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By Roderic A. Ellman

The new Woodrow Wilson Bridge (WWB) will replace the existing bridge over the Potomac River to connect Alexandria, Virginia to Prince Georges County, Maryland. The new WWB will extend approximately 1.1 miles across the river, with a 367-ft long bascule span in the main river channel where the water depth is about 36 ft. The subsurface soil profile consists of up to 50 ft of a soft organic silty clay layer that is very vulnerable to scour, underlain by a deep deposit of hard sandy clay. Foundation construction in the Potomac River required the use of cofferdams to allow structural concrete work to be performed in the dry. This paper will the present the types of cofferdams used to construct the foundations for the WWB replacement project. The bridge is primarily comprised of fixed spans in relatively shallow water and a bascule span over a navigation channel in relatively deep water. Foundation construction included the installation of 48? to 72? open end steel pipe piles and cast-in-place concrete pile caps. To achieve the desired bridge appearance, pile caps were required to extend below the water surface and below the existing river bottom in shallow water locations. Conventional steel sheet pile cofferdams with tremie concrete seal were used to construct fixed span, shallow water piers. Selection of deep water bascule span foundation cofferdams was governed by several factors including contraction scour, environmental considerations and cost. Potomac River cofferdams, i.e., relatively shallow depth cofferdams that are supported by the foundation piling were selected. This cofferdam system provided a shallow profile which minimized contraction scour and the amount of filling in the river. Design issues include load selection and cofferdam stability in very soft alluvial soils. Construction issues include erection sequence, tremie concrete mix design and placement procedures.

Jan 1, 2013

By James S. Graham

Marine design and construction methods are presented on the caisson foundations for the tower piers at the Brooklyn, Ben Franklin, Delaware Memorial 1st, Tappan Zee, Walt Whitman, Throgs Neck, Verrazano Narrows, Delaware Memorial 2nd, and Newport Bridges. All of the bridges are founded on caissons, bearing on bedrock, soil, or piling. Caissons at the Tappan Zee Bridge are partially supported by piling and partially by buoyant forces. General subsurface conditions for each are provided. The purpose of this paper is inform engineers how bridge foundations using caissons were built over major waterways in the Northeastern USA in the past, anticipating a surge of new bridge construction in the near future.

Jan 1, 2013

By Claude Bazin, François Robichaud

"The control of the operation of semi autogeneous grinding (SAG) mills is mainly achieved through adjustments of feed rate, water addition and speed of rotation. With the introduction of image based sensors it is possible to have on-line measurements of the size distribution of the ore feeding a SAG mill. This information could be used for the development of a control strategy to regulate a SAG mill feed size distribution to a set-point. The control of the size distribution is carried out by adjustment of the speed of the ore extractors underneath the ore stockpile. The potential and difficulty associated with the implementation of such control are assessed using a multivariable statistical analysis of data collected from the operation of the grinding circuit of the Agnico-Eagle Goldex mine in Val d’Or, QC. A control strategy for the ore feed size distribution is assessed using a simulator of the ore stockpile operation.INTRODUCTIONThe popularity of autogeneous (FAG) and semi autogeneous (SAG) grinding mills has been increasing over the last 20 years (Napier Munn et al., 1996). These mills use the ore or a combination of ore and steel balls as the grinding media. Since the ore is used as a media for the size reduction the mill ore feed size distribution impacts the performance of the mill. Several papers were recently published on this subject (Dance et al.,2011; Wennen & Murr, 2011; Dance & Valery, 2011; Allaire et al., 2011) showing the advantages of preparing the feed size distribution to maximize the circuit throughput or mill efficiency (Wennen & Murr, 2011; Dance & Valery, 2011; Allaire et al., 2011). With the availability of particle size sensor based on image analysis of the ore on a conveyor (Partanen et al., 2001; Bobo et al. 2004; Edwards et al., 2002; Wei & Craig, 2009) it is possible to control the size distribution of the ore feeding autogeneous or semi autogeneous mills (Partanen et al., 2001).This paper describes a method to control a size distribution index to a set point via the manipulation of the speed of the extractors that withdraw the ore from the stockpile feeding the grinding circuit. The paper consists of 4 sections. The first section describes the considered grinding circuit. A statistical analysis of the collected data on the grinding circuit is presented in the second section. This analysis demonstrates the necessity of using real-time adaptation mechanisms to develop a control strategy for the size distribution of a grinding circuit. The third section describes the method used to simulate the ore stockpile operation and the last section describes the preliminary development and assessment of a control strategy of size distribution of the ore feeding a SAG mill."

