000-GD-C-002 R.2 Civil & Structural Design

PROJECT No.
C-560
MINERA CHINALCO PERU S.A.
TOROMOCHO PROJECT
General Specification N° 000-GD-C-002
Civil and Structural Design Criteria
Aker Solutions Owner Approval: J. Wigle

333 East Wetmore Road, Suite 600
Tucson, Arizona 85705 Date: May/6/2008
REV DATE BY CHK APPROVAL DESCRIPTION
A 22 Apr 08 LGM CSH A. Ibarra Issued for Internal Review

B 01 May 08 LGM CSH A. Ibarra Issued for Client Approval
C 09 Sep 08 LGM CSH A. Ibarra Issued for Design
0 06 Jul 09 LGM CSH AHI / CSW Issued for Construction
Include Client Comment & Change on Steel
1 28 Jul 09 LGM CSH A. Ibarra
Quality
2 09 Nov 09 LGM AIH A. Ibarra Change as notice
DISTRIBUTION A B C 0 1 2 3 4 5 6 7 8 9 10
Client 5-6 6-6 7-28 9-11
Procurement
Field
Internal 4-22 5-1 9-9 6-6 7-28
Note: Signed originals on file

Project No. C560
General Specification No. 000-GD-C-002
Rev. 2
INDEX
PAGE
1 SCOPE ...............................................................................................................................3
2 APPLICABLE CODES AND STANDARDS.......................................................................3
3 CLIMATIC INFORMATION OF JOBSITE..........................................................................6
4 ORE SPECIFICATIONS.....................................................................................................6
5 CIVIL WORKS....................................................................................................................7
6 DESIGN LOADS ................................................................................................................7
7 DEFLECTIONS ................................................................................................................10
8 GEOTECHNICAL INFORMATION...................................................................................11
9 MATERIALS.....................................................................................................................11
10 DESIGN DETAILS............................................................................................................13
Q:\Doc_Control\R0534200\01_Eng_Doc\02_Str\01_Design_Criteria\560-000-GD-C-002_2.doc
2 of 16
Project No. C560
Rev. 2
1 SCOPE
This specification establishes criteria for the design of all civil and structural work for the
Toromocho Project owned by Minera Chinalco Perú S.A., located 140 km northeast of
Lima, in Morococha, Department of Junin, Peru, and is located at an altitude of between
4,500 and 5,000 m above sea level.
The design life for the structures shall be 32 years unless noted otherwise.
2 APPLICABLE CODES AND STANDARDS

Unless noted otherwise, all the design must be conform to the latest version of documents
listed below. These documents are declared to be a part of this criteria. Where there is a
conflict between these documents, the condition which is most restrictive shall apply:
2.1 ABREVIATIONS
AASHTO American Association State Highway and Transportation Officials
AISC American Institute of Steel Construction
AISE Association of Iron and Steel Engineers
AISI American Iron and Steel Institute
API American Petroleum Institute
ASCE American Society of Civil Engineers
ASTM American Society for Testing and Materials
AWS American Welding Society
AWWA American Water Works Association
CFR Code of Federal Regulations
IBC International Building Code
MSHA Mine Safety and Health Administration
NFPA National Fire Protection Association
OSHA Occupational Safety and Health Administration
RNE Reglamento Nacional de Edificaciones, Perú
3 of 16
Project No. C560
Rev. 2
SJI Steel Joist Institute
2.2 CODES
Peruvian Codes:
E.020 Cargas
E.030 Diseño sismorresistente
E.050 Suelos y Cimentaciones
E.060 Concreto Armado
E.070 Albañilería
E.090 Estructuras metálicas
GE.030 Calidad de la Construcción
RNE Reglamento Nacional de Edificaciones
International Codes:
IBC International Building Code 2006
OSHA Occupational Safety and Health Standards, 29 CFR
MSHA Mine Safety and Health Standards, 30 CFR
ASCE Minimum Design Loads for Building and Others Structures, SEI 7-05
AASHTO HB-17, Standard Specifications for Highway Bridges
AASHTO GD-2, A Policy on Geometric Design of Rural Highways
AISE TR-13, Guide for the Design and Construction of Mill Buildings
ACI 318, Building Code Requirements for Structural Concrete and

