220 V2a MHCB 00029

Object: Escondida OGP1 Project Order No.: G.
0265
Minera Escondida Limitada Part: A-C
Modified Overland Conveyor 2C Chapter:
Bechtel No.: 25713-220-V2A-MHCB-00029 Doc No.: 59045982
TAKRAF GmbH * Torgauer Str. 336 * 04347 Leipzig * Germany page 1
BECHTEL review stamp:
B 14.09.2012 Issued for approval AK MR HT

REV DATE REASON FOR REVISION BY CHECK APROVED BECHTEL
TITEL Preamble of Seismic and Structural Design Calculation
TAKRAF Doc No.: 59045982 REV
BECHTEL Doc No.: 25713-220-V2A-MHCB-00029
Q:\Auftraege_G\0265_OGP1_CV2_mod\...
Rev.: B ...TAKRAF_Lpz\Engin\Statics\A-C_PREAMBLE
14.09.2012 A-C_Preamble_Rev.B.xlsx
Object: Escondida OGP1 Project Order No.: G.0265
A-C Preamble of Seismic and Structural Design Calculation

for Escondida OGP1 Project
Modified Overland Conveyor 2C
Purchaser: Minera Escondida Limitada

Chile
TAKRAF Order number: G0265
TAKRAF Doc No.: 59045982

BECHTEL Doc No.: 25713-220-V2A-MHCB-00029
Engineers in charge
Project Manager TGER| Heiko Teuber

Lead Engineer TGER| Michael Rau
Lead Engineer - Electrical TGER| Gunnar Zergiebel
Static TGER| Andreas Kretzschmar
Logistic/Transport TGER| Uwe Kroll
Quality Assurance TGER| Florian Heinrich
Specialist of seismic design Juan Cassis Mohor 1)
1)
Civil Eng.-Ph.D., Av. Jose Pedro Alessandri 1495, Nunoa - Santiago - Chile
Revisions - Index
revision no. date editor pages status, changes, informations

A 27.07.2012 TGER| A. Kretzschmar 83 for seismic revision and approval of the
seismic design
B 14.09.2012 TGER| A. Kretzschmar 92 for first review by Bechtel
Index
A-C Preamble of Seismic and Structural Design Calculation

A General
A_1 Technical Data

A_1.1 Conveyor Data
A_1.2 Conveyed Material
A_1.3 Performance Criteria
A_2 Climatic Conditions
A_3 Codes and Standards

A_3.1 Load Assumtions
A_3.2 Load Combinations
A_3.3 Strutural Calculation
A_3.4 Construction Materials
A_4 Allowable Stresses & Design Requirements for Structural Calculation

th th
A_4.1 Allowable stress in accordance with AISC 9 or 13 Edition
A_4.2 Design Requirements according to NCh2369
A_4.3 Design Requirements according to "Design Criteria for Civil-Structural"
(25599-230-3DR-S15-00001)
A_5 Fatigue Verification
A_6 Design Requirements
B Loads
B_1 General Loads
B_1.1 Dead Loads
B_1.2 Operation Loads
B_1.3 Live Loads
B_1.4 Belt Tension
B_1.5 Impact Loads
B_1.6 Temperature Load
B_1.7 Snow Load
B_1.8 Wind Load
B_1.9 Seismic Load
B_1.10 Vibration Loads
B_1.11 Maintenance Crane Load
B_2 Actual Loads for Calculation

B_2.1 Tail Station
B_2.2 Conveyor Modules
B_2.3 Truss Sections
B_2.4 Head Station with Gallery
B_2.5 Take-Up Tower
B_2.6 Belt Reel
C Load combinations
C_1 Symbol - Definition
C_2 Load Combinations for Structural Calculation
C_3 Load Combinations for Foundations, Stability and Soil Bearing Pressure
D Structural Design Calculation of Tail Station
E Structural Design Calculation of Conveyor Modules
F Structural Design Calculation of Truss Sections
G Structural Design Calculation of Head Station
H Structural Design Calculation of Take-Up Tower
I Structural Design Calculation of Belt Reel
J Foundation Loads
Minera Escondida Limitada Part: A
Modified Overland Conveyor 2C Chapter: 1
A General
A_1 Technical Data
A_1.1 Conveyor Data
Drive Concept VFD

Drive Station Head End: One Drive at Primary Drive Pulley and
One Drive at Secondary Drive Pulley
Design Capacity (Mass) 12206 t/h

Nominal Capacity (Mass) 9765 t/h
Bulk Density 1,8 t/m3
Capacity (Volume) 6781 m3/h
Capacity Utilization (CEMA) 102 %
Belt Edge Distance 106 mm
Belt Width 1600 mm

Belt Speed 6,80 m/s
Lenght Between Centers 3988 m

Lift -57 m
Required Power All Sections Loaded 2450 kW

Required Power Ascencing Sections Loaded only 3840 kW
Required Power Descencing Sections Loaded only -900 kW
Required Power All Sections Empty 1340 kW
Number of Drive Pulleys 2

Number Of Drives 2
Drive Size 1700 kW
Motor Torque 16230 Nm
Installed Power 3400 kW
Start-up Factor Related to Motor Name Plate max 1,3

Start-up Time All Sections Loaded 180 s
Start-up Time All Sections Empty 180 s
Motor Speed 1000 rpm

Gear Box Ratio 12,5
High Speed Braking

Braking Torque 2 x 14.000 (at motor shaft) Nm
Ratio between Braking Torque and Motor Torque 0,86
Braking Time Fully Loaded 38 s
Braking Time Empty Belt 14 s
Backstop Holding Torque (incl. Safety Factor) per Conveyor 15000 Nm

Min Safety Factor for Holding Torque 1,5
Moment Of Inertia All Sections Loaded 13470 kgm²

Moment Of Inertia All Sections Empty 4930 kgm²
Take-up Unit Gravity Take-up at Head End
(Empty Running) Take-up Force 1095 kN
Diameter Drive Pulley w/o Lagging 1600 mm

Diameter Other Pulleys w/o Lagging 1000 mm
Idler Specification
Idlers In Upper Strand A3-1600-35-178x600-09 mm
Troughing Idler Angle 35 deg.
Idlers In Lower Strand A2-1600-10-152x900-06 mm
Idler Spacing Upper Strand 1,5 m

Idler Spacing Lower Strand 3,0 m
Belt Type St 3600

Belt Weight 94 kg/m
Belt Top Layer Thickness 22 mm
Belt Bottom Layer Thickness 8 mm
Minimum Belt Safety 5,0
Belt Safety - Normal Operation 6,6
Horizontal Curve Routing 2 horizontal curves without changes from current design
A_1.2 Conveyed Material
Material Primary Crushed Copper Ore

Size (100% passing) 356 mm
Bulk Density For Volume 1,8 t/m3
Bulk Density For Loading 2,1 t/m3
Angle Of Repose 37 deg.
Surcharge Angle (CEMA) 15 deg.
Work Index For Ball Mills 18 kWh/t
Moisture Content 3 %
Abrasiveness Abrasive
Corrosiveness No
A_1.3 Performance Criteria
working 365 days / year

working 7 days / week
maintenance 1 shift / week
Component sizing shall be based on 24 hours per day
15 years
A General
A_2 Climatic Conditions
Temperature
Maximum (summer high) 32 C°
Mean 10 C° Rev. B
Minimum (winter low) -10 C° Rev. B
For calculation of steel structure Dt= 30 C°
Relative Humidity 20 to 50 %
Elevation (Above mean seal level) 3200 m
Mean Barometric Pressure 68,4 kPa
Keraunic Level 3 Storm days/year
Precipitation
Rainfall Annual average 7,2 mm
Rainfall Maximum 24 hours 55,8 mm
Snow (Design Load) (NCh 431) 100 kg/m²

Frost Depth 0,7 m Rev. B
Evaporation (up to)
Winter 3,8 mm/d
Summer 10,7 mm/d
Wind Conditions
Wind velocity during operation 90,0 km/h
Wind velocity during operation 25,0 m/s Rev. B
Exposure C (ASCE 7) Gust wind speed 175,0 km/h
Exposure C (ASCE 7) Gust wind speed 48,6 m/s Rev. B
Ground Basic Pressure (NCh 432) 70 kg/m²
Exposure Coefficient (ASCE 7) C
Seconds of gust speed 3 s
Seismic
Zone (NCh 433, NCh 2369) 3
Type of ground II
A General
A_3 Codes and Standards
A_3.1 Load Assumtions 25599-230-3DR-S15-00001

Design Criteria for Civil-Structural
Snow Load NCh 431
Wind Load NCh 432
ASCE 7
Seismic Loads NCh 2369
Impact Loads DIN 22261
A_3.2 Load Combinations 25599-230-3DR-S15-00001

A_3.3 Strutural Calculation
All the steel structures shall be designed by the method of allowable stresses.
Checking with respect to the elastic limit AISC 360

Static/Fatigue strength AISC 360
Classification for fatigue investigations: ISO 5049-1 1994 class C
Dimensioning of members AISC 360

Steel structures consisting of hollow sections
predominantly static loaded AISC 360
Deflections 25599-230-3DR-S15-00001
Loads of Vibratory Equipment 25599-230-3DR-S15-00001