Jan 1, 2013

By M. G. Maruma

The effect of the amount of cold reduction and annealing temperature on the evolution of the texture of AISI 441 steel is reported. The steel was cold rolled by 62%, 78%, and 82%, followed by isothermal annealing of each sample at 900°C, 950°C, and 1025°C for 3 minutes. The crystallographic texture was determined by Phillips X?Pert PROMPD texture diffractrometer. Microstructures were characterized using optical microscopy and scanning electron microscopy (SEM).The results show that sample that received 78% cold reduction and annealing at 1025°C presented the highest Rm-value and lowest ?R-value, which would enhance its deep-drawing capability. In addition, this sample showed the highest intensity of shifted ?-fibre, notably {554}<225> and {334}<483>. It can therefore be concluded that the ?-fibre, which favours deep drawing, is optimal after 78% cold reduction and annealing at 1025°C.

Jan 1, 2013

By M. Steyn

[Zr(C9H6NO)4]?(HCON(CH3)2)?(H2O), where (C9H6NO) = 8-hydroxy quinoline (oxH), was synthesized and characterized. This tetrakis-coordinated zirconium complex crystallized in the triclinic crystal system (Pi, Z=2) along with water and N,N?-dimethylformamide(DMF) solvate in the asymmetric unit. The metal atom is surrounded by four N,O-donating bidentate ox-ligands that are arranged around the metal centre to give a square antiprismatic coordination polyhedron with a small distortion towards a dodecahedral geometry. Crystal packing is stabilized by intermolecular interactions of adjacent oxine ring systems in neighbouring molecules, as well as hydrogen bonding of the aqua and DMF solvate molecules, linking the molecular entities into a supramolecular three-dimensional network.

Jan 1, 2013

By Robert B. Bittner

Large diameter piles (2 to 3 m diameter, both driven and drilled) are being used more frequently by designers of bridge foundations. The use of these large piles allows the pile cap to be positioned off the bottom but usually still below water. Conventional cofferdams as shown in Figure 1 below are not suited to this type of pile cap. However, float-in cofferdams offer a viable alternative. This paper describes the float-in cofferdam system, its initial development for use on the Bath-Woolwich Bridge in Maine and its most recent application on the new Carquinez Bridge in California.

Jan 1, 2013

By Sam X. Yao

In construction of drilled shafts under water, placing concrete in the shafts is technically demanding and involves complex construction logistics. Past construction experience has demonstrated that high quality concrete can be placed in drilled shafts under water with a proper concrete mix and proper placement techniques. However, a significant number of failures have occurred which have resulted in excessive cost overruns and delays. These problems may have occurred because proper underwater concrete construction techniques have not been widely disseminated within the industry. This is a technical area where competent design and sound construction planning can achieve a significant reduction in both risk and cost. This paper will discuss some key technical issues in the concrete mix design, concrete production and placement for the drilled shaft construction. The paper also describes two lesson-learned case histories from drilled shaft construction projects.

Jan 1, 2013

By Benjamin Cebrian

Wall control blasting is an expensive and labor intensive operation. Obtaining a good design is a first step that is not enough to ensure desired results. Experience shows that designs are not always well implemented, not only in the contour blast itself, but also in surrounding production blasts that can affect the final pit wall. In this paper techniques and reference indicators are described in order to audit and evaluate if correct implementation of designs have been done.

