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AA SPECIFICATION SPEC_114013

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CONTENTS PAGE

1 SCOPE 2

2 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER 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

APPENDIX B: RECORD OF AMENDMENTS 19

APPENDIX C: APPROPRIATE NATIONAL STANDARDS 20

APPENDIX D: RESPONSE MODIFICATION FACTORS 21

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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.

2 REQUIREMENTS TO BE SPECIFIED BY THE ENGINEER


The Owner shall specify the following requirements on all invitations to tender, contracts
or orders:
 Number, title, date and issue of this specification
 Number, title and revision of the relevant drawings
 Machine mass, charge weight, and duty
 Design life expectancy required

3 DEFINITIONS
For the purpose of this specification the following definitions shall apply:

ACCEPTED : A computer-based numerical analysis technique which has


NUMERICAL demonstrable reliability, and is generally accepted by numerical
ANALYSIS analysis practioners
TECHNIQUE

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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APPROPRIATE : The test used to determine dynamic properties of the ground


SEISMIC TEST supporting the foundation. This may be a continuous shear wave
test (CSW) or a compression wave test, as determined be the
Geotechnical Engineer to be the most appropriate

AT : Anglo Technical Services

DESIGN : As defined by AA_SPEC_114001 and AA_SPEC_114010


DRAWINGS

DESIGN : As defined by AA_SPEC_114001 and AA_SPEC_114010


ENGINEER

ERDS : The Appropriate National Standard for Earthquake Resistant


Design

FOUNDATION : The company appointed to construct the foundation


CONTRACTOR

GRADED : Materials supplied to a guaranteed strength, and having a fully


traceable origin

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.

LSDC : The Appropriate National Standard for limit states (alternatively


referred to as load and resistance factor design) design of
structural concrete

LSDS : The Appropriate National Standard for limit states (alternatively


referred to as load and resistance factor design) design of
structural steel

OWNER : The mine company that places the order and receives the goods

QAR : Quality Assurance Representative as defined in AA_STD_100

RESPONSE : This is a factor introduced in earthquake resistant design to allow


MODIFICATION for the ductile behaviour of structures analysed elastically
FACTOR
(Note: Equivalent terms from a range of national standards are given in Appendix
C)

SCC : The Appropriate National Standard for structural concrete


construction

SCS : The Appropriate National Standard for structural steel construction

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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

SLO : The Appropriate National Standard for structural loading

STD : Anglo Discipline Standard

SWL : Safe Working Load of any floor areas intended to support spares or
equipment during installation or maintenance of heavy machines

The following terms are defined in the General Conditions of Contract:


 Anglo American, Approved, Company, Contractor, Engineer

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.

4.1.2 Deviation from this Specification

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.

4.1.3 Meaning and Precedence of Information

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.

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4.2.1 Alternative Designs

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.

Cold worked, high yield steel reinforcing shall not be used.


 Concrete

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).

The maximum grade for structural concrete shall be C 40/50.

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

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 Maximum and normal operating product charge mass, including overload


where applicable
 Maximum and normal operating grinding ball charge mass, where applicable
 Maximum motor start-up torque values and characteristics
 Maximum trip or stalling torque based on the motor characteristics and control
limits
 Short circuit torque and fluctuation with time
 Maximum braking loads, where applicable
 All static and dynamic loads applied by the machine to the foundation,
together with the frequencies of the dynamic loads
 Electro-magnetic forces between the rotor and the stator, where applicable
 Static and dynamic loads in the vertical and horizontal directions at all holding
down bolt locations, together with the frequencies of the dynamic loads
 Jacking loads, where applicable
 Construction or manufacturing tolerance for all rotating components
 Rotational speed of motor
 Rotational speed of machine
 Lifter loads and frequency, where applicable
 The gear meshing frequency between the pinion and girth gear, where
applicable
 The eccentricity of the cone or moving jaw, where applicable
 Thermal loads applied to the foundation, where applicable
 Rope break strength for mine winders
 Dynamic Loads and Frequencies

