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CONTENTS PAGE
1 SCOPE 2
3 DEFINITIONS 2
4 REQUIREMENTS 4
4.1 GENERAL 4
4.2 DESIGN 4
4.3 CONSTRUCTION 14
5 QUALITY ASSURANCE PROVISIONS 16
5.1 QUALITY MANAGEMENT 16
5.2 QUALITY PLAN 16
5.3 TESTS 17
5.4 INSPECTION 17
6 SAFETY AND RISK 17
6.1 ANGLO FATAL RISK STANDARDS 17
6.2 RISK ASSESSMENT 17
APPENDIX A: REFERENCE DOCUMENTS 19
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therein, irrespective of the cause and quantum thereof.
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1 SCOPE
This specification details the minimum standards required by Anglo American plc for the
design and construction of concrete foundations for heavy machines, as well as methods
of characterisation of the underlying ground.
This specification is intended to be used with concrete foundations for heavy machines,
having a mass of not less than 100 tons, and located either on surface or underground.
Typical heavy machines included are:
Sag mills and ball mills, whether using conventional drives or gearless mill drives
Cone crushers, jaw crushers, roll crushers and mineral sizers
Rock breakers, scrubbers, pelletisers and rotary kilns
Machinery with reciprocating engines, such as compressors and generator sets
Mine winders
The requirements of this specification shall apply to all new installations, where the
foundation is constructed specifically to support the heavy machine. The requirements
also apply when new or upgraded heavy machines are mounted on existing foundations.
This specification covers design and construction of the concrete foundation for the heavy
machine, as well as steel floors, walkways and protective screens around the heavy
machines.
3 DEFINITIONS
For the purpose of this specification the following definitions shall apply:
APPROPRIATE : The relevant national standard in force in the country in which the
NATIONAL heavy machine will be used, and where the foundation will be
STANDARD constructed
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therein, irrespective of the cause and quantum thereof.
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GROUND : This is the material underlying the foundation. The same term
applies whether this material is a soft granular soil or rock requiring
blasting for excavation.
OWNER : The mine company that places the order and receives the goods
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therein, irrespective of the cause and quantum thereof.
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SIGNIFICANT : Any natural frequency that is within the range of 70% to 140% of an
NATURAL exciting frequency arising from the operation of a heavy machine
FREQUENCY
SWL : Safe Working Load of any floor areas intended to support spares or
equipment during installation or maintenance of heavy machines
4 REQUIREMENTS
4.1 GENERAL
4.1.1 Compliance with Legislation and Anglo American Requirements
All material and services shall comply with the mandatory requirements of applicable
legislation relevant to the country and jurisdiction in which the mine site is located. The
Foundation Contractor shall confirm this compliance in writing to the Owner.
All material and services shall comply with Anglo American requirements.
Any proposed deviation from this Specification and its requirements, or modifications for
application to specific items proposed by the Foundation Contractor, shall be submitted to
the Owner for written approval. No work associated with any proposed deviation shall
proceed before this written approval is provided.
If any doubt arises as to the meaning or effect of any part of this Specification or if conflict
occurs between this Specification and other information it shall be referred to the Owner
for a ruling. The decision of the Owner shall be final.
In the event of any conflict between the technical requirements of relevant documents, the
order of precedence shall be:
This Specification.
The data sheets and/or drawings.
Other relevant documents.
4.2 DESIGN
The design and design documentation shall comply with the requirements of
AA_SPEC_114001 for Structural Steel and AA_SPEC_114010 for Structural Concrete, as
amended by this Specification.
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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This specification defines the minimum prescribed standards. Alternative designs that
represent an improved or equivalent standard may be proposed and presented to the
Owner for approval. Alternative designs may only be used after they have been approved
in writing.
4.2.2 Materials
All materials used shall comply with the requirements below. All materials shall be clearly
specified on the Design Drawings.
Condition of Material
All material shall be new, and shall comply with that specified on the Design
Drawings.
Structural Steel
All structural steel shall be graded, and shall have a yield strength of not less than
300MPa.
Reinforcing Steel
Mild steel reinforcing shall not be used, except for links and stirrups.
The concrete grade required shall be specified in compliance with the current
international norm, giving both the required cylinder strength and the required cube
strength.
The minimum grade for structural concrete shall be C 32/40 (i.e. cylinder strength =
32MPa, cube strength = 40MPa).
4.2.3 Loads
General
The minimum imposed loads defined by SLO, as modified and supplemented by the
AA_SPEC_114001 and AA_SPEC_114010, shall be used for all heavy machine
foundation structures, whether located on surface or underground.
Heavy Machine Loads
The EPCM Contractor shall supply at least the following heavy machine load
information to the Foundation Contractor:
Total masses of all components of the heavy machine, including all liners and
ancillary equipment
Masses and dimensions of any machine components that will be placed on
the surrounding floor during maintenance work
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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The Foundation Contractor shall make design provision for at least the following
dynamic loads and frequencies:
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therein, irrespective of the cause and quantum thereof.