Jan 1, 2013

By D. W. Nel

Nanofiltration (NF) has attracted much attention over the past few years due to the reduced energy consumption compared to reverse osmosis (RO) and better separation performance compared to ultrafiltration (UF). Although research has been done in the area of NF of nickel ions, sodium ions, and acid separation, not much attention has been given to the separation of high nickel concen¬trations from sulphuric acid streams. The use of NF for the separation of nickel and acid from a spent nickel electrolyte is an innovative process alternative for future industrial application within a base metal refinery. In this study, the separation performance of a composite polyamide NF membrane on a spent nickel electrolyte was investigated by varying the sodium sulphate concentration in the feed (50-150 g/l), the trans-membrane pressure (35-55 bar), and cross-flow velocity (1.5-3.5 m/s), and measuring quantities such as total permeate flux, acid rejection, nickel rejection, and sodium rejection. The nickel and acid concentration in the feed were kept constant with variations between 40-60 g/l and 25-40 g/l respectively, while the temperature of the experiments was kept constant at 50°C. The membrane was found to be very selective for nickel ions, with the rejection of nickel ions varying between 54.4% and 98.2%. The rejection of acid ions varied between -5.9% and 21.8%. The rejection of sodium ions varied between 16.6% and 72.4% at a cross-flow velocity of 2.5 m/s and sodium sulphate concentration of 50 g/l in the feed solution. An increase in trans-membrane pressure increased the rejection of nickel, sodium, and acid ions, while an increase in sodium sulphate concentration decreased the rejection of nickel and acid ions. The total permeate flux was found to increase with an increase in trans-membrane pressure and decrease with an increase in sodium sulphate concentration. The cross-flow velocity had an insignificant effect on the total permeate flux and the rejection of nickel, sodium and acid ions.

Jan 1, 2013

By Gray Mullins

This paper presents experimental results from a study to assess the interface bond between a cast-in-place concrete seal slab and prestressed concrete piles in cofferdams. Three different seal slab placement conditions - fresh water, salt water and bentonite slurry - were evaluated and the results compared against controls where no fluid had to be displaced by the concrete. Normal pile surfaces were investigated. Additionally, the situation of ?soil caked? piles was also investigated. Both model and full-scale tests were conducted. In the model tests, twenty eight 15 cm square prestressed sections were used with the embedment depth varied between d-2d, where d is the width of the pile. In the full-scale tests, 16 specimens were tested. The prestressed piles were 36 cm square with the embedment varied between 0.5d-2d. Four of the sixteen piles were cast with embedded gages located at the top, middle and bottom of the interface region. The results showed that loads were transferred to the piles over an effective area, not the entire embedded depth. Significant bond stresses developed even for the worst placement condition. Recommendations are made for revising current values in specifications.

Jan 1, 2013

By Aparup Chattopadhyay, Barun K. Gorain

"Porphyry copper deposits are the most important source of copper and also gold within the orogenic belts. These deposits are characterized by low grade copper ore (0.2% to 1% copper) and host precious metals like gold, silver and platinum. A characterization tool has been developed for complex porphyry type copper-gold deposits with an aim to quantify copper and precious metal deportment. This quantification is a challenging task due to low grades and also due to the presence of both visible and invisible precious metal content in different sulphide and non-sulphide phases. Studies were initiated on various complex ore deposits and also on samples representing various processing streams such as flotation and leach products. This paper presents the development of a systematic approach to diagnostic metallurgy using state-of-the-art optical and automated mineralogy, micro-probe, dynamic SIMS and TOF-SIMS analysis for quantification of invisible and visible precious metals content in various species. The relevance of this characterization to metallurgy will also be briefly discussed in this paper.INTRODUCTIONA novel characterization tool has been developed for double refractory gold ores and complex copper-gold ores using state-of-the-art technology for quantitative gold and copper deportment study. The characterization of these ores is a challenging task due to low copper and gold grades in ores, presence of both primary and secondary copper sulphide phases and variable proportion of visible and invisible gold in different sulphides phases (pyrite, chalcopyrite, chalcocite and bornite) and iron oxide phases (magnetite, hematite and goethite). A study was initiated on various ore deposits and also on samples representing various processing streams of pilot plant batches such as flotation concentrates and tailings. This paper attempts to discuss the deportment characterization methodology through presenting results from investigations on four samples from a flotation circuit viz, Feed, Final concentrate, Cleaner Scavenger Tail and Rougher Tail samples. These four samples represent the key streams for a typical copper-gold flotation flow sheet. The key objective of this investigation was to identify and quantify visible and invisible gold along with understanding the morphology and liberation of gold associated with various sulphides, Fe- Oxides and non-sulphide gangue species. In addition, the aim of this study was also to relate this mineralogical and gold deportment information to metallurgical performance."