The Foundation Contractor shall make design provision for at least the following
dynamic loads and frequencies:

a. Sag mills and ball mills


- Out-of-balance load of the motor at the motor rotation frequency
- Out-of-balance load of the mill at the mill rotation frequency
- Lifter loads at the lifter frequency
- Application of short circuit torque
- On gearless mill drives only, a torque fluctuation amplitude equal to 1%
of the operating torque at the pole passing frequency
b. Cone crushers, jaw crushers, roll crushers and mineral sizers
- Out-of-balance load of the motor at the motor rotation frequency
- Out-of-balance load of the crusher at the crusher operating frequency

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c. Rock breakers, scrubbers, pelletisers and kilns


- Out-of-balance load of the motor at the motor rotation frequency
- Out-of-balance load of the drum at the drum rotation frequency
- Amplitude of load fluctuation on the drum support rollers shall be taken
as not less than 25% of the nominal support roller load at a frequency
equal to the drum rotation frequency multiplied by the number of
segments from which the drum is constructed
d. Mine winders
- Out-of-balance load of the motor at the motor rotation frequency
- Out-of-balance load of the drum at the drum rotation frequency
Note: For all four of the above types of machines, the out-of-balance load shall be taken as not
less than:

FO  1,5me(2fR ) 2
 60mef R2
where m is the mass of the rotating part of the machine

e is the specified maximum construction or manufacturing tolerance

fR is the rotational frequency of the machine in cycles per second

e. Machines with reciprocating engines


- Out-of-balance load of the engine, including pistons and crankshaft, at
the engine rotation frequency
- Out-of-balance moment of the engine, including pistons and crankshaft,
at the engine rotation frequency
- A torque fluctuation amplitude which shall be taken as not less than 10%
of the maximum nominal torque, at a frequency equal to the rotation
speed multiplied by the number of pistons
 Storage and Maintenance Loads

Where it is intended that any spares or equipment are to be stored on floors


surrounding the foundation, or placed there during installation or maintenance, this
shall be stated by the EPCM Contractor, who shall provide the loads. All floors and
their supports shall be specifically designed for this purpose. Any area designed for
storage purposes or load carrying during installation or maintenance shall be
specifically and clearly marked with the floor SWL.
 Construction and Installation Loads

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.

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 Seismic Loading

Where applicable to the installation site, the foundation shall be designed to


withstand seismic loading when operating under full load. Design for seismic
loading shall be in compliance with either the ERDS, or the IBC.

Where an alternative seismic design procedure is proposed, this shall be stated in


the tender submission, together with a proper motivation for consideration by the
Owner.

In assessing the seismic design loads, the following shall apply:

a. Earthquake zone

The earthquake zone applicable to the actual location of the site shall be used.

b. Response modification factor

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.

Mill, bearings and cradle

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.

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 All lateral seismic load.


Note: “d” is the diameter of circular piles, or the smallest horizontal dimension of non-circular piles
 Fatigue Loads

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

4.2.4 Other Design Information


 Heavy Machine Foundation Performance Specification

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:

a. Overall displacement limitations

b. Limitations on the relative displacements between different machine support


points. In particular, where bearings and pinions or other drive components
are supported by separate plinths, the maximum permissible relative
displacement shall be specified

c. Dynamic behaviour limits. For types of heavy machines where international or


national standards or specifications are available for the evaluation of
vibration, these shall be used. Where no other standards or specifications are
available, the heavy machine manufacturer shall provide a specification
against which the calculated dynamic behaviour can be evaluated

These heavy machine foundation performance specifications shall be included in


the tender documentation for the foundation design.
 Minimum Life Expectancy

The minimum life expectancy to be used in the foundation design is 20 years.


Where the Owner has specified a life expectancy in excess of 20 years, this longer
life expectancy shall be used in the design.
 Walkways and Access Stairs

Any walkways and access stairs shall comply with the requirements of
AA_SPEC_114005.

