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By Christopher Mark

Area wide pillar failures, or “squeezes,” were once fairly common in underground coal mines. While rare today, they do occur. This paper describes seven case histories that were investigated by MSHA Technical Support. They occurred across the range of US coalfields, in both longwall and room-and-pillar mines, and involved development mining, pillar recovery, longwall panel extraction, and multiple seam interactions. Significant lessons from each are discussed.

Jun 25, 2024

By Daniel Harrington

On the night of June 8, 1917, the flame of a carbide lamp accidentally set fire to the uncovered and frayed insulation of an armored power cable near the 2,400-foot level of the North Butte Mining Co.'s Granite Mountain shaft. How this insulation accidentally became exposed is explained on page 15. The highly flammable oiled fabric set fire to the shaft timbers, and as this is a downcast shaft the fire spread with great rapidity, soon filling the mine workings with smoke and gas. At the time 410 men were working underground, 247 of whom escaped by various means, but most of the 163 remaining were probably overcome soon after the lire started, and perished. Only two men were actually burned. The cause of the disaster was purely accidental. The immediate effect was the unexpected reversal of normal conditions; the ultimate effect was great loss of life and the destruction of the main hoisting shaft, putting it temporarily out of service. The work of rescue and fire fighting continued eight days. The following pages present an attempt to draw some practical conclusions and suggestions from this disaster. The property of the North Butte Mining Co. consists of about 220 acres in the northeastern part of the Butte district, Montana. Next to the Anaconda Copper Mining Co. it is the largest pro¬ducer of the district. In 1916, the year before the disaster, there were 1,160 men employed. The output was 560,947 tons of ore, which yielded 24,498,181 pounds of copper, 1,047,063 ounces of silver, 1,712 ounces of gold, and 412,953 pounds of zinc. The profit was $2,479,595. The total development work for that year was 21,694 feet. During the first half of 1917, the year of the accident, the daily tonnage of ore averaged 2,000, an increase of 400 tons over that of the year 1916.

Jan 1, 1922

By Simon D. Strauss

This paper discusses the ways in which the metals industries dealt with surplus capacity in the past, primarily the twenty years, 1950 - 1970. During this period, the bulk of metals production in the market-economy countries was controlled by private sector companies. Since then, public sector companies have played an increasingly important role in the metals industries of the market-economy countries. Of course, the change was not overnight. It occurred gradually over a period of many years. Indeed, by 1965, several developing nations had adopted policies of government control of metal operations previously in private hands. The metals industries are so many, so large and so diverse that the constraints of time make it impossible to deal with all segments. To illustrate the problems of surplus capacity in the metals industries during the period, this paper focusses primarily on three metals. One experienced rapid market expansion between 1950 and 1970; one had a growth more or less in line with the expansion of the world economy; and one lagged well behind the pace of industrial expansion. No one will be surprised if aluminum is identified as the metal with rapid growth; copper is identified as the metal that kept pace with the world economy; and tin is identified as the laggard. Individual computations of the rate of growth for these metals show some variations, but most estimates place the increase in aluminum consumption in the market economy countries between 1950 and 1970 at a compound annual rate of about 8%. The corresponding figure for copper is a compound rate of 4%. Tin consumption showed no growth. A widely accepted point of view is that sharply rising demand will force the price of a commodity to increase substantially in order to attract a necessary expansion of supply. The corollary to this is that stagnant demand will hold prices down, as there is no need to stimulate new supply and it may be necessary to force marginal producers out of the market. The experience with aluminum, copper and tin in the years 1950-1970 does not support this theory. In 1950, the average prices in the United States market as reported by the American Bureau of Metal Statistics were 17.74 a pound for aluminum, 21.24 a pound for copper, and 95.54 a pound for tin. The corresponding figures in 1970 were 28.74 a pound for aluminum, 57.74 a pound for copper and 174.24 a pound for tin. Aluminum, with the greatest market growth, rose by 60%, whereas tin rose 82% and copper by 172%. Clearly, other factors were a more important influence on price than was the trend of demand To revert now to the capacity issue, during the period under review aluminum demand was rising so sharply that that industry had no sustained problem with surplus capacity. Instead, if anything, capacity may at times have been a constraint on demand. The industry succeeded in attaining explosive market growth through imaginative research and promotion programs. Some of this growth was the result of substitution of aluminum for other commodities – steel, copper, wood and glass as examples. But much of the growth was the consequence of developing entirely new products through technological innovation. Prior to World War 11, the number of aluminum producers was extremely limited. Alcoa and Alcan in North American and Pechiney and Alusuisse in Europe were the dominant firms. The developing countries had virtually no production and in Japan and Germany production was only a small fraction of the North American output. During the War years the United States had financed the construction of many new facilities. After the war these plants were sold by the government to Reynolds and Kaiser in order to foster more competition in the market. Subsequently many other concerns became aluminum producers, both in the United States and elsewhere and competition for markets intensified.

