Aker Kvaerner

Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

INDEX 1.0 2.0 3.0 4.0 5.0 6.0 7.0 SCOPE ...................................................................................................................... 3 APPLICABLE CODES AND STANDARDS............................................................... 3 CLIMATIC INFORMATION OF JOBSITE .................................................................. 4 DESIGN LOADS........................................................................................................ 5 GEOTECHNICAL INFORMATION............................................................................. 8 MATERIAL ................................................................................................................ 9 DESIGN DETAILS ................................................................................................... 11

This current revision (Rev. 3) issued by Aker Kvaerner Santiago is an updated version of document NGD-02, Rev. 2 developed by Aker Kvaerner San Ramon in order to reactivate the project

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

1.0

SCOPE
This specification establishes criteria for the design of all civil, structural, and architectural work for the San Cristobal Project located in the San Cristobal district of Nor Lipez province in the Potosi Department in southern Bolivia, approximately 500 km south of La Paz and 90 km south of the town of Uyuni.

2.0

APPLICABLE CODES AND STANDARDS

Except as noted within this specification, all design and details shall conform to the latest revision of documents listed below. These documents are declared to be a part of this specification the same as if fully set forth herein. The design shall also be in accordance with the requirements of Bolivian national, state and local codes, ordinances and regulations. Where there is a conflict between these documents, the one, which is most restrictive, shall apply. 2.1 GENERAL

Uniform Building Code (UBC) 1997 Occupational Safety and Health Administration (OSHA), Occupational Safety and Health Standards, 29 CFR Mine Safety and Health Administration (MSHA), Mine Safety and Health Standards, 30 CFR 2.2 ROAD STRUCTURES

American Association of State Highway and Transportation Officials (AASHTO), Standard Specifications for Highway Bridges 2.3 ROADS Departamental de Potosi Servicio

Standard Specifications, Prefectura Departamental de Caminos. 2.4 CONCRETE

American Concrete Institute (ACI 318), Building Code Requirements for Reinforced Concrete, 1995 2.5 MASONRY

Uniform Building Code (UBC), 1997

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

2.6

STRUCTURAL STEEL

American Institute of Steel Construction (AISC), Specification for Structural Steel Buildings Ninth Edition. American Welding Society (AWS), Structural Welding Code, Steel D 1.1 - 96 Steel Joist Institute (SJI), Standard Specification for Open Web Steel Joists. 2.7 WOOD

Uniform Building Code (UBC), 1997 See also section 2.0 of Appendix A Standard Technical and Site Data SI Units

3.0

CLIMATIC INFORMATION OF JOBSITE

Climatic Information listed in this specification based on Appendix A, Standard Technical and Site Data and on a draft version of the climatic section of the San Cristobal Environmental Baseline Summary Report by Knight Piesold, dated November 6, 1998. Further revisions to this information may be required when additional data is collected 3.1 TEMPERATURES 26.5o C -9.9 C 21.6 C -10.3 C

Recorded high temperature: (1 years) (station 9) Recorded low temperature: (station 9) Average monthly high temperature: Average monthly low temperature:

NOTE: Average monthly temperatures are based on Regional Data for Elevation 3800 meters. 3.2 PRECIPITATION (AT ELEVATION 3800 METERS) 53 mm 73 mm 81 mm 215 mm Trace

24 hr 10 year storm 24 hr - 50 year storm: 24 hr 100 year storm: Average annual precipitation: Average annual snowfall:

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

3.3

EVAPORATION 68mm 1,275 mm/year 1,820 mm/year

The average annual (March 1997 February 1998) Design Lake Evaporation Design Pan Evaporation 3.4 WIND

Prevailing wind direction: 3.5 FROST

Varies from North to Northwest

Frost depth:

1.0 meter

4.0

DESIGN LOADS
4.1 DEAD LOAD

As determined by design 4.2 LIVE LOAD As determined by UBC 2.4 kPa 4.8 kPa 4.8 KPa 2.4 kPa 4.8 kPa 9.6 kPa 6.0 kPa

Roof load: Platform where only pedestrian traffic is probable: Operating Platforms, unless shown on design drawings: Stair: Offices Assembly, lockers and control rooms, laboratory Electric switchgear rooms Warehouse: Conveyor walkway: For truss design For walkway design All other floor live loads