Commentary
AISC 325, Steel Construction Manual, Thirteenth Edition
AISC 360, Specifications for Structural Steel Buildings
AISC Seismic Provisions for Structural Steel Buildings
4 of 16
Project No. C560
Rev. 2
SJI Standard Specifications for Open Web Steel Joists
AWS D1.1/D1.1M, Structural Welding Code Steel
AISI Cold-Formed Steel Design Manual
API Std. 620, Design and Construction of Large, Welded, Low-Pressure

Storage Tanks
API Std. 650, Welded Steel Tanks for Oil Storage
AWWA D100, Welded Steel Tanks for Water Storage
AWWA M11, Steel Water Pipe: A Guide for Design and Installation
ASTM Technical Standards for Materials specified in these codes
NFPA Technical Standards to reduce the burden of fire and other hazards
Others:
AS Appendix A, Standard Technical and Site Data
AS Document 000-GD-T-001, Process Design Criteria
Golder Doc-100 Version 4, Seismic Hazard Analysis – Basic Engineer

Toromocho Project (Dated October 2008) 2
Golder Doc-206, Long Period Transition Period for Toromocho Project Site
Golder Doc-305 Version 4, Mine Site Geotechnical Design Recommendations –

Toromocho Project (Dated June 15th 2009)
2
2.3 UNITS
The dimensions on the structural steel and concrete drawings must be in millimeters.
Does not require the abbreviation "mm"
In general arrangement drawings, the elevations and coordinates must be in meters.
The units in the calculation sheets must be in metric system.
5 of 16
Project No. C560
Rev. 2
3 CLIMATIC INFORMATION OF JOBSITE

In according with Appendix A, “Standard Technical and Site Data”
3.1 TEMPERATURE
Design high temperature: 20 °C (68 °F)
Design low temperature: -4 °C (25 °F)
Relative humidity: 68.5 %
Net annual evaporation: N/A
3.2 RAINFALL
Rainfall annual average: 629 mm (24.8”)
3.3 SNOWFALL
Snowfall: 50 mm accumulation (2”)
3.4 FROST
Frost depth: 0 mm, According Appendix A
3.5 STORM
24 hr - 100 year storm: 76.4 mm
Frequency of electrical storms: High
3.6 WIND
Maximum speed: 30 km/hr (recorded)
Design velocity 135 km/hr
Prevailing direction: NE
4 ORE SPECIFICATIONS
Angle of repose 38° (degrees)
Drawdown angle 40° (degrees)
Density for weight 2.16 t/m3

Density for volume 1.77 t/m3
6 of 16
Project No. C560
Rev. 2
5 CIVIL WORKS
All the civil works: earth movement, site preparation, unsupported and supported slopes,
methods of excavation, foundation design criteria, slopes and radius for roads, etc., must
be in according with Overall Mine Site Geotechnical Design Recommendations by Golder.
6 DESIGN LOADS
6.1 DEAD LOAD

Dead loads include the weight of the structural and non-structural permanent components
of the structure.
6.2 PROCESS LOADS IN EMPTY OPERATION

These loads include the weight of containers and process equipment empty. The factor for
these loads must be the same factor of dead load in the combinations.
6.3 PROCESS LOADS IN NORMAL OPERATION

These loads include process load in empty state plus the weight of any liquid or solid
inside containers, pipes or equipment during normal operation. The factor for these loads
must be the same factor of dead load in the combinations.
6.4 PROCESS LOADS IN TESTING OPERATION

These loads include the total dead load plus the weight of the liquid required for pressure
and sealing testing.
6.5 LIVE LOADS

Loads generated by occupancy of the structure. Include the weight of mobile loads, bridge
cranes, hoists, parts of dismantled equipment and material storage. The live loads may be
reduced according to the E.020 or ASCE 7. The minimum live loads are as follows:
7 of 16
Project No. C560
Rev. 2
Occupancy Load
Roof 100 kg/m2
2
Offices 250 kg/m
2
Laboratories 500 kg/m
2
Dining 500 kg/m
2
Bathrooms 250 kg/m
2 where only pedestrian
Maintenance access walkways 250 kg/m traffic is probable
2
Stairs and ramps 500 kg/m
2
Control rooms 1250 kg/m
2
Warehouse (light load) 600 kg/m
2
Warehouse (heavy load) 1200 kg/m
2
Conveyor walkways 150 kg/m for truss design
2
Conveyor walkways 250 kg/m for walkways design
2
Others floors, as required for occupancy 500 kg/m minimum
additional to all other
Concentrated load on any panel 1000 kg loads
considered with dead
Concentrated load on elevated slabs 1000 kg load only
additional to all other
Concentrated load on floor 1000 kg loads
2
Operating platform 500 kg/m unless otherwise noted
2
Platform around mills 1250 kg/m
2
Liner platform 2000 kg/m
Reclaim Tunnel Platform 800 Kg/m²
2
Slab on grade around mills 3200 kg/m
Bridge AASHTO HS20-44
6.6 WIND LOAD