Jan 1, 1989

By T Atchison

The Vale Ferro Carajßs S11D project in northern Brazil is based on the movement of unprecedented volumes of waste and ore for mobile in-pit crushing and conveying or ætrucklessÆ systems. In peak years, the system is intended to handle a combined 160 Mt of material.The planning and implementation of the first such system for Vale, in a remote greenfield site, utilising the services of a range of international study, design and supply partners has provided a unique set of technical and project delivery challenges. The lessons from these are of value to the industry as the trend to remote and high-volume operations continues.This paper describes the key features of the mining system and documents the challenges and mitigations for important technical, cultural and project delivery issues that have arisen. It is a combined description of the journey taken by both Vale (as owner) and SKM (as delivery partner) over the course of many years.CITATION:Atchison, T, 2013. Lessons from the S11D truckless mining project, in Proceedings Iron Ore 2013 , pp 177-184 (The Australasian Institute of Mining and Metallurgy: Melbourne).

Aug 12, 2013

By Erik Richer La Fleche

LEGAL RISKS LEGAL RISKS ARE COUNTRY RATHER THAN PROJECT RISKS OTHER COUNTRY RISKS ARE POLITICAL AND MACRO-ECONOMIC RISKS COUNTRY RISKS ARE EXAMINED AFTER PROJECT RISKS COUNTRY RISKS COUNTRY RISKS INCLUDE: WAR AND ARMED CONFLICT TERRORISM AND SABOTAGE CURRENCY INCONVERTIBILTY AND TRANSFER NATIONALIZATION AND CREEPING EXPROPRIATION GOVERNMENTAL BREACH AND REPUDIATION OF CONTRACT CHANGE OF GOVERNMENT CORRUPTION COUNTRY RISKS FIRST NATIONS AND LANDOWNER CLAIMS LABOUR UNREST SINGLE CAUSE ACTIVISTS REGULATORY AND BUREAUCRATIC DELAYS CONFLICT BETWEEN GOVERNMENT LEVELS ETHIC AND RELIGIOUS TENSIONS INTERNATIONAL SANCTIONS TAXATION CHANGES CHANGES IN LAW

May 1, 2013

By T. R. Ellis

The author attempted to concurrently apply the US Uniform Standards of Professional Appraisal Practice (USPAP) and the Australian VALMIN Code to a complex mineral property appraisal assignment and previously to some modest assignments. This led the author into many severe difficulties. These difficulties included the high standards needed in the work of others and information and statements required from the client under the VALMIN Code. The exercises highlighted many positive features of both sets of standards. However, the author concluded that, without modification, VALMIN is incompatible with USPAP and the US regulatory environ¬ment. The author found that VALMIN violates US legal decisions regarding real property appraisal due to its requirement to include many items of business value. The US Securities and Exchange Commission's prohibition on reporting quantitative resource estimates proved to be a severe problem under VALMIN. Some VALMIN requirements could not be met due to the extent and quality of documents specified. Implications and thoughts regarding the development of a set of US minerals appraisal standards are discussed. Management considerations for complex mineral-property appraisal assignments are also presented.

Jan 1, 2000

By T. R. Ellis

The author attempted to concurrently apply the US Uniform Standards of Professional Appraisal Practice and the Australian VALMIN Code to a complex mineral property appraisal assignment. This led the author into many severe difficulties. These difficulties included the high standards needed in the work of others, and information and statements needed from the client. The exercise also highlighted many positive features of both documents. Some conflicts were found between the two documents. Implications and thoughts regarding the development of a set of US minerals appraisal standards are discussed.