Jan 1, 2013

By Dilek Kirgöz, Onuralp Yücel, Murat Alkan

"In this study, Mo containing Fe-based alloys, such as Fe-Ni-Cr-Mo, were synthesized using a mixture of Fe203-NiO-Cr203-Mo03 powders reducing with Al powders by metallothermic process which is a high energy efficient, fast and low-cost production technique for synthesis of cast alloys and advanced ceramics. Detailed thermochemical studies were simulated by using FactSage 6.2 Thermochemical software in order to calculate adiabatic temperature of the reactions and effects of initial molar composition on the final products. In the metallothermic processes, effects of stoichiometric Al addition and addition of the oxide powders (Alz03, Si02, CaO, MgO) on the metal recovery and compositions of final alloys were carried out. Final products were characterized by using chemical analysis (AAS), XRD, XRF and SEM/EDS techniques.IntroductionSelf Propagating High Temperature Synthesis (SHS) has significant advantages compared to the high technology furnace applications, such as very short processing time, simple operation, low energy requirement and low cost [l, 2]. In a SHS process, the ignition starts the combustion and propagates throughout the reactant mixture yielding the desired product. However, the disadvantages of the process such as inhomogeneous or unreacted products due to undesirable reaction rates needs to be overcome by changing some parameters such as ignition temperature, particle size, additive, atmosphere etc. [3, 4]. This work aims to establish a scientific and engineering background in the production of some cast Fe based alloys (Fe-Ni-Cr-Mo) which are used as surface coatings, wear-corrosion-oxidation resistive applications via SHS (Self Propagating High Temperature Synthesis) metallurgy which is attractive process technique regarding fast and low-cost production ability of cast alloys."

Jan 1, 2013

By M. Ganster, H. Krenn

The mission of the project is the fast and cost-effective rehabilitation of decommissioned lignite mining and coal upgrading facilities. This is necessary to ensure the successful future utilization of these sites. On the one hand, for founding new industrial and commercial facilities and on the other hand for touristic activities.

Jan 1, 2013

By Onuralp Yücel, Mehmet Bugdayc, Murat Alkan

"In this study, iron based alloys (Fe-Mo, Fe-Cr-Ni, etc.) were produced by using aluminothermic methods starting from Mill Scales obtained continuous casting processes. Mill scales are an oxidised layer of steel alloys containing iron oxide, which includes + 2, + 3 values, on the surface of slabs and billets occurring during annealing in heating furnace at integrated iron and steel milling plant, and continuous casting unit. In the metallothermic experiments, different ratios of starting mixtures and addition of the oxide powders (Alz03, Si02, CaO, MgO) were examined, and their effects on the metal recovery and alloy compositions were carried out. The samples were characterized by using chemical analysis (AAS), XRD, XRF and SEM/EDS techniques.IntroductionSelf Propagating High Temperature Synthesis process (SHS) has many favour compared to the furnace applications, such as low energy requirement, low cost, very short processing time and simple operation, [l, 2]. In a SHS process, the ignition starts the combustion and propagates throughout the reactant mixture yielding the desired product. However, the disadvantages of the process such as inhomogeneous or unreacted products due to undesirable reaction rates needs to be overcome by changing some parameters such as ignition temperature, particle size, additive, atmosphere etc. [3, 4]. Mill scale is a layer of iron oxide which forms on ferrous materials cooling after being processed in hot rolling or continuous casting plants. Mill scale contains iron (II) and iron (III) oxides, which result in a 70% total iron content in oxide form. Not being able to reuse this material will prevent the raw material entering the production plant from being fully utilized [5]. This study aimed to produce Fe-based alloys via SHS (Self Propagating High Temperature Synthesis) metallurgy which is attractive process technique regarding fast and low-cost production ability of cast alloys by using high metallic iron content by reducing continuous casting mill scale."