 Process building: will be in accordance with IBC2006 code with a minimum basic wind
speed not less than 135 km/hr.
 Non process building: will be in accordance with Peruvian code with a minimum basic
wind speed not less than 75 km/hr.
8 of 16
Project No. C560
Rev. 2
6.7 SNOW LOAD

 Process building: will be in accordance with IBC2006 code with a minimum basic snow
load not less than 50 kg/m2.
 Non process building: will be in accordance with Peruvian code with a minimum basic
snow load not less than 40 kg/m2.
6.8 SEISMIC LOAD

 Non process buildings: Peruvian code E.030, zone 3.
 Process buildings: IBC 2006 (SITE CLASE B)

Ss = 1.10 g 2
S1 = 0.48 g
TL = 16 seg
For process building, the seismic coefficient resulting from IBC shall not be less than
the seismic coefficient resulting from Peruvian code E.030.
 Storage tanks: API 650 - 2007
 Mills and mills foundations Horizontal seismic acceleration 0.40 g

Vertical seismic acceleration 0.27 g
6.9 VIBRATING EQUIPMENT

Vibrating loads shall be individually considered and, where feasible, shall be
independently supported.
The factor for vibrating loads shall be the same for the live loads in combinations.
Foundations for vibrating equipment will be designed to reduce vibration to levels that are
acceptable for operation of equipment and for peoples, according to Richart and Whitman.
The ratio between frequency of the equipment operation and the frequency of vibration
equipment foundation should be outside the following range: 0.7 - 1.4.
6.10 FRICTION LOADS

The following friction coefficients shall be used to determine the frictional forces caused by
restrictions on the change of temperature and sliding on surfaces:
Surface Coefficient
Steel - Steel 0.30
Seel - Concrete 0.50
9 of 16
Project No. C560
Rev. 2
6.11 CRANE FORCES

All crane support structures shall be designed for the loads as specified in AISE Technical
Report N°13. Where multiple cranes are used, loads shall be positioned to produce the
maximum forces in the members considered.
6.12 MATERIAL WEIGHT AND ANGLES OF REPOSE

According Golder Associates – Geotechnical Report 089-4151026\18000 – Latest version
6.13 FACTOR OF SAFETY

Buoyancy: 1.50 Normal 1.25 Eventual
Overturning: 2.00 Normal 1.50 Eventual
Sliding: 1.50 Normal 1.25 Eventual
7 DEFLECTIONS
Roofing and Siding:
Roofing and Siding plates L / 200
Girt & Purling L / 200
Maintenance Beam Crane (w/o impact)

a. Vertical L / 800
b. Horizontal L / 400
Operation Beam Crane (w/o Impact)

a. Vertical L / 1,000
b. Horizontal L / 500
Belt Conveyor Support Beam L / 500
Beams L / 300
Trusses L / 700
Vibratory Equipment Support Beam L / 800
Motors System Support Beam L / 1,000
Conveyors system: L / 700

a. Vertical Deflection in Trusses due to Variable Load L / 800
b. Lateral Deflection in Extreme of Stacker Trusses due to Lateral Load.
(Maximum Allowed Lateral Deflection +150 mm) L / 800
c. Support Beam for Elevated Pulleys and Motors.
10 of 16
Project No. C560
Rev. 2
8 GEOTECHNICAL INFORMATION
Unless otherwise noted, bottom of all footings and mat foundations shall be a minimum of
600mm (24”) below finish grade.
8.1 BEARING PRESSURES

8.2 EQUIVALENT FLUID PRESSURES

8.3 FRICTION
8.4 SLIDING RESISTANCE

Full values of friction and passive resistance may be used simultaneously to resist lateral
loads.
8.5 OTHER INFORMATION

