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By Paul Madsen, Bade Sozer, Thomas Hennings, Eileen Test

The Rondout Bypass Tunnel in New York has two access shafts. The upper sections of the shafts are lined with steel pipe to resist a substantial net internal water head . Initial design included a ¾-inch-thick cement mortar lining (CML) for all three components. Because of concerns with CML application on large-diameter pipes, the protective lining was redesigned for shotcrete application. This paper discusses the details of that design, mock-ups, and shotcrete application.

Jun 13, 2023

By Ross Goodman, Jean-Luc des Rivières

The Ohio River Tunnel Project encountered multiple unexpected geotechnical challenges which, continuing to develop over time, hampered excavation completion and impacted the cast-in-place final lining technique and work execution sequence for the entire project. The continued degradation of the excavated hard rock tunnel conditions led to a unique, dynamic, geologic setting that forced the project to innovate new and adaptable measures allowing for a conventional cast-in-place liner to be completed in a safe and timely manner and minimize delay.

Jun 13, 2023

By Robin Dill, Julian Prada, Kathryn Kelly, Brian Hann, Todd Moline

Narragansett Bay Commission’s (NBC) Pawtucket Tunnel Project includes construction of the 11,600-ft long, 30-ft ID, deep rock tunnel. This paper presents insight into the features and benefits of lump-sum, design-build that led NBC to select it as the project delivery method. The use of a design-build contracting process that included proprietary meetings to discuss and obtain feedback on Alternative Technical Concepts as well as to facilitate reaching consensus on modifications to the GBR-B is also described. The discussion includes features and benefits of design-build process that not only addressed NBC’s desired outcomes, but also allowed the Design-Builder to propose several innovative changes to the Base Technical Concepts included in the bid documents, and to develop a GBR-C that was compatible with their proposed means and methods of construction and addressed what they believed to be the more significant subsurface risks on the project.

Jun 13, 2023

By Ryan Ward

The Missouri River Intake Screen Structure and Tunnel (MRISST) is one phase of the Red River Valley Water Supply Project (RRVWSP), a vital piece of infrastructure in the state of North Dakota to transport water to drought-laden communities in the eastern half of the state. The scope of work consists of constructing a cofferdam in the Missouri River, mining a 1,600-foot by 74-inch tunnel from a secant pile shaft near the riverbank into a cofferdam, and erecting a 40-foot Y-shaped vertical pipe structure in the cofferdam to support the intake screens. Construction personnel worked in the river through the North Dakota winter to construct the cofferdam and contended with high hydrostatic pressures and raveling sands, gravels, cobbles and boulders while mining the tunnel. Diligent planning and meticulous execution were essential to overcoming the challenges encountered below the Missouri River.

Jun 13, 2023

By Reinhard Gertl, Maximilian Weithaler, Harald Kammerer, Juan Pablo Muñoz, Juan-Carlos Rueda

The Guillermo Gaviria Echeverri tunnel and its access roads project in Antioquia, Colombia is a mega infrastructure project that includes a road network with the longest tunnel in Latin America and several short tunnels, the latter being the focus of this study. The design of the project required careful consideration of several special factors, such as the tunnels’ steep slopes of up to 5%, high fire load of 100 MW, bidirectional operation, and short lengths that make it difficult to place ventilation equipment. The combination of all these parameters cause a challenging design problem for the ventilation systems and smoke control of the short tunnels. To address this challenge, a risk assessment study was conducted to support the design of a new and innovative ventilation strategy that deviates from relevant guidelines and standards, like the Austrian RVS [1][5][6] or the German EABT [8] in order to provide a customized solution for this particular project. This strategy resulted a cost-effective solution, that allowed a reduction in the number of required jet fans and at the same time reaches or reduces the risk level compared to traditional ventilation strategies.