Overturning 25599-230-3DR-S15-00001
A_3.4 Construction Materials
Structural Steel ASTM A36

NCh2369
Bolts For Main Structure ASTM A325

ASTM A490
Bolts For Secondary Elements ASTM A307
Anchor Bolts ASTM A36/A36M or A42-23 (NCh 206)
Concrete NCh 430 and NCh 170
A General
All the steel structures shall be designed by the method of allowable stresses.
A_4.1 Allowable stress in accordance with AISC 9th or 13th Edition
Allowable stress design in accordance with AISC 13th edition (2005)

E= 20.000 kN/cm² (29000 ksi)
G= 7.720 kN/cm² (11200 ksi)
A_4.1.1 Mechanical properties of material

Filler metal J2_16.1-102
for welded joints
yield str. Fy tensile str. Fu ASD AISC 2005 FEXX
[kN/cm²] [kN/cm²] W [kN/cm²]
ASTM A 36 24,82 40,00 1,67 41,37
Filler metal J2_16.1-102

for welded joints
yield str. Fy tensile str. Fu ASD AISC 2005 FEXX
[kN/cm²] [kN/cm²] W [kN/cm²]
ASTM A 572 Grade 50 34,5 45,0 1,67 48,3

ASTM A 500 Grade B 29,0 40,0 1,67 41,4
ASTM A 992 34,5 45,0 1,67 48,3
filler metal : min A36 FEXX = 60 ksi

J2_16.1-102 FEXX = 41,4 kN/cm²
A572 FEXX = 70 ksi
FEXX = 48,3 kN/cm²
A_4.1.2 Welded joints

Table J2.5 ASTM A 36 ASTM A 572 ASTM A 500
Grade 50 Grade B
allow. stress allow. stress allow. stress
[kN/cm²] [kN/cm²] [kN/cm²]
0,6*FEXX Wweld [-] 1,88 1,88 1,88 Weld:tension or

W 0,6*FEXX 24,8 29,0 24,8 compression
Wbase [-] 1,67 1,67 1,67
Fy 24,8 34,5 29,0
Wweld [-] 2,00 2,00 2,00 Weld:shear or
0,6*FEXX 24,8 29,0 24,8 fillet welds
Complete-joint tension normal to 14,9 20,7 17,4

penetration weld axis
groove welds
compression normal to 14,9 20,7 17,4
weld axis
tension parallel to need not be considered

compression weld axis need not be considered
Partial-joint tension normal to 13,2 15,4 13,2

penetration effective area
groove welds
compression normal to need not be considered
effective area

compression axis of weld need not be considered
shear on effect. area 12,4 14,5 12,4
Fillet welds shear on effect. area 12,4 14,5 12,4

compression axis of weld need not be considered
A_4.1.3 Bolt Connections
Bolts A325 Table 2-5 (2 - 41) Bolts A490

Diameter ["] Fu [ksi] Fu [kN/cm²] Diameter ["] Fu [ksi] Fu [kN/cm²]
1/2 ... 1 120,0 82,7 1/2 … 1 1/2 150,0 103,4
1 1/8 … 1 1/2 105,0 72,3
For structural analysis is considered that the friction coefficient will be min m = 0,5
Minimum diameter 3/4"

Minimum quantity 2 bolt per connection
A_4.1.4 Minimum pretension forces

A325 A490
max T b = 0,7*Fu*As
Bolt diam. Strength Nominal bolt Tightening Tightening
[inch] section plane shear plane strength Tb strength Tb
As[mm²] A b [mm²] [kN] [kN]
1/2 91 127 53 66
5/8 146 198 84 106
3/4 215 285 124 156
7/8 298 388 172 218
1 391 507 226 285
1 1/8 509 641 250 356
1 1/4 645 792 316 454
1 3/8 795 958 378 538
1 1/2 966 1140 458 658
A_4.1.5 Allowable working tension force on fasteners
Nominale tensile stress
A325 Fnt = 90 ksi = 62 kN/cm² Table J3.2

A490 Fnt = 113 ksi = 78 kN/cm²
Wt = 2,0 Ft = Fnt/Wt Table 7-1

(7 - 23)
A325 A490
Static Fatigue Fatigue Static Fatigue Fatigue
Bolt diam. Ft [kN] Ft [kN] Ft [kN] Ft [kN] Ft [kN] Ft [kN]
[inch] load cycles load cycles load cycles load cycles load cycles load cycles
< 20000 20000...500000 > 500000 < 20000 20000...500000 > 500000
Fnt/Wt =
[ksi] 45 40 31 56,5 49 38
[kN/cm²] 31,0 27,6 21,4 39,0 33,8 26,2
1/2 39 35 27 50 43 33
5/8 61 55 42 77 67 52
3/4 88 79 61 111 96 75
7/8 120 107 83 151 131 102
1 157 140 108 198 171 133
1 1/8 199 177 137 250 216 168
1 1/4 246 218 169 309 267 207
1 3/8 297 264 205 374 323 251
1 1/2 353 314 243 445 385 298
9th edition 9th edition 9th edition 9th edition
A_4.1.6 Bearing-type Connection
Nominale shear stress

Threads in shear plane
A325 Fnv = 48 ksi = 33 kN/cm² Table J3.2
A490 Fnv = 60 ksi = 41 kN/cm²
Threads excluded from shear plane

A325 Fnv = 60 ksi = 41 kN/cm²
A490 Fnv = 75 ksi = 52 kN/cm²
Wv = 2,0 Fv = Fnv/Wv Table 7-1

(7 - 22)
Allowable loads - Shear per bolt and shear plane
A325 A490
Threads Threads excl. Threads Threads excl.
in shear pl. from shear pl. in shear pl. from shear pl.
Bolt diam. Nominal bolt Allow. Shear Allow. Shear Allow. Shear Allow. Shear
[inch] area Fv Fv Fv Fv
[mm²] [kN] [kN] [kN] [kN]
Shear stress [ksi] 24 30 30 37,5
Shear stress [kN/cm²] 16,5 20,7 20,7 26,0
1/2 127 21 26 26 33
5/8 198 33 41 41 51
3/4 285 47 59 59 74
7/8 388 64 80 80 101
1 507 84 105 105 132
1 1/8 641 106 133 133 167
1 1/4 792 131 164 164 206
1 3/8 958 158 198 198 249
1 1/2 1140 188 236 236 296
A_4.1.7 Combined Tension and Shear Eqn. J3-3b (16.1-109)
A_4.1.8 Allowable stresses - bearing stress
Assumption: min spacing > 3*dhole nominal

min edge distance > 1,5*dhole nominal
d1 edge distance parallel to the force direction

(center of hole to the beam end or to the splice plate end)
minimum d1 = 2*d (d = diameter of nominal hole)
d2 edge distance perpendicular to the force direction

(center of hole to the web end or to the splice plate end)
minimum d2 = 1,5*d (d = diameter of nominal hole)
d3 bolt space
(center of hole to center of hole)
minimum d3 = 3*d (d = diameter of nominal hole)
Fp = 2,4 * Fu/W Eqn. J3-6a (16.1-111)
Wv = 2,0
Fp = 48,0 kN/cm² ASTM A36

Fp = 53,8 kN/cm² ASTM A572 Grade 50
A_4.1.9 Slip Critical Connection 16.1 – 110
Rn = m*Du*hsc*Tb*Ns
for 1 slip plane Ns = 1
Rn = m*Du*hsc*Tb
m= 0,5 slip coefficient Class B

0,35 slip coefficient Class A
Du = 1,13
hsc = 1,00 standard size hole

0,85 hole factor oversized and short-slotted holes
0,70 long-slotted holes
Tb = minimum pretension force
Wv = 1,50 serviceability limit state (standard size hole)

1,76 strenght limit state (oversized and short- and
long-slotted holes)
A325 Slip force Rn [kN] m = 0,5,Class B Rn/Wv [kN]

Bolt diam. standard oversized long-slotted standard oversized long-slotted
[inch] size hole short-slotted hole size hole short-slotted hole
hole hole
1/2 30 25 21 20 14 12
5/8 47 40 33 32 23 19
3/4 70 60 49 47 34 28
7/8 97 83 68 65 47 39
1 128 109 89 85 62 51
1 1/8 141 120 99 94 68 56
1 1/4 179 152 125 119 86 71
1 3/8 214 182 149 142 103 85
1 1/2 259 220 181 173 125 103
A490 Slip force Rn [kN] m = 0,5,Class B Rn/Wv [kN]

Bolt diam. standard oversized long-slotted standard oversized long-slotted
[inch] size hole short-slotted hole size hole short-slotted hole
hole hole
1/2 37 32 26 25 18 15
5/8 60 51 42 40 29 24
3/4 88 75 62 59 43 35
7/8 123 105 86 82 59 49
1 161 137 113 107 78 64
1 1/8 201 171 141 134 97 80
1 1/4 257 218 180 171 124 102
1 3/8 304 258 213 203 147 121
1 1/2 372 316 260 248 180 148
A_4.1.10 Anchor bolts ACI 349 Steel Grade ASTM A36
Allowable forces on a single bolt - kN These allowable shear and tension forces
are valid for the below mentioned values
of reduced edge distances and spaces!
3/4 " 1" 1 1/4 "
Tension Shear Tension Shear Tension Shear
kN kN kN kN kN kN
19,47 0,00 38,94 0,00 69,53 0,00
13,91 2,78 27,81 5,56 41,72 13,91
11,13 4,17 22,25 8,34 27,81 22,25
8,34 5,56 13,91 13,91 16,69 27,81
5,56 6,95 0,00 19,47 0,00 36,16
0,00 9,73
1 1/2 " 2"