1.5 kN/m 2.4 kPa or 0.9 (concentrated load) KN

As required for function of floor such as storage,

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

equipment support, vehicles, but not less than 4.8 kPa. Bridge: Concentrated load on any panel point of main trusses additional to all other loads: Concentrated load on slabs (consider with Dead Load only): Concentrated load on floor and main roof beams additional to all other loads: 4.3 WIND LOAD 120 km/h C AASHTO, HS20-44 13.4 Kn 9 kN over 0.3m x 0.3 m area 9 kN

Basic wind speed: Exposure 4.4 SEISMIC LOAD

UBC Zone:

The following seismic parameters, as defined by the Geotechnical Engineer, shall apply. UBC Table 16-I 16-J 16-Q 16-S 16-T 4.5 Parameter Seismic Zone factor Z Soil Profile Type Coefficient Ca Near-Source Factor Na Near-Source Factor Nv Value 0.25 SC 0.29 1.0 1.0

VIBRATING EQUIPMENT

Vibrating loads shall be individually considered and, where feasible, shall be independently supported. 4.6 CRANE FORCES

All crane support structures shall be designed for the loads as specified in AISC, Manual of Steel Construction. Where multiple cranes are used, loads shall be positioned to produce the maximum forces in the members considered. Maximum

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

deflection for crane girders without impact shall not exceed 1/800 of the span length. 4.7 MATERIAL WEIGHT AND ANGLES OF REPOSE 3

Refer to, General Specification N GD-01: General and Process Design Criteria for Concentrator and Infrastructure 4.8 FACTOR OF SAFETY 1.5 1.5 1.5

Buoyancy: Overturning: Sliding: 4.9

LOADING COMBINATIONS FOR BUILDING AND STRUCTURES

D.L. + Operating Load + Crane Load1 D.L. + L.L. + Operating Load3 + Crane Load2 + Wind Load1 (or seismic) D.L. + Wind Load (or seismic) Footnotes: Maximum crane loads need not be combined with more than 0.50 wind or roof live loads. Crane hook load for maintenance type cranes need not be considered in combination with wind or roof live loads. For load combination purposes, conveyor loads shall be treated as operating loads.

Other load types and combinations may be required for specific design applications, i.e. thermal expansion, etc. Conveyor supporting structures shall be designed to carry the reactions from conveyor dead load, material loads (including material loads due to clogged chutes filled to capacity) and walkway live load. Where applicable, piping and/or cable tray loads shall be added. Support structures at conveyor head/tail ends shall be designed for the applicable belt tensions, including the maximum running and maximum motor torque (start-up) belt tensions.

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

All allowable stresses for steel structures and soil-bearing values, may be increased for certain combinations in accordance with UBC. For concrete structures, loads will be factored or stresses may be increased in accordance with ACI 318.

5.0

GEOTECHNICAL INFORMATION
Unless otherwise noted, bottom of all footings and mat foundations shall be a minimum of 600 mm below finish grade, if lightly loaded and founded on free draining fill, but not less than frost depth. 5.1 BEARING PRESSURES

Design soil pressure shall not exceed the allowable values listed below. Values are applicable for foundations on engineered fill as well as for foundations on natural soil. When lateral load due to wind or seismic is included in the design, the listed values may be increased by 33 percent. Facility Crusher Area Sag Mill Ball Mills Flotation Building Column Foundations Flotation Cell Foundations Tailings Thickener Footing on bedrock 5.2 EQUIVALENT FLUID PRESSURES 8.7 kPa/m 5.5 kPa/m 39.0 kPa/m Design Soil Pressure, kPa 955 480 575 955 955 955 955

Lateral earth pressure, at rest: Lateral earth pressure, active: Lateral earth pressure, passive: 5.3 FRICTION

Coefficient of sliding friction: 5.4 SLIDING RESISTANCE

0.55

Full values of friction and passive resistance may be used simultaneously to resist lateral loads. For combinations of loads including seismic load, passive resistance shall not be considered.

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

5.5

OTHER INFORMATION

For other pertinent information see Geotechnical Investigations and Foundation Recommendations Comprehensive report, by Knight and Piesold and Co.

