shall conform to ASTM A563 and round washers shall
conform to ASTM F436. Minimum diameter of bolts shall be inches.
8.7 HANDRAILS
8.8 CONCRETE
8.11.1 Concrete masonry units shall be in accordance with NCh 181, Class
A, with a minimum compressive strength 70 kgf/cm2 (average of 5
units).
8.12 GROUT
For column and equipment bases, the grout shall be nonshrink and nonmetallic
and shall be in accordance with technical specification 24017-GC-005.
- AWS A-5.17 bare mild steel electrodes and fluxes for submerged arc
welding
- AWS A-5.18 mild steel electrodes for gas metal arc welding
- AWS A-5.1 mild steel covered arc welding electrodes for shielded metal
arc welding.
Normal dimensions and load limits for transportation by truck should be considered as
follows:
Larger dimensions and weights are possible subject to special permit, and shall be
confirmed through the Construction Traffic Department.