Tension Shear Tension Shear
kN kN kN kN
97,34 0,00 194,69 0,00
69,53 13,91 166,88 13,91
55,63 22,25 139,06 27,81
41,72 27,81 111,25 41,72
33,38 33,38 83,44 55,63
22,25 41,72 55,63 69,53
13,91 44,50 33,38 83,44
0,00 52,84 13,91 97,34
0,00 100,13
REDUCED EDGE DISTANCE AND SPACING

Assumed min. bolt edge distance and min. spacing in inches
Bolt diameter d 3/4" 1" 1 1/4" 1 1/2" 2"

[mm] 19,1 25,4 31,8 38,1 50,8
Tens. str. area [mm²] 215 391 645 966 1787
Minimum edge dist 4,5'' 5,0'' 6,0'' 7,5'' 10,0''

[mm] 114 127 152 191 254
Minimum spacing 6 6 6 7,5 10
[mm] 152 152 152 191 254
for design hmin [mm] 250 250 260 310 410

8*d 152 203 254 305 406
or 250mm 250 250 250 250 250
d anchor bolt
hmin
A General
They shall be designed according to the standard AISC 360 and supplemented with the
pertinent recommendations of the standard NCh2369.
A_4.2.1 Limits of the width to thickness ratios for compression elements

(NCH2369-2003, Table 8.1)
A_4.2.2 Limits of slenderness ratio
A_4.2.2.1 General
All components designed according to ISO 5049-1 (FEM, Section II)
lbuckl/i < 150
Loads for all components designed according to

Criterio de Diseno Estructural ANT-D-CRT-0000-SE-001
and AISC Manual of Steel Construction 9th Edition 1989
lbuckl/i < 200
A_4.2.2.2 Seismic requirements

All elements of vertical earthquake-resitant systems (NCh 2369, Para. 8.3.3.)
Earthquake-resistant diagonal elements and struts working in compression
(NCh 2369, Para. 8.7.3.1.)
1/2
lbuckl/i < 1,5*P*(E/Fy) E= 20.000 KN/cm²
yield str. Fy Max l/i

[kN/cm²]
A36, S235, Q235B 24,8 134
A572 Grade 50, A992 Grade 50 34,5 113
A500 Grade B 29,0 124
A_4.2.3 Utilization of compressed diagonal elements (NCh2369, Pra. 8.3.6.)

The earthquake stress in compressed diagonal elements shall be less or equal to 80%
of the resistant capacity defined in the steel design specification.
A_4.2.4 Bolted connections (NCh2369, Pra. 8.5.2.)

The connections of seismic diagonal elements shall be designed to resist 100% of the
tensile capacity of their gross section.
A_4.2.5 Anchorages (NCh2369, Pra. 8.6.)

The design requirements of NCh2369, Para 8.6. are to pay attention.
A General
A_4.3.1 Deflections
Deflections due to live load and wind or seismic load shall not exceed the following:
Beams in general Span/ 300

Truss Span/ 700
Beams supporting vibratory equipment Span/ 1000
Roofs Roofing and secondary members
(purlins and joist hanger) Span/ 240
Floors Floor plate and grating Span/ 200
Floor beams Span/ 240
Walls (wind lateral load) Siding and girts Span/ 180
Crane girders and monorail beams (without impact)
Vertical Span/ 1000
Horizontal Span/ 500
Crane girders and monorail beams (with impact)
Vertical Span/ 600
Horizontal Span/ 500
Belt Conveyors
Grating vertical deformation due to belt
conveyor overload Span/ 600
Grating horizontal deformation due to lateral loads Span/ 600
Horizontal deformation at the ends of the stacker
trusses due to lateral loads, (maximum deformation
shall be limited to ±150 millimeters) Span/ 800
Steel frames for head pulley supports,
speed reducers and drives Span/ 800
Walls of concrete blocks masonry and
partitions rigid joint to the structure H/ 500
Flexible walls and partitions
Firm soil H/ 250
Soft soil H/ 333
Piperack Vertical Span/ 250
A_4.3.2 Modal analysis (resonance check)
Difference between the natural frequency of the first vibration mode of the support and the
equipment frequency
structural frequency less than 2/3 of machine frequency

structural frequency greater than 1 1/2 of machine frequency
The first natural frequency of vibration of the equipment support beam (f n), shall be moved
away from the excitation frequency (fo) of the equipment, in function of the support
conditions of the supporting beam:
Beam joint to the end of Span (m) fn/fo

Column Until 6 0.80 ≥ fn/fo ≥ 1.5
Column Over 6 0.75 ≥ fn/fo ≥ 2.0
Beam Until 6 0.75 ≥ fn/fo ≥ 2.0
Beam Over 6 0.75 ≥ fn/fo ≥ 2.5
A_4.3.3 Concrete
Unless otherwise noted in drawings, the concrete design compressive strengths (f 'c)
shall be in accordance with ACI, as follows:
Use Code NCh f 'c

kgf/cm² psi
Structural concrete (footing, H35 300 3625
equipment foundations,
mill foundations, etc.)
Electric ducts H20 150 2175
Footing and building foundations H35 300 3625
Slab on grade and elevated slabs H35 300 4350
Retaining walls, recovery
tunnel and thickeners
Operating floor at Grinding H35 300 4350
Lean concrete fill H10 75 1088
Compression stress (f 'c) as stated in standard NCh 430 and NCh 170, with level of
confidence will be 90%.
A_4.3.4 Anchor bolts
The minimum bolt diameter shall be 3/4 inches
A_4.3.5 Safety Against Overturning
The design of foundations shall be based on the recommendations of the Project

Geotechnical Report.
The minimum safety factors included in the foundation design shall be as shown as
follows:
Overturning in Retaining Walls 1,5 (1,3 with seismic load)
Overturning in Foundations according to NCh 2369
Sliding in Retaining Walls 1,5 (1,3 with seismic load)
Flotation 1,5
A General
A_5 Fatigue Verification
Fatigue verification will not be considered.
A General
A_6 Design Requirements
The following minimum thickness shall be used for steel shapes
GENERAL CORROSIVE
MINIMUM THICKNESS AREAS AREAS
mm mm
Connection and stiffener plates 6 8
Web thickness of built up sections or rolled shapes 5 8
Flanges of built up sections 6 8
Angles and channels 5 6
Tubular sections 5 6
Purlins 4 6
Checkered plates 5 6
Auxiliary buildings 5 6
Structural Steel Connections
Shop Connections: Generally, the shop connections shall be welded. In some cases,
the shop connections might be bolted for pre-assembly of components according
to drawing instructions.
Field Connections: bolted; field welding only when stated in drawings.
Every connection shall be of bearing type with thread included in shear plane.
The bolts of each element shall comply with ASTM A325.
When friction type connections are required, the surface of connection failure shall
be cleaned and without paint or cleaned and covered with Class B lining as defined
in “Specifications for structural joints, Bolts ASTM A325 or A490”.
Each bolt shall be completely tight unless otherwise stated in drawings.
The bolts for secondary elements (non structural) shall be ASTM A307 or A42-23
(NCh 206).
Minera Escondida Limitada Part: B
B Loads
B_1 General Loads
B_1.1 Dead Loads D
B_1.1.1 Weight of Structure and Equipment DS,E
All masses of the structural steel and mechanical parts of the conveyor arrangement
multiplied in their center of gravity by the acceleration due to gravity are used as dead weights.
Specific
Material Weight
kg/m³
Non-Reinforced Concrete 2400
Reinforced Concrete 2500
Structural Steel 7850
Dry Wood 650
Wet Wood 850
Wood Board 550
Structural Backfill 1) 1900
F. R. P. 1500
1)
Use this value except otherwise indicated in the Geotechnical Report
For civil/structural design, the ore properties shall be as follows:
Crushed Ore
Angle of repose: Stockpiled 37.5 °

Discharge 70.0 °
Density for: Weight 2,1 t/m³

Volume 1,8 t/m³
B_1.1.2 Rock Box Material DRBox
Rock box material will be calculated from rock box volume multiplied by the density.
Rock box volume in accordance with geometrical dimensions
Material density r= 2,10 t/m³

r= 20,60 kN/m³
B_1.2 Operation Loads F
B_1.2.1 Conveyor Material Fo
S1 b
c S2
a
l3
Conveyors shall be designed for a maximum belt loading in accordance with the CEMA method,
and with consideration to the maximum lump size, in accordance with the calculation below.
The minimum edge distance shall be the greater number from either formula:
Edge distance CEMA = 5.5% of belt width + 25 mm

c= 113 mm
Edge distance particle size = 50% of largest particle size + 127 mm,
considering a maximum of 250 mm for each side
largest particle size 356 mm
c= 305 mm
> 250 mm
c= 250 mm
Capacity for belt cross section (CEMA)