4.2.5 Responsibility for Design


 New Foundations
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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.

4.2.6 Design Drawings


 Drawings to be provided by EPCM Contractor

The EPCM Contractor shall provide at least the following drawings:


 General arrangement drawings. These shall include all main dimensions
 Required clearances around the equipment for installation, maintenance and
repair
 Any special foundation or support requirements must be emphasised
 Foundation footprint drawing
 Holding down bolt drawings, showing all bolt locations, bolt sizes and bolt
schedule
 Drawings must show any saddles
 Drawings showing the location, layout and footprint of cradles, jacking points,
or other requirements for lifting equipment or temporary support for the heavy
machine during installation or maintenance
 Required foundation stiffness: mill bearing locations, pinion gearbox, barring
system and motor mounting

These drawings shall be completed and stamped “CERTIFIED FOR


CONSTRUCTION” and approved by an authorised person.
 Drawings to be Provided by Foundation Contractor

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.

In addition, the design drawings shall provide the following information:


 The location and size of all holding down bolts
 The loads for which all holding down bolts are designed

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4.2.7 Layout of Foundation


 Single Raft Base

The entire foundation shall be constructed on a single raft base. The base shall not
have any construction joints.

Where a new heavy machine is to be mounted on an existing foundation having one


or more construction joints, the EPCM Contractor shall assess the implications of
possible movement across the construction joints and shall confirm in writing that
this will not detrimentally influence the operation or the expected life of the heavy
machine.
 Plinths

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.

Where a new heavy machine is to be mounted on an existing foundation having


adjoining plinths not solidly joined together, the EPCM Contractor shall advise the
Owner if there is any detrimental influence on either the operation or the expected
life of the heavy machine.

4.2.8 Ground Dynamic Performance

All ground characteristics shall be determined by site testing undertaken by competent


Geotechnical Engineers.
 Ground Settlement

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

Ground elastic modulus

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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The Geotechnical Engineer shall consider the possibility of ground liquefaction


under seismic conditions. Where liquefaction is possible, the Geotechnical
Engineer shall specify measures to stabilise the ground to eliminate liquefaction.

4.2.9 Full System Dynamic Analysis


 Full System Dynamic Analysis Parameters

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.

Parameter Basic parameters High stiffness Low stiffness


parameters parameters

Concrete elastic Nominal value 1,4 x Nominal 0,7 x Nominal


modulus value value

Ground elastic Nominal value 2,0 x Nominal 0,5 x Nominal


modulus value value

Table 6.1: Range of Full System Dynamic Analysis Parameters

 Requirements for Full System Dynamic Analysis

The full system dynamic analysis shall include at least the following:

a) Definition of all natural frequencies and mode shapes having a frequency of


less than 1.5 times the maximum exciting frequency

b) Calculation of the stress and acceleration, velocity, or displacement response


of the system to the specified dynamic loads

c) Calculation of the stress and acceleration, velocity, or displacement response


of the system to seismic loads where applicable

In each case, the analyses shall be carried out using the basic parameters, the high
stiffness parameters and the low stiffness parameters.
 Analyses Required

The following full system dynamic analyses are 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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b) In addition, where the particular heavy machine proposed is of novel


construction, the EPCM Contractor shall arrange for AT or an independent
company approved by the Owner to perform a second independent dynamic
analysis of the full system using an Accepted Numerical Analysis Technique.
Where there is a difference of more than 5% in any of the significant
frequencies or the displacement responses calculated by the EPCM and by
the independent company, the discrepancies shall be resolved to the
satisfaction of the Owner.
Note: A heavy machine shall be considered novel if there have not been at least five machines
of similar design, and of the same size or larger, operating for at least three years.

These analyses shall be completed, and any discrepancies resolved, prior to


commencement of construction of the foundation.
 Evaluation of Analysis Results

The calculated dynamic stresses shall be evaluated in terms of the LSDS or LSDC.