Jan 1, 2013

By Hessam Yazdani

In comparison to the conventional piled foundations, the piled-raft foundations provide a more economical solution to support high-rise buildings constructed on soft soils. In this type of foundations, the bearing capacity of the underlying soil is taken into account to support the superstructure loads and the piles are placed to control both the total and differential settlements of the superstructure. Currently, there is not a standard and worldwide acceptable approach to select the location of the piles and most of piled-raft foundations are designed based on the experience of designers. Therefore, particular attention should be given to the optimal design of this type of foundations in order to minimize the considerable construction costs involved. This paper examines the capability of the ant colony optimization (ACO) algorithm to optimize the piled-raft foundations subjected to static and seismic loadings. The soil-pile interaction is considered by modeling the side and tip resistance components of the piles using the nonlinear Winkler-based p-y and t-z curves in the OpenSees program. The soil-raft interaction is taken into consideration using the Winkler springs beneath the raft. The objective of the optimization problem is to minimize the construction cost of the foundation by taking the configuration and number of the piles as design variables. The side and tip forces of the piles as well as the total and differential settlements of the foundation under the serviceability limit state are considered as the constraints for the optimization problem. Results show that in addition to the type of analysis (linear/nonlinear), the regard or disregard of the soil-pile interaction in the analysis can significantly change the optimal solution. The optimal solutions obtained match the engineering expectations and indicate the effectiveness and capability of the ACO algorithm to minimize the construction cost.

Jan 1, 2013

By K. Viking

This article deals with some of the civil engineering related problems to be encountered when offshore wind energy projects transform from prototype offshore wind energy converter farms, developed and installed during the 1990?s, to commercial farms that?s currently planned to be built. The offshore wind energy converter (OWEC) installations encounter a wide range of problems, only partial of these are geotechnical. In Europe both onshore and offshore wind farms have, from a historical point of view, usually been founded by using the monopole technique, installed with traditional impact hammers, or by using gravitational foundations. However, the rapid development of bigger turbines and larger wind farms, together with increasing considerations of fatigue aspects, has lead to financial benefits of developing and exploring other foundation techniques. This paper reviews some Scandinavian experiences regarding critical components of the design phase in relation to connecting the superstructure to the ground, and some of the main considerations of how the loads applied to the structure are transferred to the surrounding soil.

Jan 1, 2013

By S. R. Amos, N. O. Lotter, A. L. Hannaford, J. F. Oliveira, D. W. Broughton

"Ivanplats Ltd appointed Xstrata Process Support to perform the flowsheeting development work for their hypogene and supergene geomet units of the Kamoa Copper deposit, located in the Democratic Republic of the Congo. Through systematic flowsheet development using modern Process Mineralogy, the optimised milestone flowsheet delivered a saleable concentrate grade of 32.8% Cu at 85.4% recovery with hypogene ore, and a saleable concentrate grade of 45.1% Cu at a recovery of 83.4% for supergene ore. The significant value of this development is that a single flowsheet will treat both hypogene and supergene ores and produce saleable concentrates. Further work to advance the flowsheet performance has been identified for investigation in the near future.INTRODUCTIONLocation and Description of the Kamoa DepositThe Kamoa copper resource is located some 40 km west of the city of Kolwezi, in the south west of the Katanga Province of the Democratic Republic of the Congo, in the region of Central Africa. Drilling at Kamoa in 2008-2009 had discovered laterally continuous, sediment-hosted, high-grade stratiform copper mineralisation in a newly discovered copper district that forms a previously unrecognised western extension of the famous Central African Copperbelt – which hosts such world-class deposits as Kolwezi, Tenke-Fungurume, Konkola and Nchanga. This discovery showed that the western end of the Copperbelt in the Congo does not terminate at Kolwezi (Friedland & Broughton, 2009). The resource contains hypogene and supergene geomet units with a transitional zone located inbetween the (upper) supergene and the (lower) hypogene. In the hypogene unit, the major copper sulphides are bornite, chalcopyrite and chalcocite, whilst in the supergene, the sequence is led by chalcocite, then bornite, and finally chalcopyrite. Covellite is present in both units as a minor copper sulphide. Both geomet units will be mined and treated in one concentrator, either as blends or as campaigns."