Jan 1, 2000

By David Mast, Irwan Halim, Brian Hagan, Kaveh Talebi, Jason Edberg, Amanda Foote

On June 14, 2023 Jay Dee Contractors’ Tunnel Boring Machine (TBM) “Phoenix” holed through and completed mining the second drive of the I-75 Segment 3 Storage and Drainage Tunnel. Completion of the tunnel came only after overcoming several challenges, including a groundwater intrusion event which deposited thousands of cubic yards of wet ground material into the tunnel. This paper will discuss the events which delayed completion of the tunnel by over nine months, the risk management and construction approaches assumed by the Design-Build team during bid, several challenges faced by Design-Build teams when building stormwater resilience tunnels using traditional Department of Transportation standards, and recommendations for improving risk allocation and proposal documents for future similar Design-Build tunnel projects.

Jun 23, 2024

By Ivor da Cunha

Ontario Mining Association (OMA) represents 57 members that are engaged in exploring, producing & processing mineral resources in an environmentally responsible manner. Conservation Bureau at the Ontario Power Authority (OPA) develops, coordinates and stimulates commitment to electricity conservation and demand management programs ? OMA selected compressed air optimization for high impact cost savings and energy efficiency potential ? Ontario Power Authority (OPA) provided $218k funding for $532k project ? Commenced summer 2006, Final Report June 2007 ? Three representative sites participating: ? Williams, CVRD Inco & FNX McCreedy ? Different levels of energy management ? Small, medium and large mining operations ? Different corporate practices and culture

May 1, 2007

By Todd Kilduff, Paul Wilkinson

Microtunneling is rarely a straight forward “business as usual” endeavor. More often than not, these projects take twists and turns that require on the fly, out of the box solutions to get the project completed. This paper is a case history of a 63-inch diameter, Permalok, microtunneling project, extending nearly 700 linear feet under a hill forming the left-hand abutment to an earth embankment tailings dam. The job had three major and unexpected challenges that required unorthodox solutions. Challenge #1— Face Configuration: The Santiago Formation, a cemented sand formation with widely varying strengths, presented a challenge to configuring the face with regards to the number and length of pics and cutters. Subtle differences in type and size of the tooling had a big impact on the performance of the machine. Challenge #2—Eccentric Loading: Issues at the launch shaft with the Permalok pipe adaptors caused eccentric loading on the casing pipe. This issue resulted in overstressing and breaking of several pipe joints that ultimately led to seizure of the tunnel. Challenge #3—Back-tunnel Excavation and MTBM Recovery: There were many detailed considerations into excavating a recovery tunnel to retrieve the MTBM, especially being under a high hazard earth embankment dam.

Jun 13, 2021

By Edward C. Dowling

Cleveland Cliffs and affiliated companies have established a commitment to the development and use of integrated process control. Substantial capital investments in process control, coupled with the dedication of human resources to effectively use the information, have generated meaningful business results. Improvements in productivity, operating costs and product quality have been realized. This paper presents an overall process control and information strategy, specific case studies, lessons learned and the current view of the next steps in the continued journey toward integrated process control and information management.

Jan 1, 2000

By F Diaz, G Hovestadt, B Friedrich, D Latacz, M Sommerfeld

The metallurgical sector significantly contributes to the global carbon footprint and encounters the challenge of developing more sustainable production methods. This study introduces novel approaches aimed at reducing CO2 emissions within the industrial sector, some of which have been developed up to the demonstration scale. In two case studies, urban waste from the agricultural sector (corn, olives, coconut etc) and waste electrical or electronic equipment (WEEE) recycling residues (shredder light fractions (SLF)) were subjected to thermal treatment. The resulting materials were then used as substitutes for conventional fossil-based reducing agents in both the copper and ferroalloy industries. Furthermore, hydrogen was employed at different scales to assess its efficacy as a reducing agent for recovering metal oxides from fayalitic copper slags. Our findings reveal promising prospects and defined specific challenges for the integration of these alternative reducing agents in the industry. The synergistic use of pyrolysed SLF, bio-coke, and hydrogen presents a viable pathway to significantly diminish CO2 emissions while simultaneously improving the sustainability of the metallurgical sector.