Belt width B= 1,600 m
Edge distance c= 0,250 m
b= 1,100 m
l3 = 0,600 m
Angle of repose a= 35 °
Surcharge Angle (CEMA) b= 15 °
S1 = [l 3 + (b - l 3 )*cos a ]² * (tan b) /6
S1 = 0,0455 m²
S2 = [l 3 +(b - l 3 )/2*cos a ] *[((b - l 3 )/2)*sin a ]
S2 = 0,1154 m²
SS= 0,1609 m²
r= 20,60 kN/m³
theoretical load per meter

q= 3,32 kN/m
vbelt = 6,80 m/sec
Q= 8115 t/h
Capacity
Belt cross section (CEMA) Qbelt cross section = 8115 t/h
Nominal Qnominal capacity = 9765 t/h
Design Qdesign capacity = 12206 t/h
Belt speed v= 6,80 m/s
Load per meter q= q = Q/(3600*v)

qbelt cross section = 3,32
qnominal capacity = 3,99
qdesign capacity = 4,99 kN/m
B_1.2.2 Excessive Conveyor Material Fex
Capacity for belt cross section (completely filled)

Belt width B= 1,600 m
Edge distance c= 0,000 m
b= 1,600 m
l3 = 0,600 m
Angle of repose a= 35 °
Surcharge Angle (CEMA) b= 15 °
S1 = [l 3 + (b - l 3 )*cos a ]² * (tan b) /6
S1 = 0,0899 m²
S2 = [l 3 +(b - l 3 )/2*cos a ] *[((b - l 3 )/2)*sin a ]
S2 = 0,2895 m²
SS= 0,3795 m²
r= 20,60 kN/m³
theoretical load per meter

q= 7,82 kN/m
vbelt = 6,80 m/sec
Q= 19137 t/h
Belt speed v= 6,80 m/s
Load per meter qbelt completely filled = 7,82 kN/m
B_1.2.3 Clogging Chutes FCCh
Chute material will be calculated from chute volume multiplied by the density.
Chute volume in accordance with geometrical dimensions
Material density r= 2,10 t/m³

r= 20,60 kN/m³
B_1.3 Live Loads LL
Roofs 100 kg/m²

Laboratories, floors 500 kg/m²
Stairs and walkways 250 kg/m²
Platforms and elevated floors 500 kg/m²
Control rooms, floors 500 kg/m²
Electric rooms, floors 1250 kg/m²
Walkways of conveyor galleries 250 kg/m²
Concentrated horizontal load applied at top of handrails 90 kg
Concentrated vertical load applied at center of stairs step 140 kg
B_1.4 Belt Tension BT
Results from belt calculation
Forces from belt tension in the convex curve BTcc
FV = BT carr + BT return [kN/m]

R
Forces from belt tension in the horizontal curve BThc
FH = BT carr + BT return [kN/m]

R
B_1.5 Impact Loads IL
Horizontal and vertical impact loads at transfer points

Values calculated in accordance with DIN 22261
Vertical load
IL v = 1,0 * q * v * (h/g) 1/2 [kN]
Horizontal load
IL h = 2,0 * q * v² [kN]
g
with: g 10 m/s²
q material load per meter
v belt speed
h height of falling material
B_1.6 Temperature Load T
For calculation of steel structure Dt= 30 °C
B_1.7 Snow Load S
Design load for snow s= 1,000 kN/m²
For Seismic analysis purposes, the snow load shall not be considered concurrent with the
seismic action.
B_1.8 Wind Load
Standard ASCE 7-05
Importance factor I= 1,0

Topographic factor Kzt = 1,0
Air density 0 m height r0 = 1,2240 kg/m³

3000 m height r 3000 = 0,9072 kg/m³
density factor 0,741
qz = 0,613 * K z * K zt * I * V²
Force coefficient Cf = 1,8 (ASCE 7-05, Figure 6-20)

Gust effect factor G= 0,85 (ASCE 7-05, Point 6.5.8)
Cf * G = 1,53
Wind force F= qz * G * Cf * Af
Af projected area normal to wind
Af will be determined in accordance with the shape of the particular components
B_1.8.1 Wind During Operation W
Entire system to operate against a maximum wind velocity from any direction.
v= 90 km/h
v= 25 m/s
Velocity pressure Height above Height above Exposure C Velocity Velocity

ground level ground level pressure pressure
(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
48,8 160 1,39 0,533 0,395
42,7 140 1,36 0,521 0,386
36,6 120 1,31 0,502 0,372
30,5 100 1,26 0,483 0,358
27,4 90 1,24 0,475 0,352
24,4 80 1,21 0,464 0,344
21,3 70 1,17 0,448 0,332
18,3 60 1,13 0,433 0,321
15,2 50 1,09 0,418 0,310
12,2 40 1,04 0,398 0,295
9,1 30 0,98 0,375 0,278
7,6 25 0,94 0,360 0,267
6,1 20 0,90 0,345 0,256
4,6 15 0,85 0,326 0,241
0,0 0 0,85 0,326 0,241
B_1.8.2 Wind Out Of Operation WW
Maximum storm wind velocity v= 175,0 km/h

v= 48,6 m/s
Ground basic pressure q= 70 kg/m²
Velocity pressure Height above Height above Exposure C Velocity Velocity

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
48,8 160 1,39 2,013 1,492
42,7 140 1,36 1,970 1,460
36,6 120 1,31 1,898 1,406
30,5 100 1,26 1,825 1,353
27,4 90 1,24 1,796 1,331
24,4 80 1,21 1,753 1,299
21,3 70 1,17 1,695 1,256
18,3 60 1,13 1,637 1,213
15,2 50 1,09 1,579 1,170
12,2 40 1,04 1,506 1,117
9,1 30 0,98 1,420 1,052
7,6 25 0,94 1,362 1,009
6,1 20 0,90 1,304 0,966
4,6 15 0,85 1,231 0,913
0,0 0 0,85 1,231 0,913
B_1.9 Seismic Load E
B_1.9.1 General
Standard for calculation NCh. 2369-2003
Seismic zone 3
Soil type (Engineering Technical Log – Bechtel & Takraf)
Soil type head area CV-02C III Rev. B
Soil type tail area CV-02C II Rev. B
Total weight P= sum of permanent loads and live loads

P= D + 0,25 * LL + F o Rev. B
Structural response R= 4 Tail Station, Head Station,

modification factor Take-Up Tower, Truss Section
Rev. B and Conveyor Modules, Belt Reel
Damping ratio x= 0,02
Effective maximum A0 = 0,4 *g

ground acceleration
Soil type II III Rev. B
Parameter relative to type T' = 0,35 0,62 s

of foundation ground n= 1,33 1,8
Fundamental vibration period T* = 0,50 s in work
Seismic coefficient C= [2,75*A 0 /(g*R)] * [(T'/T*) n ] * [(0,05/ x ) 0,4 ]

C shall not be lower than C min = 0,25 A o /g
C shall not be greater than C max = Table 5.7
Seismic coefficient for soil type II (tail area CV-02C) Rev. B
C= 0,247 < Cmax = 0,320

C= 0,247 > Cmin = 0,100
 Seismic loads will be calculated with Cmax

C= 0,320
Seismic coefficient for soil type III (head area CV-02C) Rev. B
C= 0,584 > Cmax = 0,320

C= 0,584 > Cmin = 0,100
 Seismic loads will be calculated with Cmax

C= 0,320
B_1.9.2 Horizontal Eh
Base shear Q0 = C*I*P

Q min = 0,5 * I * A 0 /g * P
Base shear for soil type II (tail area CV-02C) Rev. B
Q0 = 0,384 *P
Qmin = 0,240 *P
Eh = Qo = 0,384 *P
Base shear for soil type III (head area CV-02C) Rev. B
Q0 = 0,384 *P
Qmin = 0,240 *P
Eh = Qo = 0,384 *P
Seismic loads are to consider in two orthogonal directions but not simoultaneosly!
B_1.9.3 Vertical Ev
Vertical seismic force for soil type II and III
Fv = ± 2/3 * A 0 /g * I * P
Fv = 0,320 *P
Ev = Fv = 0,320 *P
B_1.10 Vibration Loads VL
These loads correspond to unbalanced dynamic forces due to the operation of the equipment
at certain conditions. The Supplier must deliver the main excitation frequency of the equipment
as well as any other frequency that on its opinion is relevant.
equipment frequency


B_1.11 Maintenance Crane Load G
Mass to be lifted 5,0 t
Lifting load factor 1,20
Hoist load G= 60,0 kN
B Loads
B2 Actual Loads for Calculation
B_2.1 Tail Station
x
21,0
B_2.1.1 Dead Loads D
Ass.-Group Pcs Designation Weight

[t]
Tail return station 82,57
2000 Steel Structure 55,45
2100 Main support structure tail return station 21,00
1 1 Tail pulley support 5,00
2 1 Loading module structure 8,00
3 1 Belt splice module 8,00
2200 Loading chute 22,75
1 1 Loading chute / hopper 20,00
2 1 Liner plates, loading chute 2,50
3 5 Rubber bars for curve chute 0,25
2300 Walkways tail return station 9,50
1 1 Tail pulley support walkways 2,00
2 1 Loading module walkways 5,50
3 1 Belt splice module walkways 2,00
2400 Conveyor crossover 2,20
1 1 Conveyor cross over 2,20

