SP0579-005.00-G25-0134 Sub 01 Status A

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PROJECT NO: SP0579

PROJECT NAME: Etoile Copper
VENDOR/CONTRACTOR: Outotec
CLIENT: SENET
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PURCHASE ORDER NUMBER/CONTRACT NO: SP0579-MM005-3M6-005
TAG NO. / EQUIPMENT NUMBERS:
DRS CATEGORIES: C1
EQUIPMENT TITLE: Ball Mill
STATUS STAMP
Approved – Work May Proceed

Permission to proceed does not constitute acceptance or approval of
design details, calculations analysis, test methods or materials
developed or selected by the supplier and does not relieve the supplier
from full compliance with contractual obligations.
By Erns Hattingh (e.hattingh@senet.co.za) at 2:12 pm, Aug 07, 2015
REMARKS
VENDOR NO: FS001

DOCUMENT TITLE: Foundation Specification
REVISION: 14
SENET DOCUMENT NUMBER: SP0579-005.00-G25-0134

SUBMISSION NUMBER:
SUBMISSION DATE:
SP-PROJ-07-5 Vendor DocCover Sheet - Word Rev01 23-03-

15.docx
Dokument/Document Kapitel/Chapter
Mill Foundation Design Specification

FS 001
Utfärdare/Author Godkänd/Approved Sidan/Page
Jeff Belke 1(19)
REV. No. DATE DESCRIPTION BY CHKD APPD
12 13.11.2013 Additions to approved grouts list, indicated in italics BDB JB JB
13 19.08.2014 Clarification to foundation load case requirements BDB NG NG
14 04.11.2014 Correction to Seismic Acceleration units BDB BDB NG
This document is the private and the confidential property of Outotec and may only be used with written permission of Outotec’s
management. This document shall not be copied, altered or plagiarized without the written permission of Outotec. Upon completion
of any contract this document shall be deleted from all computer files and all printed copies destroyed.
1.0 SCOPE
This specification covers the design of mill foundations and is intended to provide
complimentary advice to the project specification foundation drawings.
Both gear and gearless driven mills are described herein. Where applicable,
subsections specific to each drive type are included.
For the purposes of this specification the following definitions shall apply:
Outotec: the Mill Supplier
Engineer: the Mill Foundation Designer
2.0 FOUNDATION LOAD DRAWING
This section is intended to provide additional detail to help understand the Foundation
Load Drawing.
2.1 The table within the Foundation Load Drawing summarises all loads acting on
the foundations from the mill, the charge, the drive train and seismic conditions.
All loads caused by the mill, the charge, the drive train and seismic conditions
have been separated and are displayed in columns across the table. Each load
is broken down into forces acting in the X, Y and Z axis, acting at each of the
main mill support bearings and pinion bearings, which are displayed in rows
down the table. The details of how these forces should be applied to the
foundations is described in Section 4.2.
Gear Driven
The Drive Loads and Charge Loads both contain a continuous load component
and a dynamic load component. The continuous component is displayed in the
left column of each of the two load columns and the dynamic component in the
right.
Gearless Motor Driven

The Charge Loads contain a continuous load component and a dynamic load
component. The continuous component is displayed in the left column and the
dynamic component in the right.

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2.2 All of the loads defined in the load table on the Foundation Load Drawing are
Primary Loads, with no safety factor applied, so as to be suitable for use in
combination using methods defined by local design standards.
The Engineer must apply the requirements of the applicable civil and structural
standards for foundation design.
2.3 The Seismic force is calculated by multiplying the fully loaded mill weight by the
Seismic acceleration co-efficient. The mill loadings are based on a seismic
acceleration coefficient of 0.1 m/s2 unless otherwise stated.
2.4 Forces in the Dead Loads column include self weight only excluding charge or
drive related forces; whereas all forces listed in other columns are live loads. In
the case of live load columns the dynamic component of the live load, if
applicable, is listed in a ”fraction” type fashion adjacent to the steady state
component of that live load. The dynamic load range is determined by:
1. the steady state component added to the denominator of the adjacent
fraction to
2. the steady state component added to the numerator of the adjacent
fraction.
2.5 The loads are separated into the X, Y and Z axis, which are defined as positive
in the following directions:
• X axis is horizontal and parallel with the mill centre line and is positive in
the direction from the feed end to the discharge end.
• The Y axis is horizontal and perpendicular to the mill centre line and is
positive in the direction from the left pinion bearing to the right, when
looking at the mill from the feed end.
• The Z axis runs vertically and is positive in the direction from the top of
the foundations into the strata.
2.6 There are a number of significant load cases which can occur during operation
of the mill, these are made up of a combination of individual loads which can be
separated and defined. These load cases are defined as follows:
• The Stationary Mill, Empty load case occurs as the mill is stationary with
no charge.
• The Stationary Mill, Design Charge load case occurs when the mill is
stationary, filled with the design charge.
• The Normal Operation load case occurs when the mill is filled with the
design charge and rotating in steady state at design rotation speed.

