1.

0 PURPOSE OF THE DOCUMENT

The purpose of this report is to outline design outline used on the foundations to the conveyor plan to be
installed at the Orapa Mine CRD Expansion Project.

2.0 INTRODUCTION
Debswana appointed Bergstan Botswana as the Civil Engineers / Structural for the Design of concrete
column bases at one of the mining sites at the Orapa mine. The superstructure, which is in steelwork, is
being handled by Woods Plc engineers and their output reactions will be the input for the design of the
bases.

3.0 THE PROJECT

This project consists of the setting up of the conveyor belt system that would move material from the
mining areas to the processing and storage areas.

The output reactions of the base of the steel columns will be the input for the design of the concrete
stub column bases or bearing pads.

In the absence of geotechnical survey and some of the bases being in disturbed ground material, it was
assumed that the earth moving equipment to be employed would consolidate the fill to a bearing
capacity of 150kPa. Which was thus used for the sizing of the pad foundations. Since the foundations
are being cast against material that has through various chemicals used for extraction of the required
product, the condition is assumed to be severe exposure.

4.0 SPECIALISTS SERVICES

The specialist services required was as follows:
▪ Engineering survey to locate all existing assets of Debswana since this is an active area. This is
required as part of establishment.
▪ Engineering survey to position the bases according to the location of the plant stanchions. This is
required as part of the construction works to ensure accuracy as modifications of the steel
structure to accommodate out of tolerance location may not be possible.

5.0 STRUCTURAL DESIGN PHILOSOPHY

This report details the structural design approach for the construction of the concrete substructure onto
which the steelwork top structures will be carried. It details the overall design philosophy, stability
requirements, load statement, basic member sizes. All concrete elements are assumed to be carrying
dynamically loaded equipment.

The structural steel superstructure system for the plant will be designed and constructed by others. The
base column system is on the same grid as the steelwork grid established by Wood’s Plc, as the
principal consultants. To ensure continuity, the various base loads have been derived from the reactions
of the superstructure steelwork that were provided. Holding down bolt configuration has also been
derived from the models of the steelwork design outputs.

5.1 STRUCTURAL STABILITY AGAINST OVERTURNING.

Reinforced concrete stub columns carry axial loads (vertical and horizontal) to the corresponding
bases. Moments at the bases are small as the columns are short. The orientation of the stubs is
according to the configuration of the incoming base plates.

6.0 STRUCTURAL LOAD STATEMENT

The design of the plant facility was carried out by others. (Woods Plc.) and was based on relevant parts
of SANS 10160 - Basis of Structural Design and Actions for Buildings and Industrial Structures

6.1 SELF-WEIGHT LOADS:

▪ Density of reinforced cement concrete - 25.00 kN/m³

▪ Density of plain cement concrete - 24.00 kN/m³
▪ Density of structural steel - 78.50 kN/m³

6.2 IMPOSED LOADS:

▪ Tanks, plant and equipment - Based on actual reactions

▪ Imposed loads for inaccessible roofs - 0.3 kN/m2
▪ Imposed loads accessible Roofs - 1.5 kN/m2

6.3 WIND LOADS

▪ Vertical and horizontal - Based on actual reactions.

6.4 SEISMIC ACTIONS

▪ Not Required for the plant facility location

7.0 DESIGN GUIDELINES, SPECIALIST LITERATURE AND PROGRAMMES USED

The following were referenced and used for the structural engineering design.
i. DEB-SPC-EN-SI-04 - Structural Steelworks General Specification
ii. DEB-SPC-EN-SI-03 - Concrete Works General Specification
iii. SPEC-EAM-CS-DS 114001 - Design of Steel Structures
iv. SPEC-EAM-CS-DS 114010 - Design of Concrete Structures
v. Reynolds's Reinforced Concrete Designer's Handbook 11th Edition

The following Prokon software modules for structural analysis and design:
i. Frame Analysis Module
ii. Rectangular Column Design, RecCol. Module
iii. Circular Column Design, CirCol Module:
iv. RC Pad Footing Design Module.

8.0 DESIGN PARAMETERS

Concrete Characteristic Strength fcu

i. Columns - 35 MPa/19mm
ii. Bases - 35 MPa/19mm

Concreter Cover
i. Columns - 50 mm.
ii. Bases - 50 mm.

Reinforcing Steel Characteristic Strength fy

i. High Yield Deformed Steel Bars (Y) - 450 MPa
ii. Plain Mild Steel Bars (R) - 250 MPa
iii. High Tensile Welded Steel Mesh - 485 MPa
The following table gives load factors to be applied to commonly encountered nominal loads when
determining design load combinations at the ultimate limit state.