[t]
5000 Outfit 27,12
5100 Belt rip detection system 0,25
3 1 Belt rip detection system at tail end 0,15
4 1 Longitudinal rip detection at tail end 0,10
5150 Digital Image Analysis System 3,20
1 Support for DIAS 3,00
1 Digital Image Analysis System 0,20
5200 Idlers 8,12
5 16 Standard carry idler sets, tail station, A3 1600 - 178 x1,07
600 - 6309
6 16 Impact idler sets, rigid frame, tail station, C3 1600 - 203/152
3,78 x 600 - 6310
7 20 Skirtboard idler sets, retract frame, tail station, A3 1600
2,08- 178 x 600 - 6309
9 4 5-35 transition idler sets, tail station, A3 1600 - 178 x0,30
600 - 6309
10 8 Standard 10 return idler sets, tail station, B2 1600 - 152
0,38x 900 - 6306
11 10 Standard 10 return idler sets, rubber disc, tail station,0,37
B2 1600 - 152 x 900 - 630
12 2 Flat return idler sets, tail station, B2 1600 - 152 x 9000,07
- 6306
13 1 Return training idler set, inverted V, tail station 0,06
5300 Belt scraper 0,13
4 1 V-plow, tail station 0,13
5400 Pulleys 8,30
3 1 Tail pulley, dia. 1000 mm, tail station 8,30
5600 Conveyor covers 0,48
2 12 Conveyor covers, 1000 mm, with hinges, tail station 0,48
5700 Safety guards 4,50
9 1 Tail pulley support, safety guards 1,00
10 1 Loading module, safety guards, tail end 3,00
12 2 Reel support structure, safety guards, tail end 0,50
5800 Miscellaneous equipment 2,15
8 15 Skirtboard sealing clamp devices, tail station 0,15
9 1 Structural & mechanical bolts, tail station 1,50
10 1 Small mechanical parts, tail station 0,50
Fz,D = -825,7 kN
B_2.1.2 Operation Loads F
B_2.1.2.1 Conveyor Material Fo
Conveyor Material
Length L= 21,00 m
Load per meter qdesign capacity = 4,99 kN/m
Fz,Fo = -104,7 kN
B_2.1.2.2 Excessive Conveyor Material Fex
Length L= 21,00 m
Fz,Fex = -164,2 kN
B_2.1.2.3 Clogging Chutes (Loading Chute) FCCh
Cross Section Area ARB = 3,2 m²

Length d= 6,2 m
Volume V= 19,84 m³
Material density r= 20,60 kN/m³
Fz,FCCh = -408,7 kN
B_2.1.3 Live Loads LL
Length L1 = 24,00 m
Width B= 1,00 m
Area ALL = 24,00 m² per side
Basis weight walkway and q= 250 kg/m²

stairs
LL = 12000 kg
Fz,LL = -120,0 kN
B_2.1.4 Belt Tension BT
T4
4
T4
fully loaded empty belt

steady start stop steady start stop
T4 [kN] = 669 684 436 669 684 436
2 x T4 [kN] = 1338 1368 872 1338 1368 872

d pulley [m] 1,000 1,000 1,000 1,000 1,000 1,000
fully loaded start z
684 kN
4 x
684 kN
Return Pulley [kN] upper belt lower belt sum resultant

Fx = 684,00 0,00 684,00
4
Fz = 684,00 0,00 684,00 967,32
Fx,BT = 1368,0 kN
Fz,BT = 0,0 kN
no horizontal and no vertical curve
B_2.1.5 Impact Loads IL
IL v = 1,0 * q * v * (h/g) 1/2
q= 4,99 kN/m
v= 6,80 m/s
g= 10 m/s²
h= 4,5 m/s²
ILv = Fz,IL = -22,7 kN
B_2.1.6 Temperature Load T
B_2.1.7 Snow Load S
Length L1 = 24,00 m
Width (walk way + main girder) b1 = 1,50 m
Area AS = 36,00 m² per side
Fz,S = -72,0 kN
B_2.1.8.1 Crosswise, y-Direction Wy

Area A1 = 35,00 m² right from chute

A2 = 20,00 m² part chute
A3 = 8,00 m² left from chute
A4 = 5,00 m² pulley support
Asum = 68,00 m²
Maximum height h= 3,800 m
Height above Height above Exposure C Velocity Velocity

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
4,6 15 0,85 0,326 0,241
0,0 0 0,85 0,326 0,241
Velocity pressure (3000 m) qz = 0,241 m²

Cf * G = 1,53
F= qz * G * Cf * Af
Fy,W = 25,1 kN
B_2.1.8.2 Along, x-Direction Wx
assumption: 2/3 of wind load across (according to DIN 22261)
F W,x = 2/3 * F W,y
Fx,W = 16,7 kN
B_2.1.9.1 Crosswise, y-Direction WWy

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
4,6 15 0,85 1,231 0,913
0,0 0 0,85 1,231 0,913

Cf * G = 1,53
F= qz * G * Cf * Af
Fy,WW = 94,9 kN
B_2.1.9.2 Along, x-Direction WWx
F WW,x = 2/3 * F WW,y
Fx,WW = 63,3 kN
B_2.1.10 Seismic Load E
Seismic zone 3
Soil type II Rev. B
Structural response R= 4
B_2.1.10.1 Horizontal Eh

Qo = 0,384 *P
Total weight P= D + 0,25 * LL + F o Rev. B
PD = 825,7 kN
PLL = 120,0 kN
PFo = 104,7 kN
P= 983,0 kN
Eh = Qo = 377,5 kN
Eh,x = Qo,x = 377,5 kN

or
Eh,y = Qo,y = 377,5 kN
B_2.1.10.2 Vertical Ev
Fv = ± 2/3 * A 0 /g * I * P
Fv = 0,320 *P
PD = 825,7 kN
PLL = 120,0 kN
PFo = 104,7 kN
P= 983,0 kN
Ev = Fz,EL,v = -314,6 kN
B_2.1.11 Vibration Loads VL
equipment frequency


B Loads
B_2.2 Conveyor Modules
B_2.2.1 General
y x
Belt width 1600 mm

Belt speed 6,8 m/s
Module height 1,50 m

Module length 6,00 m
Bulk density for loading 2,1 t/m3
Nominal capacity (mass) 9765 t/h

Design capacity (mass) 12206 t/h
Excessive capacity (mass) 19137 t/h
Material load per meter nominal capacity 3,99 kN/m

Material load per meter design capacity 4,99 kN/m
Material load per meter excessive capacity 7,82 kN/m
Belt weight 94 kg/m
B_2.2.2 Dead loads D

[t]
Conveyor Modules 2,39
3100 Conveyor Modules 0,33
1 1 Standard ground-mounted conveyor module 0,33
5000 Outfit 2,07
5200 Idlers 0,76
1 4 Standard carry idler sets, A3 1600 - 178 x 600 - 63090,56
3 2 Standard 10 return idler sets, B2 1600 - 152 x 900 - 0,20
6306
5600 Conveyor covers 0,09
1 0,015 Conveyor covers, 1000 mm, with hinges 0,09
7 0,015 Safety Guards 0,09
5XXX Belt 1,13
7 0,094 Belt 1,13
Fz,D = -23,9 kN
Module Length 6,00 m
Conveyor material (design capacity) 4,99 kN/m
Fz,Fo = -29,9 kN
Conveyor material (excessive capacity) 7,82 kN/m
Fz,Fex = -46,9 kN
Forces from belt tension in the convex curve BTcc
fV = BT carr + BT return [kN/m]

R
fV = 1368,0 kN
500,00 m
fz,BT = -2,7 kN/m
Fz,BT = -16,4 kN

Module area A= 5,7 m² Rev. B

Cover area A= 6,6 m²
Projected area A= 12,3 m²

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
4,6 15 0,85 0,326 0,241
0,0 0 0,85 0,326 0,241

Cf * G = 1,53
F= qz * G * Cf * Af
Fy,W = 4,5 kN
F W,x = 2/3 * F W,y
Fx,W = 3,0 kN
B_2.2.7.1 Crosswise, y-Direction WWx

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
4,6 15 0,85 1,231 0,913
0,0 0 0,85 1,231 0,913

Cf * G = 1,53
F= qz * G * Cf * Af
Fy,WW = 17,2 kN
F WW,x = 2/3 * F WW,y
Fx,WW = 11,4 kN
Seismic zone 3
Soil type II Rev. B
Structural response R= 4 Rev. B

Qo = 0,384 *P
PD = 23,9 kN
PFo = 29,9 kN
P= 44,9 kN
Eh = Qo = 17,2 kN
Eh,x = Qo,x = 17,2 kN

or
Eh,y = Qo,y = 17,2 kN
Fv = ± 2/3 * A 0 /g * I * P
Fv = 0,320 *P
PD = 23,9 kN
PFo = 29,9 kN
P= 44,9 kN
Ev = Fv = 14,4 kN
equipment frequency