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FO 1,5me(2fR ) 2
60mef R2
where m is the mass of the rotating part of the machine
Provision shall be made for the loads due to lifting or alignment of equipment as
required by the EPCM Contractor. Construction loads shall be taken as the weight
of the heaviest sub-assembly or the whole machine as applicable, multiplied by an
impact factor of not less than 1,4.
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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Seismic Loading
a. Earthquake zone
The earthquake zone applicable to the actual location of the site shall be used.
Where the equivalent static load method is used, the response modification
factor shall be taken as:
Foundation
Where the height of the centroid of the heavy machine above the base of the
foundation does not exceed the minimum horizontal dimension of the
foundation at its base, the response modification factor shall be taken as 3.
Where the height of the centroid of the heavy machine above the base of the
foundation exceeds the minimum horizontal dimension of the foundation at its
base, the response modification factor shall be taken as 2.
The mill, together with the bearings and steel cradles is required to remain
elastic in the event of an earthquake. The response modification factor shall
thus be taken as 1.
c. Ground type
The ground type shall be assessed in terms of either the ERDS, or the IBC, as
applicable to the project. All ground characteristics shall be obtained from a
Geotechnical Engineer’s test results, listed in a written report.
Lateral Loads on Piles
If the underlying ground is such that it is required to use piles to support the heavy
machine and foundation, the ground around the upper 5d of the piles, and/or the
underside of the foundation raft, and/or raking piles shall be engineered to resist all
of the following loads acting in combination:
A static lateral load of not less than 5% of the total weight of the heavy
machine, but excluding the foundation weight.
A dynamic lateral load equal to twice the total out of balance force arising from
the heavy machine.
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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No fatigue life design check is required for concrete components of the foundation.
Any steel components of the foundation (plinths, cradles, sole plates, holding down
bolts carrying uplift loads, etc) shall be designed to have a fatigue life at least equal
to the required life of the heavy machine. The fatigue loads to be used in the fatigue
life calculation shall be based on the operational requirements of the heavy
machine, including at least the following:
Maximum motor start-up torque loads
Normal braking loads
Dynamic loads during operation
The heavy machine manufacturer shall specify performance requirements for the
foundation as this relates to the heavy machine. These performance requirements
shall include, but not be limited to:
Any walkways and access stairs shall comply with the requirements of
AA_SPEC_114005.
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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The Foundation Contractor is responsible for ensuring that the layout and the
structural design of the foundation are acceptable.
Existing Foundations
The EPCM Contractor is responsible for ensuring that the layout of all components
of the new heavy machine fit onto the existing foundation. Where any adaptor
plates or frames are required, the EPCM Contractor shall complete the design. If
any layout or geometrical information for the existing foundation is not available on
drawings, the EPCM Contractor shall obtain the necessary information by physical
measurement on site.
The EPCM Contractor is responsible for ensuring that the structural design of the
foundation is adequate. If the material grades are not indicated on drawings, the
EPCM Contractor shall obtain them by coring and testing at an accredited materials
laboratory.
Design drawings provided by the Foundation Contractor shall comply with the
requirements of AA_SPEC_114001 for Structural Steelwork and with
AA_SPEC_114010 for Structural Concrete.
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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The entire foundation shall be constructed on a single raft base. The base shall not
have any construction joints.
All foundation plinths shall be of solid construction, without any construction joints.
Where any two plinths adjoin, they shall be constructed as one unit, with provision
for adequate reinforcing connecting them together.
The modulus of subgrade reaction and the ground bearing capacity to be used for
ground settlement shall be determined from plate bearing tests performed at the
depth of the intended base of the foundation.
Ground Dynamic Characteristics
The ground elastic modulus to be used for determining the dynamic performance of
the foundation and the full system should preferably be determined from the
dynamic shear modulus obtained from Appropriate Seismic Tests. The dynamic
strain values in the ground are small, so the nominal elastic modulus shall generally
be taken as 0.8 times the value obtained from the Appropriate Seismic Test. Where
blasting is used to form the excavation for the foundation, the probable extent of
ground fragmentation shall be considered by the Geotechnical Engineer, and the
nominal elastic modulus should be taken as not greater than 0.7 and not less than
0.4 times the value obtained from the Appropriate Seismic Test.
Where the ground elastic modulus for small dynamic strains is determined from
plate bearing tests, the nominal elastic modulus value shall be determined using the
rebound stiffness value, or shall be taken as the initial tangent modulus.
Liquefaction
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therein, irrespective of the cause and quantum thereof.
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The values of certain material properties for the foundation and the ground are
generally not accurately known. It is thus required that a range of parameters must
be used for the system dynamic analysis, in order to bound the possible system
responses.
The parameters shown in Table 6.1 shall be used for three separate dynamic
analyses, in order to determine upper and lower bounds on the system behaviour.
The full system dynamic analysis shall include at least the following:
In each case, the analyses shall be carried out using the basic parameters, the high
stiffness parameters and the low stiffness parameters.
Analyses Required
a) For all new installations, and all upgrades or new heavy machines on existing
foundations, the EPCM Contractor shall conduct a dynamic analysis of the full
system using an Accepted Numerical Analysis Technique. The dynamic
analysis shall include at least the machine, its drive motors, the foundation
and the underlying ground.