Jun 19, 2024

By Tyler Rockley, Greg Bailey

This paper is an engineering case study of a blast performed on a highly weathered sandstone isthmus in an area sensitive to vibration and airblast, the challenges associated with such a blast, the methods used to understand rock characteristics, the blast design considerations and a discussion of the blast results. The purpose of the blast was to remove approximately 12 feet (3.7 m) of surface material in order to install a pumping station. The isthmus provided several challenges due to the weathering of the rock and multiple open faces with surrounding water. The highly fractured and weathered rock was subject to about ten years of freeze thaw cycles, influx of water and seasonal submersion. As such, all actual rock conditions were indefinite, including fracturing, rock properties, degradation and competency. The isthmus also had immediate neighbors who were unused to the environmental effects of blasting. To help continue to keep the social license to operate in the area, it was important to reduce the ground vibration, blast duration, dust and airblast. These factors required a better understanding of how the rock would respond to blasting. In order to do this, test blasts were performed on the same geologic formation in a different location of the quarry that was less sensitive to vibration and airblast effects, allowing the blast parameters and design to be verified and refined. The test blasts were performed while monitoring vibration, air blast, material movement and overall shot performance, and the blasting parameters were adjusted accordingly. The isthmus blast was performed based on the final design from these test blasts. The drilling and loading of the shot all met acceptable criteria and were comparable to the test blasts. The blast performance, however, was not as expected; the depth impacted by the blast was substantially more than expected. Since the test blasts were performed in the same formation, but in material that was significantly less weathered than the isthmus, the actual effect of this weathering was the only difference between test blasting and the isthmus blast. Thus, these results can be used for future reference to highlight the effects of blasting such highly weathered rock and help instruct the blast design in similarly complex conditions.

By Robert L. Goehring, Fred Munene

This case history for three major additions to a tire manufacturing plant in north Georgia discusses the impact of highly variable Karst (sinkhole) geology on both foundation design and construction. For Phase 3, alternatives were considered for a heavily loaded mixing tower with up to 2,000 kip column loads. A non-traditional approach of using auger cast piles was adopted. To satisfy a risk-averse Owner, a pile load testing program including strain gauges was conducted. One test pile was cored full depth to demonstrate effective bearing on steeply inclined rock. For Phase 4, similar methodology was used at another critical mixing tower structure associated with that phase and the installation procedure was refined to reduce grout take. In Phase 5 construction, another mixing tower and the equipment pits were supported on auger cast piles. After pile installation, a sinkhole opened up between two equipment pits. Remedial grouting was performed. Development also required construction of a R&D building over a 96 inch diameter RCP storm sewer. Auger cast piles were used to support the building to avoid overstressing the existing pipe and risk separating joints. This case history outlines lessons learned while constructing auger cast piles in Karst and proving quality was built into the foundations.

By Shinichi Konda, Gary Nishimura

"Thousands of years ago large glaciers carved much of the landscape in Puget Sound, depositing abrasive and granular soils including cobbles and boulders along with layers of clay and sand. Tunneling in this geology – common throughout much of the northern and Midwestern U.S. – is challenging and can be unpredictable. The use of pressurized face tunneling, most commonly with EPBs and slurry type machines, has made excavation in this geology more efficient, but difficulties still remain. Through analysis of recent projects in Seattle, Washington, USA, the authors draw conclusions as to the best TBM designs and operational parameters for this variable, abrasive and often difficult ground. Performance data is analyzed with an eye towards advancements that could further improve TBM tunneling in glacially deposited soils. INTRODUCTION Over the past several ice ages, extensive glaciers reaching across much of North America transported large amounts of soil and rock as they moved across the land. The substantial weight of the ice sheets mixed together a wide range of soil types along with a variety of rocks and boulders of all sizes. Many rock formations were reduced to pebbles or particles containing highly abrasive characteristics. Any boulders able to survive were generally comprised of harder materials which were scattered throughout the soil. This highly variable mixture of abrasive soils and high strength boulders can be found in many areas across the Puget Sound and other regions of the country. Wherever they are encountered, they often create a difficult and unpredictable mining environment for both equipment design and operation. Modern TBMs are optimized early in the design process for specific types of geology, and unexpected conditions can require extensive modifications. In addition, several operational parameters need to be adjusted to balance ground characteristics, and advance rates can be significantly affected in mixed and rapidly changing soil conditions. Both EPB and slurry machines can be used successfully in these conditions, provided their respective operating criteria are met. Ideally, an EPB is operated with a relatively thick muck consistency, which accommodates moderate changes in soil permeability and maintains a reliable pressure differential through the screw conveyor. However, this also causes higher wear on rotating components and requires more energy at the cutterhead. Alternatively, slurry machines typically operate best with a more fluid muck consistency that can be easily pumped through the extensive piping system. This tends to reduce the wear on the cutterhead and the power requirements of the cutterhead drive system, but also makes the machine more sensitive to changing soil conditions. Generally, the slurry piping system is also more capable of controlling high face pressures, although the screw conveyor of an EPB can also be designed to accommodate most high-pressure conditions."