The acceleration, velocity, or displacement response shall be evaluated in terms of


relevant international or national specifications, or the heavy machine
manufacturer’s specifications, as listed in the heavy machine foundation
performance specification.
 Minimum Fundamental Frequency

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.

4.2.10 Design Review

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:

a) Sag Mills and Ball Mills


 For all mills, the finite element analysis of the foundation to confirm that this
has sufficient strength and stiffness
 For all mills, the finite element analysis of any steel components of the
foundation to confirm that these have sufficient fatigue life
 For mills with gearless mill drives, the finite element analysis of the mill, the
mill bearings, the motor stator and the foundation to confirm that these
components have sufficient stiffness to withstand magnetic forces of the
gearless drive without unacceptable variation of the motor air gap
 For all mills where applicable, the full system dynamic analysis to confirm
appropriate natural frequencies and dynamic response

b) Crushers and Mineral Sizers


 The finite element analysis of the foundation to confirm that this has sufficient
strength and stiffness

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 The finite element analysis of any steel components of the foundation to


confirm that these have sufficient fatigue life
 Where applicable, the full system dynamic analysis to confirm appropriate
natural frequencies and dynamic response

c) Rock Breakers, Scrubbers and Pelletisers


 The finite element analysis of the foundation to confirm that this has sufficient
strength and stiffness
 The finite element analysis of any steel components of the foundation to
confirm that these have sufficient fatigue life
 Where applicable, the full system dynamic analysis to confirm appropriate
natural frequencies and dynamic response

d) Machinery with Reciprocating Engines


 The finite element analysis of the foundation to confirm that this has sufficient
strength and stiffness
 The finite element analysis of any steel components of the foundation to
confirm that these have sufficient fatigue life. This will include piping and other
stiff elements spanning between the foundation and supports off the
foundation
 Where applicable, the full system dynamic analysis to confirm appropriate
natural frequencies and dynamic response

4.2.11 Record of Analyses

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

The construction shall comply with the requirements of AA_SPEC_114002 and


AA_SPEC_114011, as amended by this Specification.

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.

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4.3.3 Compliance with Design Drawings

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.

4.3.4 Construction Details


 Holding down bolt templates

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

Consideration shall be given to placing holding down bolts in sleeves to facilitate


their replacement in the event of cracking or corrosion. Where sleeves are not used
for holding down bolts, the reasons shall be provided to the Owner.

4.3.5 Certification

All materials used shall be traceable.

Chemical composition and mechanical properties certification of materials shall be


submitted to the Project Engineer or the Owner on request.

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

The performance of the structures supplied in terms of this specification, as defined


by the order, shall be warranted by the Supplier.
 Performance Test

a. Impact Test

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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.

b. Evaluation of Impact Test

The test may be accepted as demonstrating acceptable correlation with the


analytical prediction of dynamic characteristics of the full system provided:

All significant natural frequencies are not more than 5% closer to their
associated exciting frequency

No significant natural frequencies vary by more than 10%

The coefficient of variation of the mode shapes associated with all significant
natural frequencies does not exceed 25%

c. Action on Unacceptable Correlation

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

5.1 QUALITY MANAGEMENT


The requirements of ISO 9001 shall apply. All optional requirements in ISO 9001 shall be
compulsory requirements for material supplied against this specification.

Quality management and quality assurance arrangements shall be in accordance with


AA_STD_100, Quality Requirements for Suppliers of Critical and Major Equipment.

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.

5.2 QUALITY PLAN


The Foundation Contractor shall compile and submit a quality plan for the design and
construction of all foundations for heavy machines. This quality plan shall:
 be separate from the quality plan for design and construction of other structures
 list all major works, specifications, tests, methods of test, equipment to be used and
acceptance/rejection criteria

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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.

6 SAFETY AND RISK

6.1 ANGLO FATAL RISK STANDARDS


All work on foundations for heavy machines shall take cognisance of the Anglo Fatal Risk
Standards, in particular the standards for AA_AFRS_1, Light Vehicles, AA_AFRS_7
Working at Heights and AA_AFRS_8, Lifting Operations.