Jun 13, 2023

By Victor Despointes, Stephane Polycarpe, Kathryn Kelly, Chris Feeney, Brian Hann, Vojtech Ernst Gall

The Pawtucket Tunnel is a 2.2-mi, 30.2-ft diameter CSO storage tunnel in Rhode Island. The primary tunnel is built using a dual-mode open-EPB TBM capable of sealing the face within 120 seconds to manage poor ground and water ingress which is launched from within a SEM starter tunnel. The main tunnel connects to four adits along its alignment, three of which are SEM tunnels and one being a MTBM tunnel. This contribution describes the selection process, potential risks, and requirements for the TBM, as well as the design of the main tunnel, the adits, and the adit-bored tunnel connections.

Jun 13, 2023

By Clayton Williams, Dale M. Hata, Glenn M. Boyce

The Upper Llagas Creek Flood Protection Project in Northern California encompasses portions of the communities of Morgan Hill and Gilroy, and unincorporated areas of Santa Clara County. The project provides for flood protection improvements along Llagas Creek and two of its tributaries, West Little Llagas Creek and East Little Llagas Creek. Llagas Creek is one of the tributaries of the Pajaro River and drains a watershed of approximately 104 square miles. The river system has a history of flooding the watershed communities, and the project’s goal is to provide 100-year flood protection by creating a bypass infrastructure, including channels, cut-and-cover culverts, and a tunnel. The project has been divided into several phases. This paper describes Phase 2A, which consists of approximately 2,150 linear feet of lined horseshoe-shaped bypass tunnel measuring 14 feet wide by 12 feet high. The bypass tunnel was sequentially excavated using a combination of roadheader and controlled blasting through colluvium and weathered to fresh greenstone. The tunnel was mined near residences, requiring strict noise and vibration controls. Phase 2A also includes the construction of twin bypass concrete culverts, portal shoring, and dewatering systems. It features the use of a Design Review Board and partnering for project delivery. This case study discusses the bypass tunnel design, progress of tunnel construction, plans to complete the work, construction risks, and the software and procedural tools being used to manage the project, including ProjectWise construction management software.

Jun 13, 2023

By Ray Brainard, Adriana Ventimiglia, Amanda Kerr

The $2 billion Horizon Lateral includes over 30 miles of trenched and tunneled pipeline with diameters up to 120 inches.Related infrastructure includes large and small pumping stations, reservoirs, and flow control facilities. This paper will discuss the strategy and processes used to determine contract packaging and contracting delivery methods for the various project elements with an emphasis on the tunnels and trenchless crossings. Prior Authority experience and the rigorous risk-based approach to develop the preferred alignments played a large role in determining the outcomes along with schedule concerns and permitting and easement acquisition.

Jun 13, 2023

By Ricky Chipka, Roshan Thapa, Richard Yovichin, Greg Rogoff, Patrick Niemuth

A 4.5-mile-long, 96-inch-diameter outfall pipeline was constructed between North Texas Municipal Water District’s proposed Sister Grove Regional Water Resource Recovery Facility and the Stiff Creek Discharge Structure. Two TBM-mined tunnel segments were excavated for the outfall pipeline through rock and mixed-face conditions within the Austin Chalk Formation. The TBM mining performance was tracked in detail and evaluated during mining. This paper discusses the TBM configuration, TBM utilization, advance rates, and challenges of both tunnel segments.

Jun 13, 2023

By Jeremy Cawley, Jeff Murphy, Horry Parker, Brock Gaspar, Jake Keegan

The Lower Olentangy Tunnel project includes 47,000 cubic yards of planned ground improvement for earth pressure balance machine (EPBM) tunneling (5.2 km) and microtunneling (335 m) in glacial soils. Jet grouting started in late 2021 and will continue through 2023 to complete operations at 5 shafts, 14 safe havens, 5 watermain ground improvement zones, and a river crossing. Typical jet grout columns are installed at depths between 15–24 meters. Discrete soil-cement blocks range from 267–8,900 cubic yards in volume. This paper discusses the methodology, testing, and technical considerations associated with jet grouting operations in glacial overburden across an urban environment.