Jan 1, 2016

By Nehad Elsafty

It is always necessary to expand existing buildings, so that they could meet the growing societal needs. Compared with demolishing them and then constructing new ones, the expansion of existing buildings could not only reduce project cost, but also save the use of energy and raw materials in projects. Therefore, it is widely adopted in most under-developed countries. However, the expansion of existing buildings is not an easy task. It has been involved with a lot of issues in defining the scope of work, planning landscape, managing construction activities, etc. This paper investigates the potential challenges in expanding existing buildings. The project of expanding the Al-Agoza Hospital, one of the biggest and oldest hospitals in Cairo, Egypt, is selected as a case study. In the case study, the project documents have been carefully reviewed. The project engineers and the health-care professionals working in the hospital have been interviewed. This way, the point of views from the owner, the architect/engineer, and the contractor have been taken into account. Several lessons are learned through the discussion with these people. The results from this paper are expected to provide pieces of useful advice and suggestion for the expansion of existing buildings in the future.

Aug 1, 2013

By B Newcombe

From many years practical industrial experience the author has drawn together a list of the key points to consider when embarking on a large-scale geometallurgical project. Fundamental aspects which must be considered include (but are not limited to):understanding the variability of the orebody both laterally and with depth;comminution properties and variability;flotation properties, requirements and variability – differing ore zones may have substantially different requirements for optimal performance;the role of texture – the consequences of both grain size and distribution and how the circuit will handle these;realistic expectation in terms of the financial requirements and time frame results are required within; andintegration of, and communication between key personnel within the various departments of the site (mining, geology and processing) is a fundamental aspect of any geometallurgically based processing system. An example of a highly complex nickel sulfide ore will be used as the basis of discussion.

Sep 5, 2011

By Jonathan K. Hrica, CASSANDRA L. HOEBBEL, Jennica L. Bellanca

Accidents involving powered haulage and mobile equipment like haul trucks are a major safety concern in the U.S. mining industry. They account for more than 50 percent of surface mine fatalities each year [1]. A recent National Institute for Occupational Safety and Health (NIOSH) analysis of 91 fatal incidents identified loss of vehicle control and situational awareness as key contributors [2]. However, the first-hand perspectives of operators are often missing, emphasizing the need for deeper insights into operators’ decisionmaking, lessons learned, sensory cues and mental strategies used during near-miss events. The findings in this analysis will help inform the development of training and safety solutions to prevent or reduce haul truck accidents.

May 1, 2025

By Frank J. Arland

Augered-Cast-in-Place piles have been used successfully for many deep foundation applications. The four case studies discussed herein describe ACIP pile projects where problems developed during ACIP pile installation requiring changes to the method or sequence of installation. The case studies illustrate the importance of understanding existing subsurface conditions and project constraints when considering the use of this pile type. Ground loosening and over-excavation of soil during the augering process, a significant concern for fine to medium sands and non-plastic silts below the water table, can significantly impact adjacent structures. This risk needs to be evaluated during the pile selection process and generally can be mitigated, but not eliminated, by requiring the use of piling equipment with high torque and slow auger rotation speed to advance the auger with minimum amount of rotation. In some applications where high lateral stresses in the soil are present such as at the base of retaining structures, the use of ACIP piles may not be appropriate if structure movement is unacceptable. On the other hand, ACIP piles have been successfully used to support deep foundations in preconsolidated varved deposits where the new structure was designed to accommodate recompression settlement.

Jan 1, 2004

By Matt Bilson, Ritesh Mahajan, Antoni Kuras, Wataru Okada

The Waterview Tunnel comprises twin 2.4 km long 13.1 m internal diameter three lane road tunnels in Auckland, New Zealand. The City Rail Link (CRL) is a 3.45 km long, 6.24 m internal diameter twin rail tunnel underneath Auckland’s city center. This paper presents an overview of the tunnel geometry, segmental lining congurations, geometric constraints, performance criteria and functional reuirements for the large diameter Waterview Tunnels and smaller diameter CRL tunnels. Other key aspects, which include sustainability, innovations, construction performance and practical aspects are discussed and compared. Lessons learnt from these mega tunnelling projects are also presented.

Jun 23, 2024