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• The Startup Forward Direction load case occurs when the mill is filled
with the design charge and accelerated from stationary to operating
rotation speed in the forward rotation direction.
• The Startup Reverse Direction load case occurs when the mill is filled
with the design charge and accelerated from stationary to operating
rotation speed in the reverse rotation direction.
• The Inching Forward load case occurs when the mill is filled with design
charge and inched in the forward rotation direction.
• The Inching Reverse load case occurs when the mill is filled with design
charge and inched in the reverse rotation direction.
• The Seismic load case occurs when the mill is stationary filled with the
design charge during a seismic event. Although it is likely that the mill will
be under normal operation during a seismic event, in most cases the
addition of the drive load will reduce the total load on the main bearings
and it is therefore considered conservative to model the seismic load
case excluding the drive load.
Loads under each load case in the foundation loading table occur
concurrently with the exception of the seismic load and dynamic
components of the charge load.
The seismic loads listed in the table are the maximum values for each
location & direction and therefore cannot be applied concurrently. The
components of the seismic load listed in the table occur as follows:
o Lateral Y, occurs concurrently at free and held bearings (summing
the lateral Y for the free and held bearings gives the total seismic
base shear).
o Axial X, occurs only at the held bearing (this is the total seismic
base shear) if the lube system is energized
o Axial X occurs at both the held and free end bearing piers if the
lube system is off noting the value for the free end pier is a small
portion of the held end pier to reflect the worst case axial load
carried due to friction between the journal and bearings.
o OR a combination of the Y and X directions ensuring the resultant
of the components does not exceed the total seismic base shear
and the value in each direction and at each location does not
exceed the associated value for that location in the loading table.
The total dynamic charge load as applicable to each bearing housing is

listed in both the lateral Y and vertical Z directions. This total load cannot
occur concurrently in both directions so modeling must consider the worst
case scenario resultant from just one of the following loadings:

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o Lateral Y, the dynamic force may be applied entirely in the Lateral

Y direction.
o Vertical Z, the dynamic force may be applied entirely in the Vertical
Z direction
o A combination of the Y and Z directions ensuring the resultant of
the components does not exceed the value listed in either the
lateral or vertical rows of the table.
The Drive Load – Startup, Operation and Motor Short Circuit (Gearless mill
drives only) applied to the main bearing housings should be applied in either
the lateral Y or vertical Z directions, or any combination of the two directions
ensuring the resultant of the components does not exceed the value listed in
either the lateral or vertical rows.
The Drive Load – Startup, Operation and Motor Short Circuit (Gearless mill
drives only) applied to the stator supports should be applied in the lateral Y
and vertical Z directions concurrently.
2.7 Each load case is a made up of a combination of individual loads, as displayed

across the top of each column in the load table. These loads are defined as
follows:
• The Dead Load defines the forces associated with the mass of the empty mill
including liners.
• The Drive Load defines the forces associated with the transmission of torque
through the drive train during normal operation. The Drive Load has a
continuous component and a dynamic component. The continuous
component defines the constant force transmitted through drive train and the
dynamic component defines the fluctuating forces caused by the gear
meshing. The dynamic load variations occur at the gear meshing frequency.
• The Drive Load – Start-up column defines forces associated with the
gearless mill drive during start-up at trip level motor eccentricity / air gap
reduction.
• The Drive Load – Operation column defines forces associated with the
gearless mill drive during operation at trip level motor eccentricity / air gap
reduction.
• The Drive Load – Short Circuit column defines forces associated with the
gearless mill drive during a motor short circuit event.
• The Charge Load defines the forces associated with the mass of the charge
and has a continuous component and a dynamic component. The continuous
component defines the static weight force of the charge and the dynamic
component defines the fluctuating forces due to the mass of material carried