Jun 13, 2023

By Nik Sokol, Mike Jaeger, Leo C. Weiman-Benitez

Silicon Valley Clean Water signed a progressive-design-build (PDB) contract with Barnard Bessac Joint Venture (BBJV) to design and construct the Gravity Pipeline tunnel in Redwood City, CA. Owner and Design-Builder teamed with designer Arup to provide a final product: 3.3 miles of 182 in. O.D. precast concrete segmentally lined tunnel with 10 ft. and 11 ft. I.D. Fiberglass Reinforced Polymer Mortar (FRPM) carrier pipe, complete with two FRPM Drop Structures. BBJV and Arup collaborated with SVCW to evaluate alternative design concepts, negotiate an agreeable price and reduce contingencies through a transparent estimating process, and deliver the project ahead of schedule.

Jun 13, 2023

By Luis Fernandez-Deza, James Hawn, Dustin Mount, Jean-Marc Wehrli

The RiverRenew Tunnel System project in Alexandria, VA forms part of a CSO scheme aimed at reducing overflows of combined stormwater and sewage into the Potomac River during storm events. A major piece of the project is a 12-foot internal diameter tunnel of approximately 12,000 feet length lined with a single-pass precast concrete segmental liner and excavated by an Earth-Pressure Balanced Shield TBM. The tunnel lies between 120 to 140 feet below grade in the clays of the Upper Potomac Formation with occasional dips of more granular, saturated soils of the Terrace Formation and the Alluvium. The TBM is launched from a figure-8 configuration Pumping/Screening Shaft located within AlexRenew’s operational Water Resource Recovery Facility. This paper discusses the challenges encountered during the launch of the TBM in short mode within a highly congested site and from narrow deep shafts.

Jun 13, 2023

By Nick Karlin

Dragados USA is constructing the LA Effluent Outfall Tunnel, a 7-mile, 18 ft internal diameter effluent discharge tunnel, utilizing a 21.6 ft (6.585 m) Herrenknecht Mixshield TBM. This paper highlights the means and methods used for TBM launch from a 55 ft diameter shaft excavated in wet with diaphragm wall support of excavation. This included SEM excavation of jet grout blocks for starter and tail tunnels, temporary concrete structures and steel installations, TBM sealing system, umbilical management for TBM hydraulic, electric and bentonite circuits as well as complex segment delivery logistics. The many launching challenges were overcome thanks to the innovative approaches from the project team.

Jun 13, 2023

By M. Z. Emad, N. Abbas, Y. Majeed

Room-and-pillar mining is commonly employed for the extraction of rock salt in undergroundmines. Pillar stress is a major concern in these mines as it is directly related to stability and mineralrecovery. In this study a flat jack method was used to measure pillar stresses in three undergroundrock salt mines in Pakistan. The field work included determination of in-situ stress, in-situ elastic modulus, recording of field variables (pillar length and width, height and width of opening, opening width to height ratio, extraction ratio, and overburden height) and collection of salt block samples. The geomechanical properties of rock salt (uniaxial compressive strength, Young’s modulus, Brazilian tensile strength, and density) were also determined to estimate overburden stress, pillar strength, and factor of safety (both estimated and actual). It was found that the measured pillar stresses are proportional to the overburden stress values, with their magnitude ranging from 6.05 MPa to 11.97 Mpa, and the pillars were found to be stable. Regression analysis was performed to develop statistical models for in-situ stress and in-situ elastic modulus. Finally a quick guideline chart was developed to determine the suitable length of pillar for a given span and required level of safety.