B Loads
B_2.3 Truss Sections
1,8
3,35°
18,0

[t]
Truss Sections 25,86
1100 Main support structure 13,00
1 Conveyor trusses 8,00
1 Walkways 5,00
5000 Outfit 12,86
5200 Idlers 1,21
13 Standard carry idler sets, A3 1600 - 178 x 600 - 63090,87
7 Standard 10 return idler sets, B2 1600 - 152 x 900 - 0,34
6306
Safety Guards 1,50
5XXX Belt 10,15
0,094 Belt 10,15
Fz,D = -258,6 kN
Conveyor Material
Length L= 18,00 m
Fz,Fo = -89,8 kN
Length L= 18,00 m
Fz,Fex = -140,7 kN
Length L1 = 18,00 m
Width B= 1,00 m
Area ALL = 18,00 m² per side

stairs
LL = 9000 kg
Fz,LL = -90,0 kN
B_2.3.5 Snow Load S
Length L1 = 18,00 m
Width (walk way + main girder) b1 = 1,50 m
Area AS = 27,00 m² per side
Fz,S = -54,0 kN

Area A1 = 32,00 m² bridge

A2 = 25,00 m² cover
Asum = 57,00 m²

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
6,1 20 0,9 0,345 0,256
4,6 15 0,85 0,326 0,241

Cf * G = 1,53
F= qz * G * Cf * Af
Fy,W = 21,9 kN
F W,x = 2/3 * F W,y
Fx,W = 14,6 kN

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
6,1 20 0,9 1,304 0,966
4,6 15 0,85 1,231 0,913

Cf * G = 1,53
F= qz * G * Cf * Af
Fy,WW = 82,7 kN
F WW,x = 2/3 * F WW,y
Fx,WW = 55,2 kN
Seismic zone 3
Soil type III

Qo = 0,384 *P
PD = 258,6 kN
PLL = 90,0 kN
PFo = 89,8 kN
P= 384,4 kN
Eh = Qo = 147,6 kN
Eh,x = Qo,x = 147,6 kN

or
Eh,y = Qo,y = 147,6 kN
Fv = ± 2/3 * A 0 /g * I * P
Fv = 0,320 *P
PD = 258,6 kN
PLL = 90,0 kN
PFo = 89,8 kN
P= 384,4 kN
Ev = Fz,EL,v = -123,0 kN
equipment frequency


B Loads
B_2.4 Head Station with Gallery Rev. B

complete new design
[m]
z
6,90
30,0 22,0 x
B_2.4.1.1 Weight of Structure and Equipment DS,E
Ass.-Group Pcs Designation Drive Station Gallery

Weight Weight
[t] [t]
Complete weight 378,81 109,10
1000 228,10 83,00
1100 Main support structure head drive station200,00 60,00
1 1 Main steel structure 100,00 50,00
2 2 Pontoon 100,00
3 2 Ground anchor 10,00
4 1 Chute platform (former underpass) 10,00
1200 Discharge chute head drive station 0,00 18,00
1 1 Discharge chute 16,00
2 1 Liner plates, discharge chute 2,00
1300 Walkways head drive station 17,00 5,00
1 1 Head end drive station walkways 17,00 5,00
1500 Take-up carriage 11,10 0,00
1 1 Take-up carriage 10,00
2 14 Rope sheaves 0,70
3 125 Rope, m 0,40
Drive Station Gallery

Ass.-Group Pcs Designation Weight Weight
[t] [t]
5000 Outfit 148,21 24,60
5100 Belt rip detection system 0,25 0,00
1 1 Belt rip detection system 0,15
2 1 Longitudinal rip detection 0,10
5200 Idlers 6,04 3,64
1 52 Carry idler sets, A3 1600 - 178 x 600 - 6309 4,34 2,94
2 24 Return idler sets B2 1600 - 152 x 900 - 6306 1,70 0,70
5300 Belt scraper 0,00 0,45
1 1 Primary belt scraper 0,31
2 1 Secondary belt scraper 0,14
5400 Pulleys 53,00 13,00
1 2 Drive pulley, dia. 1600 mm 30,00
2 2 Bend Pulley 1400 mm 13,00 13,00
3 1 Take-up pulley, dia. 1200 mm 10,00
5500 Conveyor drives 69,93 0,00
1 2 1700 kW drive assembly, gear reducer 24,00
2 2 Drive motor 26,00
3 2 Lubrication unit 0,77
4 2 RUPEX coupling 1,20
5 2 Flange coupling 3,80
6 2 Disc brake 0,90
7 2 Hydraulic pack, brake system 0,10
8 2 Swing base 12,00
9 2 Torque arm 0,80
10 2 High speed protection cover 0,16
11 2 Low speed protection cover 0,20
5600 Conveyor covers 1,11 0,66
1 59 Conveyor covers, 1000 mm, with hinges, head end 1,11 0,66
5700 Safety guards 1,76 0,97
1 124 Safety guards 1,76 0,97
5800 Miscellaneous equipment 5,50 1,56
1 1 Hoist 5,0 t for maintenance, head station 0,20
2 2 Wheels discharge chute, dia. 200 mm 0,36
4 2 Bumpers for take-up carriage, head station 1,00
5 1 Structural & mechanical bolts, head station 1,50 0,50
6 1 Small mechanical parts, head station 0,50
7 1 Maintenance devices, head station 2,50 0,50
5XXX Belt 10,62 4,32
1 0,094 Belt 10,62 4,32
8000 Electrical equipment 2,50 1,50
8100 Electrical equipment 2,50 1,50
1 1 Electrical equipment 2,50 1,50
Fz,D = -4879,1 kN
B_2.4.1.2 Rock Box Material DRBox
Area ARB = 1,50 m²

Depth d= 2,00 m
Volume V= 3,00 m³
Fz,DBox= -61,8 kN
Length drive station LDS = 38,00 m

Length gallery LG = 22,00 m
Fz,Fo, drive station = -189,5 kN

Fz,Fo, gallery = -109,7 kN
Fz,Fo = -299,2 kN
B_2.4.2.2 Excessive Live Load Fex
Length drive station LDS = 38,00 m

Length gallery LG = 22,00 m
Fz,Fo, drive station = -297,1 kN

Fz,Fo, gallery = -172,0 kN
Fz,Fex = -469,1 kN
B_2.4.2.3 Clogging Chutes (Rock Box) FCCh
Area ARB = 9,00 m²

Depth d= 2,00 m
Volume V= 18,00 m³
Fz,FCCh = -370,8 kN
Lengths drive station L1 = 12,00 m drive unit head

L2 = 12,00 m drive unit tail
Width (single-sided) B= 1,00 m
Area ALL = 24,00 m²
Lengths drive station L3 = 37,00 m upper level

L4 = 41,00 m lower level
L5 = 10,00 m middle
L6 = 7,00 m stairs middle
L7 = 10,00 m stairs head
Width (both sides, each) B= 1,00 m

stairs
LLDS = 58500 kg
Fz,LL,DS = -585,0 kN
Lengths gallery L1 = 22,00 m bridge

L2 = 7,00 m head

stairs
LLG = 29000 kg
Fz,LL,G = -290,0 kN
Fz,LL = -875,0 kN
#4 #3 #1
#2
T1
T2
T4
T4 1
2
5 T2
T2 T2
4 3
T4
T3 T3
fully loaded empty belt

steady start stop steady start stop
T1 [kN] = 1065 1140 545 740 775 495
T2 [kN] = 1085 1160 550 755 790 500
T3 [kN] = 820 860 555 655 675 530
T4 [kN] = 565 565 565 565 565 565
T1 + T2 [kN] = 2150 2300 1095 1495 1565 995

T2 + T3 [kN] = 1905 2020 1105 1410 1465 1030
2 x T4 [kN] = 1130 1130 1130 1130 1130 1130
d pulley [m] 1,600 1,600 1,600 1,600 1,600 1,600
Mtorque =
(T3-T4)*dpulley/2 212,0 240,0 -4,0 80,0 92,0 -24,0
Mtorque =
(T3-T4)*dpulley/2 204,0 236,0 -8,0 72,0 88,0 -28,0
belt tension at pulleys
z fully loaded empty belt

start stop
T1
1140 495 kN
0,0 0,0 °
1 x
1160 500 kN
2,0 2,0 °
T2
T2
1160 500 kN
2,0 2,0 °
2
1160 500 kN
11,5 11,5 °
T2
T2
1160 500 kN
11,50 11,5 °
3
860 530 kN
0,0 0,0 °
T3
T4
565 565 kN
4,9 4,9 °
4
860 530 kN
0,0 0,0 °
T3
T4
565 565 kN
0,0 0,0 °
5
565 565 kN
0,0 0,0 °
T4
start with fully loaded belt

z
1
2
5
4 3 x
Discharge pulley [kN] upper belt lower belt sum resultant

Fx = -1140,00 -1159,29 -2299,29
1
Fz = 0,00 -40,48 -40,48 2299,65
Bend pulley [kN] upper belt lower belt sum resultant

2 Fx = 1159,29 1136,71 2296,01
Fz = 40,48 -231,27 -190,78 2303,92
Drive pulley 1 [kN] upper belt lower belt sum resultant

3 Fx = -1136,71 -860,00 -1996,71
Fz = 231,27 0,00 231,27 2010,06
[kN] upper belt lower belt sum resultant

Drive pulley 2 4 Fx = 562,94 860,00 1422,94
Fz = 48,26 0,00 48,26 1423,75
Take up pulley [kN] upper belt lower belt sum resultant