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Jeff Belke 5(19)
by each lifter. The charge dynamic variations occur at the lifter passing
frequency.
• The Startup Forward Load defines the forces associated with the
transmission of torque through the drive train as the mill is accelerated from
stationary to normal operating speed in the forward rotation direction.
• The Startup Reverse Load defines the forces associated with the
transmission of torque through the drive train as the mill is accelerated from
stationary to normal operating speed in the reverse rotation direction.
• The Inching Forward Load defines the forces associated with the
transmission of torque through the drive train as the mill is inched in the
forward rotation direction. There is a Left and Right column as the inching
drive can be located on either side.
• The Inching Reverse Load defines the forces associated with the
transmission of torque through the drive train as the mill is inched in the
reverse rotation direction. There is a Left and Right column as the inching
drive can be located on either side.
• The Seismic Load defines the additional reaction forces from the mill onto
the main bearings caused by a seismic event.
• The brake stopping force defines loads associated with braking the mill.
3.0 INSTRUCTIONS FOR FOUNDATION DESIGN
Notes:
1. The occurrence of vibrations must be considered during the design of the
supporting structure.
2. Outotec strongly recommends the use of concrete foundations to minimise the
possibility of excessive vibration (steel structures are difficult to design to achieve
the vibration limits stated herein).
3. The continuous lines show the location of embedment parts and the limits of
foundations that must be kept so as to avoid clashes with the mill components.
4. The concrete outlines shown are indicative only and should not be interpreted as
final design concrete dimensions.
5. Unless otherwise stated in the Contract the mill Purchaser is responsible for the
foundation design and dimensions, subject to dimensional limits nominated
herein.
6. The foundation design must take into account strata conditions taken from
repeatable and reliable geotechnical surveys

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Design:
The Engineer must model the foundation system, including the whole structure
and strata, based on the load cases listed below in Table 1 – Gear Drive Mills
and Table 2 – Gearless Drive Mills:
Load Cases Concurrent Loads

Stationary Mill, Empty Dead Load
Stationary Mill, Design Charge Dead Load + Charge Load
Normal Operation Dead Load + Charge Load + Drive Load
Startup Forward Direction Dead Load + Charge Load + Startup Forwards
Startup Reverse Direction Dead Load + Charge Load + Startup Reverse
Inching Forward (Note A) Dead Load + Charge Load + Inching Forward
Inching Reverse (Note A) Dead Load + Charge Load + Inching Reverse
Seismic Dead Load + Charge Load + Seismic
Note A: Inching loads (both forward and reverse) apply

only to the pinion used for inching (typically
called the ’A’ pinion).
Table 1: Load cases and corresponding concurrent loads as detailed on foundation load
drawing for gear drive mills
Load Cases Concurrent Loads

Stationary Mill, Empty Dead Load
Stationary Mill, Design Charge Dead Load + Charge Load
Normal Operation Dead Load + Charge Load + Drive Load -
Operation
Startup Dead Load + Charge Load + Drive Load -
Startup
Motor Short Circuit Dead Load + Charge Load + Drive Load –
Motor Short Circuit
Seismic Dead Load + Charge Load + Seismic
Braking Dead Load + Charge Load + Brake Stopping
Force
Table 2: Load cases and corresponding concurrent loads as detailed on foundation load
drawing for gearless drive mills

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Under all load cases the foundation must achieve:

1. Lower than maximum concrete stresses
2. Lower than maximum ground bearing pressures
3. Maximum vibrations anywhere in the mill foundations of less than 5mm/s
RMS (Seismic and motor short circuit load cases excluded)
4. Not more than 200 microns of differential longitudinal movement between the
mill’s main bearing pedestals (piers). (Seismic and motor short circuit load
cases excluded)
Additional concrete / reinforcements must be added until the above limits are
met.
4.0 TECHNICAL NOTES
4.1 It is very important that the connection of the foundation to the underlying strata
is accurately modeled, as the Mill Supplier has found in many past cases of high
foundation vibration the root cause has been the inaccurate modeling of the
strata connection.
4.2 For the purposes of modeling Outotec suggests torques and loads are applied to
the foundation as follows:
1. Torques nominated as occurring around the mill centre line or shaft
centerlines should be applied to the foundation hold down bolts against
which they will act via rigid links.
2. Horizontal forces nominated as occurring at the top of pedestals should
be transferred to the foundation by conversion of the loads to equally
distributed surface pressures applied to the appropriate shear key recess
area (depth times width) through which the forces will be transferred.
3. Vertical up forces nominated as occurring at the top of pedestals should
be applied to the foundation hold down bolts against which they will act
via rigid links.
4. Vertical down forces nominated as occurring at the top of pedestals
should be transferred to the foundation by conversion of the loads to
equally distributed surface pressures applied to the appropriate base
plate area (length times width) through which the forces will be
transferred.
Having said this the Engineer needs to apply current best practice to the torque
and load application to ensure accurate analysis.
4.3 There are no specific additional start up or inching foundation limits.