6.2 RISK ASSESSMENT


6.2.1 New Installations

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.

6.2.2 Minimum Requirements

In addition to all construction related risks, the risk assessment shall consider at least the
following:

a. Site climatic conditions


 The site elevation, temperature range, humidity, ambient dust level, oxygen
level etc.

b. Access and access protection


 Access to site for all construction vehicles.
 Separation of the Foundation Contractor’s area of responsibility from other site
construction and operational activities.

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c. Blasting
 Where blasting is required, special consideration shall be given to the
associated risks.

6.2.3 Site Safety Requirements

The Foundation Contractor shall be thoroughly familiar with all site safety requirements,
and shall enforce compliance by all employees.

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APPENDIX A: REFERENCE DOCUMENTS


AA SPEC 114013; Foundations for Heavy Machines

The latest issue of the following documents is deemed to form part of this specification:

AA_AFRS_1 : Light Vehicles

AA_AFRS_7 : Working at Heights

AA_AFRS_8 : Lifting Operations

AA_STD_99 : Risk Management on Projects

AA_STD_100 : Quality Requirements for Suppliers of Critical and Major Equipment

AA_SPEC_114001 : Design of Steel Structures

AA_SPEC_114002 : Construction of Structural Steelwork

AA_SPEC_114005 : Steel and FRP Flooring, Stairs, Ladders and Guardrails

AA_SPEC_114010 : Design of Concrete Structures

AA_SPEC_114011 : Construction of Structural Concrete

AA_SPEC_323001 : Grinding Mills and Scrubbers – Gear Driven

AA_SPEC_330001 : Gyratory Crushers

AA_SPEC_330002 : Cone Crushers

IBC : International Building Code, International Code Council (Seismic Design)

ISO 9001 : Quality Management Systems - Requirements

APPENDIX B: RECORD OF AMENDMENTS

Issue 0 : New Document (Dr. G. Krige; March 2010)

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APPENDIX C: APPROPRIATE NATIONAL STANDARDS


Country
Code Australia Europe South Africa USA
Letter
s
ERDS SANS 10160-4 “Basis of Structural IBC “International Building Code”
Design and Actions for Buildings and ASCE 7-05 “Minimum Design Loads for
Industrial Structures. Part 4: Seismic Buildings and other Structures”
Actions and General Requirements for
Buildings”
LSDC AS 3600 “Concrete EN 1992 “Design of SANS 10100-1 “The structural use of
Structures”. Concrete Structures”. concrete. Part 1: Design”.
SANS 10100-2 “The structural use of
concrete. Part 2: Materials and execution
of work”.
LSDS AS 4100 “Steel Structures”. EN 1993 “Design of Steel SANS 10162-1 “The structural use of steel.
Structures”. Part 1: Limit-state design of Hot Rolled
Steelwork”.
SCC AS 3600 “Concrete EN 1992 “Design of SANS 2001 CC1 “Construction works
Structures”. Concrete Structures”. Part CC1: Concrete works (structural)”.
SCS AS 4100 “Steel Structures”. EN 1993 “Design of Steel SANS 2001 CS1 “Construction works Part
Structures”. CS1: Structural steelwork”.
SLO AS/NZS 1170 “Minimum EN 1991 “The structural SANS 10160 “The General Procedures
Design Loads on Structures”. loading basis of design, and Loadings to be Adopted in the Design
dead, imposed, fire, snow of Buildings”.
and wind loads”.

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APPENDIX D: RESPONSE MODIFICATION FACTORS

Equivalent terms used in different national standards to mean the same as “response modification
factors” are listed below:

Chile NCh 2369 Response modification factor

South Africa SANS 10160-4 Behaviour factor

USA UBC Global ductility coefficient

IBC Not used. Refer to ASCE 7

ASCE 7 Response modification coefficient

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