Jan 1, 2013

By Evgenii Pavlov, Ivan Tronin, Viktor Timofeev, Vladimir Kislov, Sergei Bogovalov

"Modeling of the magnetohydrodynamical (MHD) and thermodynamical processes during the industrial scale Direct Chill (DC) casting of aluminum slabs is performed using a combination of ANSYS/CFX and ANSYS/EMAG software. The electromagnetic field is modeled through ANSYS/EMAG, while hydrodynamic and thermodynamic processes are modeled through ANSYS/CFX. Both packages were modified in order to calculate MHD flows in the liquid pool that forms during aluminum DC casting, and they were unified into a software combination that provides simultaneous simulation of all the above processes. The simulation shows that the electromagnetic stirring of the molten aluminum changes the shape of the solidification front (solid-liquid interface) very dramatically, namely it becomes significantly flatter. This effect should improve the internal structure of aluminum DC slabs and allows us to increase the casting velocity.IntroductionProduction of Aluminum alloys with high mechanical properties and structural uniformity is one of the main goals of industry. The preferred production method of aluminum alloys in most modern plants is Direct Chill (hereafter DC) casting because it offers high productivity and commercial success. One important limitation of this technology is the development of centerline shrinkage in slabs larger than about 1 meter. The improvement of the internal structure of long DC cast slabs can be achieved by electromagnetic stirring (hereafter ES) of the liquid metal above the solidification front. This intensifies heat transport in the zone close to the solidification front and suppresses shrinkage formation."

Jan 1, 2013

By Joshua Hoffman, Braden Lusk, John Rathbun

A Flyrock Prevention Taskforce was established in Kentucky with the support of Kentucky's Department of Natural Resources, Kentucky's Explosives Industry, and the University of Kentucky. This paper presents the initial work of the Flyrock Prevention Taskforce towards its missions of identifying the root causes of flyrock incidents based on the analysis of previous events, and tracking the progress of flyrock elimination in the future. Work identifying root causes of flyrock events is presented through the development of a database which manages information about the blasts which caused flyrock. This data includes: blasting and seismograph records, drill logs, videos of the event when available, company notes/incident reports, and any additional information regarding probable cause. Work tracking the progression of flyrock elimination efforts is presented in this paper through the introduction of a flyrock index. Several metrics are proposed for this index, and are discussed for their appropriateness and shortcomings. In order for these indexes to be valid forms of tracking flyrock incident rates additional records must be kept and reported, such as the annual consumption of explosives by surface coal blasting. Suggestions for record keeping, flyrock investigation practices, and means of tracking flyrock incident rates are proposed in this paper.

Jan 1, 2013

By Michael A. Knott

Large lateral forces on bridge foundations due to extreme events such as vessel collisions, earthquakes, and wave forces on storm surges during hurricane events are often the controlling design condition for bridge foundations. A review of the American Association of State Highway and Transportation Officials (AASHTO) vessel collision analysis and design codes used in the United States for highway bridges will be presented. The paper includes the background and development of the AASHTO Guide Specification and Commentary for Vessel Collision Design of Highway Bridges (1991) and vessel collision provisions of the AASHTO LRFD Bridge Design Specifications (3rd Edition 2004 and the approved 2005 Interims). Experience in using the AASHTO codes will be discussed and observations on the adequacy and gaps, comparison with the European Standard Code, and recommendations for immediate and long term needs will be presented.

Jan 1, 2013