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4.4 Where multiple mills are involved:

• Foundation split lines should be incorporated between individual mill
foundations to reduce induced vibration between mills.
• The rotation direction of adjacent mills, particularly geometrically similar mills,
should alternate clockwise / anticlockwise. It is understood this is not always
practical and if not efforts need to be made to reduce adjacent mill vibrations
compounding between each other.
4.5 The mill design is quite tolerant of post installation settlement:

1. Max allowed differential settlement between the different mill items (mill’s
main bearings, motor, etc) delta s= 0,5 mm. More maybe acceptable
subject to Outotec review.
2. Max allowed differential settlement between equipment connected to the
mill (conveyors, pump sumps, etc.) and the mill is 5 mm, but adjustments
maybe required to accommodate this amount.
3. Max allowed inclination delta s / L = 0,3 mm/m.
Key considerations in respect to settlement that occurs during installation,

commissioning and operation are as follows:
• where that settlement affects the pinion contact, hot alignment will be needed
(as is recommended post commissioning),
• where the settlement affects feed seal alignment the feed chute alignment
may need adjustment,
• post settlement the induced vibration from the dynamic process loads must
not exceed 5mm/s RMS and
• post settlement the displaced foundations must not induce interference
between stationary and rotating sections of the mill. This must be
considered on a case by case basis.
4.6 Earthquake loads can be significant and the Engineer must take these into
account when designing the foundation / reinforcements. In particular the Mill
Supplier supplied shear keys must be installed into block outs in the concrete so
as to not rely on the grout bond strength to transfer the seismic loads. The
foundation steel reinforcing must surround these block outs so the shear keys
are enclosed in the horizontal plane by the reinforcing
4.7 The Engineer shall specify the use of a Mill Supplier Approved Grout or Mill
Supplier approved equivalent. The Mill Supplier requires proposed alternatives
to the Approved list to have the following characteristics:
• Minimum compressive strength of 40 MPa within 7 days of pouring at
20 deg C,
• Minimum compressive strength of 60 MPa within 28 days of pouring
at 20 deg C,

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Mill Supplier Approved Grouts:

• BASF Masterflow 928 up to 100mm in depth
• BASF Masterflow 870 up to 100mm in depth and not less than 10mm
• BASF Masterflow 524L up to 125mm and not less than 25mm in
depth
• Conbextra HF (preferred grout) up to 70mm in depth
• Conbextra TS up to 150mm in depth
• Emaco S55 up to 40mm in depth
• Embeco S55 up to 40mm in depth
• Embeco 885 up to 150mm in depth
• Five Star Fluid Grout 100 up to 150mm in depth
• Multigrout 815 NP up to 40mm in depth
• SikaGrout 212 recommended pours 20mm to 50mm in depth,
maximum 100mm in depth
• Duragrout up to 70mm in depth
• Bemix Standard up to 70mm in depth
• Tarmac Cemrok / Easi-flow / ExCel up to 100mm in depth
• Chockfast Orange (specifically recommended for repairs) up to
70mm in depth
• BASF Masterflow 648CP (specifically recommended for grouting sub
sole packers) up to 35 to 65 mm in depth
• Conbextra EP65 (specifically recommended for grouting sub sole
packers) up to 35 to 65 mm in depth
• Epigen 0301 (specifically recommended for grouting sub sole
packers) up to 50mm in depth
• Sikadur 42 TH (specifically recommended for grouting sub sole
packers) applied in depth more than 15mm and up to 150mm
• Sikadur 42 CL (specifically recommended for grouting sub sole
packers) applied in depth more than 25mm and up to 100mm
• Loctite Fixmaster Marine Chocking Orange (specifically
recommended for grouting sub sole packers) applied in a depth more
than 25mm and up to 32mm
• Loctite Nordbak Backing Material (specifically recommended for
grouting sub sole packers) applied in a depth up to 50mm

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Jeff Belke 11(19)
Note: some grouts are suitable for extension via addition of aggregates to
achieve greater depth than nominal maximum. Where this is required the grout
manufacturer’s instructions shall be followed. With written approval from the Mill
Supplier the following extension procedure maybe used:
1. Mix grout in accordance with manufacturer’s instructions.
2. Add screened 5 to 10mm washed, damp coarse aggregate by weight as
per the following table to suit the desired pour depth:
Depth of Pour Required Relative to the % By Weight Aggregate