LOAD FACTORS TO BE APPLIED TO NOMINAL LOADS

LOAD COMBINATION
Gn Qn Qmn Qfn Qrn Wn Cvn Chn Tn
1 1.5
2 1.2 * 1.6 1.6 1.3 0.5# 0 0.8 0.8 0.6
3 1.2 * 0.5+ 1.6 1.3 0.5# 0 0.8 0.8 0.6
4 1.2 * 0.5+ 1.6 1.3 0.5# 0 0.8 0.8 0.6
5 1.2 * 0.5+ 1.6 1.3 1.6 0 0.8 0.8 0.6
6 1.2 * 0.5+ 1.6 1.3 0.5# 1.3$ 0.8 0.8 0.6
7 1.2 * 0.5+ 1.6 1.3 0.5# 0 1.6 1.2 0.6
8 1.2 * 0.5+ 1.6 1.3 0.5# 0 1.2 1.6 0.6
9 1.2 * 0.5+ 1.6 1.3 0.5# 0 0.8 0.8 1.2
10 0.9 1.3$

The following table gives load factors to be applied to commonly encountered nominal loads when
determining design load combinations at the serviceability limit state.
LOAD LOAD FACTORS TO BE APPLIED TO NOMINAL LOADS
Gn Qn Qmn Qfn Qrn Wn Cvn Chn Tn
COMBINATION
1 1.1 1.0 1.0 1.0 0.3# 0 0.5 0.5 0.5
2 1.1 0.3+ 1.0 1.0 0.3# 0 0.5 0.5 0.5
3 1.1 0.3+ 1.0 1.0 0.3# 0 0.5 0.5 0.5
4 1.1 0.3+ 1.0 1.0 1.0 0 0.5 0.5 0.5
5 1.1 0.3+ 1.0 1.0 0.3# 0.6 0.5 0.5 0.5
6 1.1 0.3+ 1.0 1.0 0.3# 0 1.0 0.75 0.5
7 1.1 0.3+ 1.0 1.0 0.3# 0 0.75 1.0 0.5
8 1.1 0.3+ 1.0 1.0 0.3# 0 0.5 0.5 1.0
9 1.0 0.6

NOTES:
i. Dominant imposed loads being shown bold.
ii. * For permanent loads which can be accurately assessed only. Use 1.4 if there is any doubt
about the accuracy of the load.
iii. For other loads, e.g. seismic and settlement loads, refer to SANS 10160.
iv. Throughout this Appendix, the appropriate load can also be read as load effect, annotated as;
▪ Gn = Permanent load
 ▪ Qn = Imposed floor load
▪ Qmn = Imposed material load (e.g. bunker contents), plant load or
equipment load
▪ Qfn = Imposed load from fluids (e.g. tank or pipe contents)
▪ Qrn = Imposed roof load
▪ Wn = Wind load
▪ Cvn = Vertical crane load
▪ Chn = Horizontal crane load
▪ Tn = Temperature load

Attached also find the detailed book load configurations from the structural steel frame design.

9.0 DESIGN STANDARDS

Design standards and material specifications for the study have been evolved primarily based on the
latest SANS standards as applicable. The design standards hereunder cover all aspects of design:
i. SANS 2001: Civil Engineering Construction material specifications and methods to be used.
ii. SANS 10160: Basis of structural design and actions for buildings and industrial structures
iii. SANS 10100: Reinforced Concrete
iv. SANS 10162: Structural Steelwork

Where necessary, we will indicate the risks of deviation from a specific standard for the client.

10.0 GREEN CONSTRUCTION ASPECTS:

To comply with the requirements to reduce the carbon footprint as far as possible regarding the
structure the following specifications are recommended for the project:

▪ No sandstone aggregate will be allowed in column bases, minimum OPC content 70% - mix
designs to be submitted to engineer for acceptance. The absolute quantity of Portland cement,
as an average across all concrete mixes, must be reduced by 30% by substituting it with
industrial waste products.
 ▪ 90% of all reinforcement / stressing steel and steel products) by mass, in the project is to have
a post-consumer recycled content greater than 60%.

11.0 CONCLUSION

▪ All dimensional tolerances must comply to the provisions of Debswana and if not available,
relevant SANS 2001 allowances.
▪ All workmanship to be as indicated in the design drawing notes or where missing, latest
SANS10 100 Part 2.
▪ Ultimate limit state load factors and load combinations for the plant structure were
assumed and used for the design.