Jun 5, 2023

By K. J. Craig, M. A. Swart, Q. G. Reynolds, L. Hockaday

A solar reflector soiling study was carried out at a ferromanganese smelter in South Africa to assess the soiling rates at different locations around the plant. Several meteorological parameters were monitored to give insight into the conditions that lead to increased soiling. Mineralogical characterization of dust samples collected from the reflectors and the atmosphere revealed that only a certain size fraction is of importance with regard to soiling, and that the dust can be attributed to both raw materials and smelter products. Proximity to the dust source was the primary driver for increased soiling. The site that experienced the most soiling was very close to raw material heaps; this was deemed an outlier and was excluded from the summary statistics. The secondary driver for increased soiling was location relative to the smelter dust sources and the wind’s direction and speed. The reflector set at the best location experienced 13.1% less soiling than the set at the ‘worst’ (but still feasible) location, represented by an averaged mean daily reflectance loss of 0.0186. The study revealed that while there are periods of intense soiling at this particular site, proper planning of reflector location in relation to the smelter dust sources can significantly mitigate the soiling rate.

Jun 5, 2023

By A. T. van Zyl, M. Mthenjane, M. J. Cole

Growing global concern over the impacts of climate change, attributable largely to fossil fuel energy sources, has led to the widely shared goal for a ‘just transition’ to cleaner energy and reduced dependence on carbon-based fuels. As the world’s 14th biggest CO2 emitter and being particularly vulnerable to the impacts of climate change, South Africa must embark on a just transition pathway. This paper reviews expected coal mine closures and associated community vulnerabilities and local governance challenges in South Africa. Decommissioning schedules for all coal-fired power stations and operating coal mines are plotted, and 69 mining host communities and 21 municipalities are mapped, classified, and described. Community socio-economic profiles are measured using a set of SDG indicators and census data and municipalities assessed through financial audits. Our research shows that five coal-fired power plants (8.9 GW) and 15 coal mines (29.5 Mt/a) will probably close by 2030, and a further four plants (14 GW) and 23 mines (106 Mt/a) by 2040. Thus, the shift to cleaner energy will likely occur without the premature closures implied by the just transition. The impact of mine closure on the 2.5 million residents of host communities will be significant, particularly as levels of income, employment, and education are already very low and many municipalities are in financial distress. The South African approach to the just transition needs to take local realities into account and the narrative must support an effective transition that does not undermine energy security and economic growth.

Jun 5, 2023

By D Hope, D K. Mukhopadhyay, J D. Harvey

South32 (S32), a globally diversified mining and metals company, is listed on securities exchanges around the world (ASX, JSE, LSE), with its primary listing being on the Australian Securities Exchange (ASX). Chapter 5 of the ASX Listing Rules (Australian Securities Exchange (ASX), 2019b) requires a mining entity to provide a summary of governance arrangements and internal controls with respect to its estimation processes, estimates and reporting of Mineral Resources and Ore Reserves annually. As a global company, it is also important to design and implement all governance processes and internal controls which can be used consistently across the organisation. The three lines model (previously known as the ‘three lines of defense’ model) is employed across South32 to manage risk where the first line (Practitioners) designs, implements and executes processes and controls to manage risk; the second line (Stewardship) identifies material gaps and improvement opportunities in the first line by monitoring conformance with the group requirements, legislative and regulatory obligations. Second line also assists with the development and improvement of core fundamentals based on industry good practise. The third line (Group Assurance) provides independent and objective assurance over the Group’s system of risk management and control. The estimation of resources and reserves for most of the operations within South32 is managed by the Planning function. The estimation process is part of the annual Life of Operation Plan (LoOP). The LoOP identifies and assesses the strategic alternatives for the development of an operation and recommends the preferred pathway based on value and risk. The LoOP starts with opportunity framing and the updated resources as an input and ends with the short-term plan and annual budget (the outputs). Ore Reserves estimates are one of the outputs from the LoOP. All the inputs and outputs follow internal standards and procedures which includes peer review and performance reconciliation. Stewardship (Second line) which is a centralised function has standards in place to ensure compliance to internal controls and external regulatory requirements. This includes assessment of the competence of Competent Persons, technical reviews, independent audits and training in the relevant chapters of the ASX Listing Rules, Guidance Notes and Appendices. Group Assurance (Third line) which reports to the Risk and Audit Committee of the Board of Directors ensures the design and operating effectiveness of the processes, standards and procedures associated with the estimation and reporting of resources and reserves. While the level of scrutiny has a different intent for each line in the three lines model, the overall purpose is to achieve a consistent outcome across the organisation