6.0

MATERIAL
Specific makes and catalog numbers of the various items of materials and equipment included in this specification are to establish a minimum acceptable quality of the items. Items of equal quality by other manufacturers may be used. All material shall be new and shall conform to the following requirements unless noted otherwise on the drawings: 6.1 CONCRETE All structural concrete and concrete for floor slabs, walkways and ramps shall develop a minimum compressive strength of 28 MPa at 28 days. Lean concrete shall have a minimum compressive strength of 15 MPa. Cement shall conform to ASTM C150, Type II, unless otherwise indicated on drawings. Grout under all structural steel base plates shall be Masterflow 928 by Master Builders, Inc. or equivalent. Grout under equipment subjected to thermal variation and/or vibration shall be Embeco 885 by Master Builders, Inc. or equivalent. Reinforcing steel shall be deformed bars, limited to No. 10, 13, 16, 19, 25, 29 and 36 sizes, and shall conform to ASTM A 615M, Grade 420. Welded wire fabric shall be an electrically welded approved brand, 152x152MW18.7xMW18.7, conforming to ASTM A 185. Metal deck under elevated slabs shall be 0.9 mm thick Type B Formlock galvanized panels, as manufactured by Verco Manufacturing, Inc. or equivalent. Anchor bolts shall conform to ASTM A 307, except all nuts shall be American Standard Hexagon Heavy Series conforming to ASTM A 563. MASONRY Concrete masonry units shall be Grade 1 (normal weight), Type I, conforming to ASTM C 90. Compressive strength of masonry, fm, shall be 10 MPa. Mortar shall be Type S mortar conforming to ASTM C 270.

6.2

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

Allowable stresses for masonry shall be those permitted for no special inspection.

For reinforcing bars see Section 6.1. 6.3 6.4 STEEL Structural steel, including steel plate, shall conform to ASTM A36 or A 36M. High-strength bolts shall conform to ASTM A 325. Machine bolts shall conform to ASTM A 307. Shielded metal arc welding electrodes shall conform to E70XX series of AWS A5.1. Structural pipe shall conform to ASTM A 53, Grade B. Open web steel joists shall be K-Series with 207 MPa allowable stress. Structural tubing shall conform to ASTM A 500, Grade B. Stud anchors shall be as manufactured by TRW Inc./Nelson Stud Welding Division. MISCELLANEOUS STEEL Floor grating, unless stated otherwise on the drawings, shall be 32 mm x 5 mm welded steel bar grating with cross bars at 100 mm on centers, Type W/B, as manufactured by IKG Industries. or equivalent. Floor plate shall be 6 mm thick skid resistant, raised medium pattern, steel plate. Stair treads shall be welded bar grating with checkered plate nosing. Stair treads shall have 25 mm x 5 mm steel bearing bars with cross bars at 100 mm on centers. Treads shall be as manufactured by IKG Industries. Handrail shall be fabricated from 1 nominal diameter standard weight steel pipe conforming to ASTM A 53, Grade B with 125mm x 6mm kick plate. Trench frames and covers shall be heavy duty, 50 mm thick, gray iron, catalog no. R-4990, type A, as manufactured by Neenah Foundry Company. Drilled-in concrete anchor bolts shall be WEJ-IT wedge anchors as manufactured by ANKRtite Fastening Systems.

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

6.5

Adhesive anchoring shall be Hilti HIT HY 150 anchoring system, with Hilti HIT or HAS threaded anchor rods meeting the requirements of ASTM A36M. ARCHITECTURAL Roofing panels shall be 0.76 mm thick Centria Style-Rib with 38 mm deep ribs at 183 mm on center. Siding panels shall be 0.61 mm thick Centria Style-Rib 38 mm deep ribs with 183 mm on center. Wall insulation shall be glass fiber with thickness and "R" values as shown on the drawings.

7.0

DESIGN DETAILS
7.1 CIVIL

Unless shown otherwise on the drawings, yard grading shall have a slope of not less than 2 percent. Side slopes of cuts and fills shall not be steeper than two horizontal to one vertical, unless otherwise shown on the design drawings. Cut slopes in Rock shall be no steeper than 1:1, unless otherwise shown on the design drawings. Minimum cover for culverts shall be 400 mm. For roads subject to haul truck traffic, minimum cover shall be 1 meter. Chain link fence shall be galvanized and a minimum of 1800 mm high. Main plant access shall be designed for HS20-44 (AASHTO) loading, a maximum speed of 50 km/h, a maximum grade of 6 percent and a minimum horizontal curve radius of 60 meters. Road width for two lane traffic shall not be less than 7300 mm plus shoulder width of 1200 mm each side. (To be coordinated with MSC). Internal plant site roads shall be designed for a maximum travel speed of 30 km/h, a maximum grade of 8 percent and a minimum horizontal curve radius of 10 meters, except a maximum grade of 10 percent may be allowed for distances not exceeding 100 meters. Road width for two lane traffic shall not be less than 6000 mm plus shoulder width of 900 mm each side. Vertical roadway clearance shall be 5 meters. Storm Drainage