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therein, irrespective of the cause and quantum thereof.
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The calculated dynamic stresses shall be evaluated in terms of the LSDS or LSDC.
In order to ensure that the foundation is not unduly flexible, the minimum value of
the fundamental natural frequency of the full system shall not be less than 2.0Hz.
The Owner will review the Foundation Contractor’s design, selection of materials of
construction, dynamic analysis and interpretation of ground data. Such review may
include evaluation by an independent Consultant engaged by the Owner and will include
review of at least the following:
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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Final copies of all the above analyses shall be bound together and submitted for the
Owner’s records. If previously performed analyses on similar size and type of heavy
machines are utilised in lieu of any of the analyses specified above, written documentation
demonstrating how the previously performed analyses can be applied shall be included.
4.3 CONSTRUCTION
4.3.1 General
4.3.2 Materials
The Supplier shall ensure that all material used in construction of the foundation complies
with the requirements of this specification and is as specified on the relevant design
drawings. Materials conforming to standards other than those covered by this
specification shall be tested in order to demonstrate their conformance to the relevant
standards specified herein, and their use shall be approved in writing by the Design
Engineer.
Additional costs incurred in obtaining approval and using approved substitutions shall be
borne by the Supplier.
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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All work shall comply in all respects with the design drawings. If the Foundation
Contractor requires clarification of any information on the design drawings, such
clarification shall be obtained from the Design Engineer.
If the Foundation Contractor has good reason to modify or change any part of the work
specified on the design drawings, this shall be agreed with the Design Engineer, who shall
revise the design drawings accordingly, and issue the revised drawings for construction.
For all new installations, the EPCM Contractor shall supply templates or jigs for
mounting the holding down bolts, which will be installed by the Foundation
Contractor. The EPCM Contractor will be responsible for final acceptance of the
holding down bolt positions before casting of concrete.
For all upgraded or new heavy machines to be mounted on existing foundations, the
EPCM Contractor shall measure the existing holding down bolt positions and shall
ensure that the upgraded or new heavy machine base fits onto the existing holding
down bolts. Where this cannot be achieved, the EPCM Contractor shall provide a
sole plate or properly designed transition piece between the existing holding down
bolts and the base of the upgraded or new heavy machine.
Sleeved holding down bolts
4.3.5 Certification
4.3.6 Tolerances
All tolerances for concrete construction shall be as specified by the appropriate SCC.
All tolerances for steel construction shall be as specified by the appropriate SCS.
4.3.7 Performance
Performance Guarantee
a. Impact Test
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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For gearless mill drives only, the EPCM Contractor shall perform an impact
test on the completed mill on site, to demonstrate that the actual dynamic
characteristics are as predicted in the design.
All significant natural frequencies are not more than 5% closer to their
associated exciting frequency
The coefficient of variation of the mode shapes associated with all significant
natural frequencies does not exceed 25%
Where the impact test does not show acceptable correlation, the following
procedure must be carried out:
- the analytical model must be calibrated to match the test results
- the calibrated analytical model must be used to demonstrate acceptable
performance of the full system
- if acceptable performance cannot be demonstrated, the calibrated
analytical model must be used to design foundation modifications in
order to achieve acceptable performance
5 QUALITY ASSURANCE PROVISIONS
All test and inspection reports shall be suitably signed off by the responsible parties and
included in a Quality Data Pack, which shall be submitted prior to the issuing of an
Acceptance Certificate at completion of the works.
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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define hold points for inspection by the Design Engineer, which hold points shall
include as a minimum: completion of excavation and compaction of any backfill
below the foundation; and completion of fixing of steel reinforcing
The quality plan shall be approved by the Project Engineer prior to commencement of
manufacture.
5.3 TESTS
The Foundation Contractor shall provide test samples and arrange for these to be tested
by an approved testing authority. The costs of all tests shall be borne by the Foundation
Contractor.
5.4 INSPECTION
The QAR shall have access at all reasonable times to the construction site. The QAR is
authorised to witness any stage of manufacture of reinforcing steel, construction, tests
and to inspect documentation. The QAR is authorised to reject any items not complying
with the requirements of this specification. In the event of a dispute arising regarding the
interpretation of test results the decision of the Project Engineer shall be final.
The Foundation Contractor shall conduct a risk assessment and generally work in
compliance with AA_STD_99, Risk Management on Projects for all work on site. This risk
assessment shall be completed prior to any work being carried out.
In addition to all construction related risks, the risk assessment shall consider at least the
following:
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therein, irrespective of the cause and quantum thereof.
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c. Blasting
Where blasting is required, special consideration shall be given to the
associated risks.
The Foundation Contractor shall be thoroughly familiar with all site safety requirements,
and shall enforce compliance by all employees.
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.
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The latest issue of the following documents is deemed to form part of this specification:
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therein, irrespective of the cause and quantum thereof.
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Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained therein, irrespective of the cause and quantum thereof.
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Equivalent terms used in different national standards to mean the same as “response modification
factors” are listed below:
Anglo American accepts no liability for any damage whatsoever that may result from the use of this material or the information contained
therein, irrespective of the cause and quantum thereof.