May 24, 2023

By G Zhang, I Glacken

Multiple indicator kriging (MIK) has been used in the minerals industry for some decades. As one of the non-linear estimation methodologies, MIK has advantages related to resolving multiple or mixed populations, high variability data and strongly skewed distributions. Applying the MIK methodology requires a lot more effort when compared to other non-linear methodologies, for example localised uniform conditioning. This is due not only to the variogram modelling for multiple indicators, but the validation is also very important because the panel model is fundamental for follow-up work, including the generation of recoverable resources at the local or SMU scale. Apart from this, only a few reported case studies of MIK have documented post-processing of the estimated modelled distribution, representing the probability distribution at point scale at un-sampled locations. The MIK post processing should include the change of support from the point scale to the panel scale, and then the extraction of quantile values from the panel conditional cumulative distribution function (CCDF) for localisation of grades into the SMUs within each panel, based on a ranking estimate marking the SMUs from high to low. In this paper, we present a case study on a gold deposit with the MIK method with full-post processing implemented for recoverable resources. The MIK point estimate was carried out with an indirect lognormal change of support from point to panel scale, and localisation was done with a custom script. The localised uniform conditioning (LUC) method was also applied for comparison purposes. The comparison shows that MIK has advantages compared to LUC when comes to capturing the high-grades, especially when mixed or varying anisotropy is present within the mineralisation.

May 24, 2023

By A. Jahedsaravani, M. Massinaei, M. Zarie

Deep learning is a subset of machine learning that uses artificial neural networks for extracting high-level features from image data. In the present study, a soft sensor is proposed for the prediction of the flotation performance through froth features generated by the use of pre-trained convolutional neural networks. Several state-of-the-art convolutional neural networks (AlexNet, GoogLeNet, VGGNet, ResNet, and SqueezeNet) pre-trained on the ImageNet database are used to predict the metallurgical performance of two flotation systems. The first case study is a batch copper flotation system video-captured over a wide range of process conditions. The second case study is an industrial coal flotation column equipped with a continuous video recording system. The pre-trained networks are used to extract features from the froth images, and these features are subsequently used to predict the flotation conditions and performance. The prediction results by the pre-trained algorithms were compared with the traditional image processing algorithms. This demonstrates the ability of the pre-trained structures to generalize to images outside the ImageNet database. GoogLeNet outperforms other network architectures and provides more accurate predictions of the flotation process behavior and performance.

May 5, 2023

By S. Schutte, J. Pelders, F. Magweregwede, S. Ngobese, W. Botha

A people-centric, systematic approach that involves different stakeholders is considered necessary to successfully address changes associated with modernizing the South African mining industry. In this paper we discuss the inclusion of various South African mining industry stakeholders, particularly the employees, in equipment design and development processes. Data was acquired through a literature review and inputs from South African mining industry stakeholders through focus group discussions, interviews, and an online survey. It was suggested that some of the areas that could be improved by the inclusion of employees in the process are design quality, ergonomics, equipment acceptance by the workforce, safety, efficiency, skills, insight into context of use, and early design iterations and identification of problems. Among the issues considered to be barriers to inclusion were lack of buy-in, lack of resources, difficulty in manufacturers accessing the mines, difficulties in involving too many people, intellectual property concerns, and unavailability of mine employees due to their key responsibilities. Identified critical factors in the equipment design and development process include iterative design, stakeholder participation throughout the process, needs analysis through consultation, and change management. A guideline was developed for worker inclusion in equipment design and development that could be used by the South African mining industry. The study identified several economic and social benefits of including stakeholders in the early stages of design and development. It is recommended that the South African mining industry considers using the developed guideline.

Apr 5, 2023