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

Design intensity shall be in accordance with the Rainfall Intensity-DurationFrequency curve. Calculation of the runoff quantities shall be determined by SCS (Soil Conversion Service) unit Hydrograph method or by other rational method. Design frequency will be as follows: Facility In-plant storm drainage Criteria 10 year frequency storm with the hydraulic grade line for a 50 year frequency storm. Pipes shall be designed to flow 75% full. 10 year frequency storm with the culvert head water for the 100 year frequency storm located a minimum of 300mm below any building floor or other critical elevation. Culverts shall be designed to flow 75% full. 10 year frequency storm with 100 year frequency storm water levels checked to assure critical areas will not be flooded. Locate ditches/channels at a minimum of 300 mm below any building floor or other critical elevation. Ditches/channels shall be designed to flow 75% full. Flow velocity shall be limited to 1.5 meter/second.

Culverts

Ditches/Channels

Runoff from outside of the plant site area will be diverted around the plant site wherever practical. All runoff flowing into or collected within the plant site areas will flow into a retention basin. The retention basin will be designed to retain a runoff volume equal to a 10 year frequency, 24 hour duration storm For additional information refer to design criteria for hydraulic and sediment control structures prepared for this project by Knight and Piesold LLC, dated Sept. 3, 1999. 7.2 CONCRETE

Strength design method shall be used for structural concrete. Concrete cover for reinforcing steel shall be as follows: Uniformed concrete cast against and permanently exposed to soil: Formed concrete exposed to weather: Formed concrete exposed to soil with waterproofing membrane on soil side: 75 mm 50 mm 50 mm

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

Formed concrete in contact with soil: Beams, girders and columns exposed to wet process area: Beams, girders and columns not exposed to weather nor contact with soil: Slab and walls exposed to wet process area: Slab and walls not exposed to weather nor contact with soil:

65 mm 65 mm 40 mm 50 mm 25 mm

Splicing of reinforcing bars shall be in accordance with ACI 318. All splices shall be Class B unless specified otherwise. 7.3 MASONRY

Working stress design with a specified compressive strength, fm, of 10 MPa and without special inspection shall be used for concrete masonry. Unless otherwise required, 200 mm x 200 mm x 400 mm concrete masonry units shall be used. Unless otherwise required, only cells containing reinforcement shall be filled solidly with grout. 7.4 STEEL

In general, working stress design shall be used for all structural steel. Where possible all shop connections shall be welded and all field connections shall be bolted. All bolted beam connections shall conform to the AISC Manual of Steel Construction, ninth edition, Part 4, Table II, using the minimum row of bolts listed below, unless otherwise indicated on the drawings or in this specification. Depth of Beam (d) 125 mm - 175 mm 200 mm - 250 mm 300 mm - 400 mm 450 mm - 525 mm 600 mm - 675 mm 750 mm 825 mm 900 mm Min. Row of Bolts (n) 1 2 3 5 7 8 9 10

Single-plate shear connections, conforming to Table X-A, may be used for 200 mm and 250 mm beams in platform framing.

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Project C-479 General Specification NGD-02 Civil, Structural and Architectural Design Criteria Rev. 3

All welded beam connections shall conform to the AISC Manual of Steel Construction, Ninth edition, Part 4, Table III in combination with Table II, unless otherwise indicated on the drawings. Unless detailed on the drawings, end connections for truss members, bracing members and axially loaded struts shall be apportioned to develop the forces shown on the drawings, but not less than 65 kN for single angles and not less than 130 kN for double angles and structural tees. End connections for wide flange shape bracing members shall be claw angle type per AISC Vol. II, Connections. minimum diameter high-strength bolts shall be used for connections of all main structural members and all platforms, unless otherwise indicated on the drawings. In general, high strength bolted connections shall be slip critical type. For connections which are not subjected to vibration or stress reversal or where slippage can be allowed, bearing type connections may be used if so indicated on the drawings. For such bearing type connections, threads may be included in the shear plane. ? diameter machine bolts may be used for connecting purlins, girts, handrail and miscellaneous steel. ? diameter machine bolts shall be used for connecting all stair treads unless otherwise noted on the drawings. Safety cage shall be provided for ladder rise of 6 meters or more and also for ladder rise of 3.6 meters or more, where the front landing radius is less than 2.5 meters. 7.5 ARCHITECTURAL

Insulation shall be secured between the purlins, under the roof panels and between girts and siding. The vapor barrier shall be towards the interior of the building. Deck panels shall be plug welded to support steel members in accordance with the manufacturer's standards.

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