Grout’s Maximum Nominal Extension
(No more than 150mm may be used for the
Maximum Nominal)
100% (i.e. the datasheet nominal depth) Nil Additional Aggregate
100 to 150% 35 to 50% Aggregate in Mix
Greater than 300% Consult with Outotec
3. Mix until coarse aggregate is uniformly and completely wetted with grout.
4. For mixes using a concrete mixer (rotating drum mixer) add water and
coarse aggregate to mixer first with mixer running followed by grout.
Concrete mixers are only acceptable when extending grout with coarse
aggregate.
Mill Supplier Non-Approved Grouts:

• Concrete. Concrete must not be used for grouting.
4.8 The Engineer should cast in plates around the foundations to allow the use of
hanging scaffold for the installation process. The use of hanging scaffold will
reduce the quantity of grade erected scaffolding significantly and reduce the
installation crew’s use of mobile access equipment such as boom lifts.
Suggested cast in arranged are included in Appendix A.
4.9 Cast in items are very buoyant during the concrete pour and so must be
restrained well so as to avoid detrimental displacement. It is common for civil
contractors to ill consider the buoyancy of the cast ins resulting in displacement
of the cast ins that cannot be accepted for the mill installation, resulting in
extensive remedial works to achieve acceptable cast in placement. It is not
practical for the Mill Supplier to provide the cast in items connected to frames or
restrained in some manner so as to fix the cast ins relative to each other due to
transport limitations. In order to facilitate the Engineer making suitable restraints
in Appendix B we provide examples of frames used to fix cast ins relative to

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Jeff Belke 12(19)
each other, in this way reducing the risk of detrimental displacement during the
concrete pour provided these frames fitted with the cast ins are suitably
restrained to the reinforcing. The intent of that shown is the cast-ins are bolted
to the frames for the duration of the pour, only removing the frame when the
concrete has cured. Please note the frames in Appendix B are only examples
that may or may not provide a suitable restraint arrangement for the cast in
items specific to the mill project in question. It the responsibility of the Engineer
to provide a solution to adequately restrain the cast in items during the concrete
pour so as to achieve the cast in positions needed for the mill installation.
4.10 In conclusion there are many pit falls associated with foundation design. The
paper, ”Considerations for Grinding Mill Foundations.pdf” provides a good,
practical wrap up of some of the issues discussed herein. This paper is in the
2014 SME Proceedings and can be provided by Outotec on request.

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Appendix A: Suggested Hanging Scaffolding Cast in Plates


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Appendix B: Suggested Cast in Frames to Limit Displacement during Pour


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PROJECT NO: SP0579

Approved – Work May Proceed

By Erns Hattingh (e.hattingh@senet.co.za) at 2:12 pm, Aug 07, 2015

VENDOR NO: FS001

SENET DOCUMENT NUMBER: SP0579-005.00-G25-0134

SP-PROJ-07-5 Vendor DocCover Sheet - Word Rev01 23-03-

Mill Foundation Design Specification

2.0 FOUNDATION LOAD DRAWING

Gearless Motor Driven

Mill Foundation Design Specification

Mill Foundation Design Specification

The total dynamic charge load as applicable to each bearing housing is

Mill Foundation Design Specification

o Lateral Y, the dynamic force may be applied entirely in the Lateral

2.7 Each load case is a made up of a combination of individual loads, as displayed

Mill Foundation Design Specification

3.0 INSTRUCTIONS FOR FOUNDATION DESIGN

Mill Foundation Design Specification

Load Cases Concurrent Loads

Note A: Inching loads (both forward and reverse) apply

Load Cases Concurrent Loads

Mill Foundation Design Specification

Under all load cases the foundation must achieve:

4.0 TECHNICAL NOTES

4.3 There are no specific additional start up or inching foundation limits.

Mill Foundation Design Specification

4.4 Where multiple mills are involved:

4.5 The mill design is quite tolerant of post installation settlement:

Key considerations in respect to settlement that occurs during installation,

Mill Foundation Design Specification

Mill Foundation Design Specification

Mill Supplier Approved Grouts:

Mill Foundation Design Specification

Depth of Pour Required Relative to the % By Weight Aggregate

Mill Supplier Non-Approved Grouts:

Mill Foundation Design Specification

Mill Foundation Design Specification

Appendix A: Suggested Hanging Scaffolding Cast in Plates

Mill Foundation Design Specification

Mill Foundation Design Specification

Appendix B: Suggested Cast in Frames to Limit Displacement during Pour

Mill Foundation Design Specification

Mill Foundation Design Specification

Mill Foundation Design Specification

Mill Foundation Design Specification

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