5 Fx = -565,00 -565,00 -1130,00
Fz = 0,00 0,00 0,00 1130,00
Fx,BT = -1707,1 kN
Fz,BT = 48,3 kN
stop with empty belt

z
1
2
5
4 3 x
Discharge pulley [kN] upper belt lower belt sum resultant

Fx = -495,00 -499,70 -994,70
1
Fz = 0,00 -17,45 -17,45 994,85
Bend pulley [kN] upper belt lower belt sum resultant

2 Fx = 499,70 489,96 989,66
Fz = 17,45 -99,68 -82,23 993,07
Drive pulley 1 [kN] upper belt lower belt sum resultant

3 Fx = -489,96 -530,00 -1019,96
Fz = 99,68 0,00 99,68 1024,82
[kN] upper belt lower belt sum resultant

Drive pulley 2 4 Fx = 562,94 530,00 1092,94
Fz = 48,26 0,00 48,26 1094,00
Take up pulley [kN] upper belt lower belt sum resultant

5 Fx = -565,00 -565,00 -1130,00
Fz = 0,00 0,00 0,00 1130,00
Fx,BT = -1062,1 kN
Fz,BT = 48,3 kN
Torque support drive pulley 1

start fully loaded 1160 kN
stop empty belt 500 kN
Fz,gear
Fz,motor
Fz,1 Fz,2
a b c

a= 1,50 m Fz,gear = -130 kN

b= 2,00 m Fz,motor = -220 kN
c= 1,50 m
b+c= 3,50 m
Action force from deadweight
Fz,1 = -280,0 kN
Fz,2 = -70,0 kN
Action force from torque (start fully loaded)

M= 240,0 kNm
Fz,1 = -Fz,2 -68,6 kN
Action force from torque (stop empty belt)

M= -24,0 kNm
Fz,1 = -Fz,2 6,9 kN
Torque support drive pulley 2

Fz,motor
Fz,gear start fully loaded 860 kN
Fz,1 Fz,2
b+c
b+c= 3,500 m
Action force from deadweight
Fz,1 = -280,0 kN
Fz,2 = -70,0 kN
Action force from torque (start fully loaded)

M= 236,0 kNm
Fz,1 = -Fz,2 -67,4 kN
Action force from torque (stop empty belt)

M= -28,0 kNm
Fz,1 = -Fz,2 8,0 kN
no horizontal and no vertical curve
Rope Tension Force for Take-up Rev. B

added
Number of ropes 2
Number of reeving 5
Necessary tension force -1130,0 kN
R -115,0 kN
B_2.4.5 Impact Loads IL
IL h = 2,0 * q * v²
g
q= 4,99 kN/m
v= 6,80 m/s
g= 10 m/s²
ILh = Fx,IL = 46,1 kN
B_2.4.7 Snow Load S
Lengths drive station L1 = 12,00 m drive unit head

L2 = 12,00 m drive unit tail
Width (single-sided) B= 3,00 m
Area AS = 72,00 m²
Lengths drive station L3 = 37,00 m upper level

L4 = 41,00 m lower level
L5 = 10,00 m middle
L6 = 7,00 m stairs middle
L7 = 10,00 m stairs head
Area AS = 315,00 m²
Basis weight walkway and q= 1,00 kN/m²

stairs
Fz,S,DS = -387,0 kN
Lengths gallery L1 = 22,00 m bridge

Area AS = 66,00 m²
Lengths gallery L2 = 8,00 m head

Width B= 6,00 m
Area AS = 48,00 m²
Basis weight walkway and q= 1,00 kN/m²

stairs
Fz,S,G = -114,0 kN
Fz,S = -501,0 kN

Area drive station ADS = 190,00 m²

Area gallery AG = 75,40 m²
Area sum Af = 265,40 m²

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
9,1 30 0,98 0,375 0,278
7,6 25 0,94 0,360 0,267
Cf * G = 1,53
F= qz * G * Cf * Af
Fy,W = 111,7 kN
F W,x = 2/3 * F W,y
Fx,W = 74,4 kN
B_2.4.9 Wind Out Of Operation W

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
9,1 30 0,98 1,420 1,052
7,6 25 0,94 1,362 1,009
Cf * G = 1,53
F= qz * G * Cf * Af
Fy,WW = 422,2 kN
F WW,x = 2/3 * F WW,y
Fx,WW = 281,4 kN
B_2.4.10 Seismic Load
Seismic zone 3
Soil type III

Qo = 0,384 *P
PD = 4879,1 kN
PD,RBox = 61,8 kN
PLL = 875,0 kN
PFo = 299,2 kN
P= 5762,9 kN
Eh = Qo = 2212,9 kN
Eh,x = Qo,x = 2212,9 kN

or
Eh,y = Qo,y = 2212,9 kN
Fv = ± 2/3 * A 0 /g * I * P
Fv = 0,320 *P
PD = 4879,1 kN
PD,RBox = 61,8 kN
PLL = 875,0 kN
PFo = 299,2 kN
P= 5762,9 kN
Ev = Fz,EL,v = 1844,1 kN
equipment frequency


B_2.4.12 Maintenance Crane Load G
Mass to be lifted 5,0 t
Lifting load factor 1,20
Hoist load Fz,G = -60,0 kN
B_2.4.13 Connecting Loads from 18m Truss
Vertical loads DL -129 kN

LL -45 kN
Fo -45 kN
Fex -70 kN
S -27 kN
Ev -62 kN
Horizontal loads Wy 11 kN
WW y 41 kN
Eh 74 kN
B_2.4.14 Transport and Assembly Rev. B
possible special bearings
B Loads
B_2.5 Take-Up Tower
17,0
4,00
Take-Up Tower 169,40

1000 Head drive station with take up system
169,40
1500 Take up device head drive station 169,40
1510 Steelwork take up device 89,70
1 1 Take-up tower structure 62,70
2 1 Take-up counterweight box 15,00 Rev. B
4 1 Take-up tower walkways 10,00
5 1 Take-up tower safety guards 2,00
1520 Mechanical parts take up device 4,70
1 1 Service winch 3,50
2 16 Rope sheaves 0,80
3 125 Rope, m 0,40
1530 Take up counterweight 75,00
1 1 Take-up counterweight 75,00 Rev. B
without winch Fz,D = -1659,0 kN

complete Fz,D = -1694,0 kN
Platforms
Quantity Width Length Area
[-] [m] [m] [m]
5 0,90 1,80 8,10
1 0,90 1,00 0,90
2 0,90 6,80 12,24
2 0,90 4,30 7,74
Stairs
[-] [m] [m] [m]
5 0,80 4,70 18,80
Sum Area ALL = 47,78 m²

stairs
LL = 11945 kg Rev. B
Fz,LL = -119,5 kN
Take-up counterweight
Fz = -750,0 kN
Rev. B
added
Rope Tension R= -115,00 kN

Reaction force 1 (45° deflection) F1= 162,63 kN
Reaction force 2 (180° reversal) F2= -230,00 kN
B_2.5.5 Snow Load S
Platforms
[-] [m] [m] [m]
5 0,90 1,80 8,10
1 0,90 1,00 0,90
2 0,90 6,80 12,24
2 0,90 4,30 7,74
Stairs
[-] [m] [m] [m]
5 0,80 4,70 18,80
Structure and Counterweight

[-] [m] [m] [m]
1 4,50 4,50 20,25
Sum Area AS = 68,03 m²
Fz,S = -68,0 kN Rev. B

Rev. B
Area A1 = 71,75 m² Structure

A2 = 7,00 m² Counterw. Box
A3 = 34,00 m² Stairs
Asum = 112,75 m²

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
18,3 60 1,13 0,433 0,321
15,2 50 1,09 0,418 0,310

Cf * G = 1,53
F= qz * G * Cf * Af
Fy,W = 54,8 kN

Rev. B
Area A1 = 71,75 m² Structure
A2 = 7,00 m² Counterw. Box
Asum = 78,75 m²
F= qz * G * Cf * Af
Fx,W = 38,3 kN

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
18,3 60 1,13 1,637 1,213
15,2 50 1,09 1,579 1,170

Cf * G = 1,53
F= qz * G * Cf * Af
Fy,WW = 207,4 kN
F= qz * G * Cf * Af
Fx,WW = 144,8 kN
Seismic zone 3
Soil type III

Qo = 0,384 *P
Total weight P= D + 0,25 * LL Rev. B
PD = 1659,0 kN
PLL = 119,5 kN
P= 1742,6 kN
Eh = Qo = 669,2 kN
Eh,x = Qo,x = 669,2 kN

or
Eh,y = Qo,y = 669,2 kN
Fv = ± 2/3 * A 0 /g * I * P
Fv = 0,320 *P
Total weight P= D + 0,25 * LL Rev. B
PD = 1659,0 kN
PLL = 119,5 kN
P= 1742,6 kN
Ev = Fz,EL,v = -557,6 kN
B_2.5.9 Transport and Assembly Rev. B
possible special bearings
B Loads
B_2.6 Belt Reel
4,5
6,8

[t]
Belt Reel 6,10
1000/2000 Belt Reel 6,00
1100/2100 Main support structure 3,00
4 1 Reel support structure 3,00
1300/2300 Walkways tail return station 3,00
4 2 Reel support structure walkways 3,00
5000 Outfit 0,10
5900 Belt Reel Drives 0,10
1 Drives 0,10
Fz,D = -61,0 kN
B_2.6.2 Operation Loads Fo
Belt Coil
Belt coil weight G= 30,0 t
Fz,Fo = -300,0 kN

Area A1 = 13,00 m² Belt coil

A2 = 2,00 m² Structure
Asum = 15,00 m²

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
4,6 15 0,85 0,326 0,241
0,0 0 0,85 0,326 0,241

Cf * G = 1,53
F= qz * G * Cf * Af
Fy,W = 5,5 kN
Area A1 = 8,00 m² Belt coil

A2 = 2,00 m² Structure
Asum = 10,00 m²
F= qz * G * Cf * Af
Fx,W = 3,7 kN

(0 m) (3000 m)
Kz qz qz
[m] [ft] [-] [kN/m²] [kN/m²]
4,6 15 0,85 1,231 0,913
0,0 0 0,85 1,231 0,913

Cf * G = 1,53
F= qz * G * Cf * Af
Fy,WW = 20,9 kN
F= qz * G * Cf * Af
Fx,WW = 14,0 kN
Seismic zone 3
Soil type III

Qo = 0,384 *P
PD = 61,0 kN
PFo = 300,0 kN
P= 271,0 kN
Eh = Qo = 104,1 kN
Eh,x = Qo,x = 104,1 kN

or
Eh,y = Qo,y = 104,1 kN
Fv = ± 2/3 * A 0 /g * I * P
Fv = 0,320 *P
PD = 61,0 kN
PFo = 300,0 kN
P= 271,0 kN
Ev = Fz,EL,v = -86,7 kN
Minera Escondida Limitada Part: C
Bechtel No.:25713-220-V2A-MHCB-00029 Doc No.: 59045982
C Load combinations for structural calculation

C_1 Symbol - Definition
Symbol Description
D Dead Loads
DS,E Weight of Structure and Equipment
DRBox Rock Box Material
F Operation Loads
Fo Conveyor Material
Fex Excessive Conveyor Material
FCCh Clogging Chutes
LL Live Loads
BT Belt Tension
IL Impact Loads
T Temperature Load
S Snow Load
W Wind During Operation
WW Wind Out Of Operation
E Seismic Load
Eh Horizontal
Ev Vertical
VL Vibration Loads
G Crane Load
C_2 Load Combinations for Structural Calculation

Rev. B
Load combination no. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14
LC no. in design criteria 1) 1 2 3 4 5 6 8 9 10 11
Factor (applied on
1 1 1 1 1 1 1,33 1,33 1 1,33 1,33 1,33 1,33 1,33
allowable stresses)
Reduction factor 1 1 1 1 1 1 0,75 0,75 1 0,75 0,75 0,75 0,75 0,75
Diagonals NCh 2369 8.3.6. 0,94 0,94
Symbol Description
DS,E Struct. weight 1 1 1 1 1 0,6 1 1 1 1 1 1 1 1
DRBox Rock box material 1 1 1 1 1 0,6 1 1 1 1 1 1 1 1
Fo Conveyor mat. 0/12) 0/12) 0/12) 0/12) 0/12) 0/12) 0/12) 0/12)
LL Live loads 1 0,75 0,75 1 1 1 1
BT Belt tension 1 1 1 1 1 1 1 1 0/12) 0/12) 0/12) 1 1 1
IL Impact loads 1 1 1 1 1 1 1 1
T Temperature load 1 0,75
S3) Snow load 1 0,75 0,75 1
W 4) Wind during operat. ±1 ± 0,75 ±1 ±1 ±1 ±1
Eh5) Seismic load horiz. ±1 ±1 ±1
Ev Seismic load verti. ±1 ±1 ±1
G Service crane 1 1 1
FCCh Clogging chutes 1
Fex Excessive conv. mat. 1
WW 4) Wind out of op. ±1
1)
25599-230-3DR-S15-00001-00B Design Criteria for Civil-Structural
7.2 LOAD COMBINATIONS Table ". . . for sizing of foundations,
stability and soil bearing pressure"
2)
absent load / present load
3)
For Seismic analysis purposes, the snow load shall not be considered
concurrent with the seismic action.
4)
Wind loads will be calculated in two orthogonal directions ± W x or ± W y
5)
Horizontal seismic loads will be calculated in two orthogonal directions ± Eh,x or ± W h,y
C_3 Load Combinations for Foundations, Stability and Soil Bearing Pressure
Rev. B
Load combination no. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13
LC no. in design criteria 1) 1 2 3 4 5 6 7 8 9
Factor (applied on
1 1,30 1,30 1,30 1,33 1,33 1 1 1,33 1,33 1,33 1,33 1,33
allowable stresses)
Reduction factor 1 0,77 0,77 0,77 0,75 0,75 1 1 0,75 0,75 0,75 0,75 0,75
Diagonals NCh 2369 8.3.6. 0,94 0,94
Symbol Description
DS,E Struct. weight 1 1 1 1 1 1 1 1 1 1 1 1 1
DRBox Rock box material 1 1 1 1 1 1 1 1 1 1 1 1 1
Fo Conveyor mat. 0/12) 0/12) 0/12) 0/12) 0/12) 0/12) 0/12)
LL Live loads 1 1 1 1 1 1 1
BT Belt tension 1 1 1 1 1 1 0/12) 1 0/12) 0/12) 1 1 1
IL Impact loads 1 1 1 1 1 1 1 1
T Temperature load
S3) Snow load 1 0,5 1 1
W 4) Wind during operat. ±1 ±1 ± 0,5 ±1 ±1 ±1 ±1
Eh5) Seismic load horiz. ±1 ±1 ±1
Ev Seismic load verti. ±1 ±1 ±1
G Service crane 1 1 1
FCCh Clogging chutes 1
Fex Excessive conv. mat. 1
WW 4) Wind out of op. ±1
1)
25599-230-3DR-S15-00001-00B Design Criteria for Civil-Structural
7.2 LOAD COMBINATIONS Table ". . . for sizing of foundations,
stability and soil bearing pressure"
2)
absent load / present load
3)
For Seismic analysis purposes, the snow load shall not be considered
concurrent with the seismic action.
4)
Wind loads will be calculated in two orthogonal directions ± W x or ± W y
5)
Horizontal seismic loads will be calculated in two orthogonal directions ± Eh,x or ± W h,y

220 V2a MHCB 00029

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

220 V2a MHCB 00029

Uploaded by

Copyright:

Available Formats

Object: Escondida OGP1 Project Order No.: G.

BECHTEL review stamp:

B 14.09.2012 Issued for approval AK MR HT

TAKRAF Doc No.: 59045982 REV

BECHTEL Doc No.: 25713-220-V2A-MHCB-00029

A-C Preamble of Seismic and Structural Design Calculation

Purchaser: Minera Escondida Limitada

TAKRAF Order number: G0265

TAKRAF Doc No.: 59045982

Project Manager TGER| Heiko Teuber

revision no. date editor pages status, changes, informations

A-C Preamble of Seismic and Structural Design Calculation

A_1 Technical Data

A_2 Climatic Conditions

A_3 Codes and Standards

A_4 Allowable Stresses & Design Requirements for Structural Calculation

A_5 Fatigue Verification

A_6 Design Requirements

B_2 Actual Loads for Calculation

D Structural Design Calculation of Tail Station

E Structural Design Calculation of Conveyor Modules

F Structural Design Calculation of Truss Sections

G Structural Design Calculation of Head Station

H Structural Design Calculation of Take-Up Tower

I Structural Design Calculation of Belt Reel

A_1.1 Conveyor Data

Drive Concept VFD

Design Capacity (Mass) 12206 t/h

Belt Width 1600 mm

Lenght Between Centers 3988 m

Required Power All Sections Loaded 2450 kW

Number of Drive Pulleys 2

Start-up Factor Related to Motor Name Plate max 1,3

Motor Speed 1000 rpm

High Speed Braking

Backstop Holding Torque (incl. Safety Factor) per Conveyor 15000 Nm

Moment Of Inertia All Sections Loaded 13470 kgm²

Diameter Drive Pulley w/o Lagging 1600 mm

Idler Spacing Upper Strand 1,5 m

Belt Type St 3600

A_1.2 Conveyed Material

Material Primary Crushed Copper Ore

A_1.3 Performance Criteria

working 365 days / year

Keraunic Level 3 Storm days/year

Snow (Design Load) (NCh 431) 100 kg/m²

A_3.1 Load Assumtions 25599-230-3DR-S15-00001

A_3.2 Load Combinations 25599-230-3DR-S15-00001

A_3.3 Strutural Calculation

Checking with respect to the elastic limit AISC 360

Dimensioning of members AISC 360

Loads of Vibratory Equipment 25599-230-3DR-S15-00001

A_3.4 Construction Materials

Structural Steel ASTM A36

Bolts For Main Structure ASTM A325

Concrete NCh 430 and NCh 170

A_4.1 Allowable stress in accordance with AISC 9th or 13th Edition

Allowable stress design in accordance with AISC 13th edition (2005)

A_4.1.1 Mechanical properties of material

ASTM A 36 24,82 40,00 1,67 41,37

Filler metal J2_16.1-102

ASTM A 572 Grade 50 34,5 45,0 1,67 48,3

filler metal : min A36 FEXX = 60 ksi