For other pertinent information see Geotechnical Report 089-4151026\18000 – Latest
version (by Golder Associates)
9 MATERIALS
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:
9.1 CONCRETE
All structural concrete and concrete for floor slabs, walkways and ramps shall develop a
minimum compressive strength of f’c = 30 MPa at 28 days.
Sag Mill & Ball Mill Piers shall have a minimum of f’c = 45 MPa
Lean concrete shall have a minimum compressive strength of f’c = 10 MPa.
For light modular buildings foundation (Construction camp, offices), concrete shall develop
a minimum compressive strength of f’c = 21 MPa at 28 days.
11 of 16
Project No. C560
Rev. 2
Cement shall conform to ASTM C150, Type II or V Portland or equivalent.
Reinforcing steel shall be deformed bars, limited to diameter: #3 to #11, except for #9 and
#10, and shall conform to ASTM A615M, Grade 420, Fy=420 MPa or Peruvian quality
ARN 420, according ITINTEC 341.031 (Fy=420 MPa).
Also is acceptable Chinese quality HRB500E (Fy=500 MPa), but for design purposes use
Fy=420 MPa. For Chinese steel bars, diameters will be considered in mm.
2
Welded wire fabric shall be an electrically welded approved brand, 152 x 152-MW18.7 x
MW18.7 conforming to ASTM A 185.
Metal deck under elevated slabs shall be at less 0.8 mm Type B Formlock galvanized
panels or equivalent.
Anchor bolts shall conform to ASTM A307, except all nuts shall be American Standard
Hexagon Heavy Series conforming to ASTM A 563.
9.2 MASONRY (NOT APPLICABLE)

2
9.3 STEEL
Structural steel for main structures, including steel plate, shall be according to Chinese
Standard GB/T1591-1994, Q345 (B or C Quality). Main structures are defined in spec
number 000-GC-S-004 Miscellaneous and Structural Steel.
Design tensile strength are according to the following table:
Flange Thickness (mm) Yield Point (MPa) Tensile Strength (MPa)

Th < = 16 345 470 to 630
16 to 35 325 470 to 630
Th > 35 295 470 to 630
Steel quality Q345, may be replaced by ASTM A572, Fy=345 MPa
Structural steel for secondary structures, including plate, shall be according to ASTM A36
Secondary Structures are defined in the Spec 000-GC-S-004
Yield Point = 251 MPa
Also Structures designed with ASTM A36 properties, may be replaced by Chinese quality
Q345.
High-strength bolts shall conform to ASTM A325M or Chinese 8.8S
Machine bolts shall conform to ASTM A307M.
Shielded metal arc welding electrodes shall conform to E70XX series of AWS A5.1.
12 of 16
Project No. C560
Rev. 2
Structural pipe shall conform to ASTM A53M, Grade B.
Open web steel joists shall be K-Series with 207 MPa allowable stress.
Square or rectangular structural tubing shall conform to ASTM A500, Grade B.
Stud anchors shall be as manufactured by TRW Inc./Nelson Stud Welding Division.
9.4 MISCELLANEOUS STEEL

To ensure lateral and vertical seismic stability in cranes wheels supports should be used a
seismic clip.
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. Steel Quality Shall be ASTM A36 or Chinese quality Q235
Floor plate shall be 6 mm thick skid resistant, raised medium pattern, steel plate. Steel
Quality Shall be ASTM A36 or Chinese quality Q235.
Purling and Girt, Steel Quality Shall be ASTM A36 or Chinese quality Q235
Stair treads shall be welded bar grating with checkered plate nosing. Stair treads shall
have 32 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 32 mm nominal diameter standard weight steel pipe
conforming to ASTM A53M, Grade B with 125 mm by 6 mm 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 expansion anchor bolts shall be WEJ-IT wedge anchors as

manufactured by ANKRtite Fastening Systems.
Adhesive anchoring shall be Hilti HIT HY 150 anchoring system, with Hilti HIT or HAS
threaded anchor rod meeting the requirements of ASTM A36M.
10 DESIGN DETAILS
10.1 CIVIL
Side slopes of cuts and fills shall be in accordance with Doc 305 by Golder.
2
Minimum cover for culverts shall be 400 mm.
Chain link fence shall be galvanized and a minimum of 1800 mm high.
13 of 16
Project No. C560
Rev. 2
Main plant access roads shall be designed for HS20-44 (AASHTO) loading, a maximum
speed of 50 km/hr, a maximum grade of 10 percent (8% recommended) and a minimum
horizontal curve radius of 35 meters. Minimum length of vertical curve 61 meters.
Road width for two lane traffic shall not be less than 7000 mm plus shoulder width of 1000
mm each side.
Internal plant site roads shall be designed for a maximum travel speed of 30 km/hr, a
maximum grade of 10 percent (8 recommended) and a minimum horizontal curve radius
of 10 meters. Minimum length of vertical curve 15 meters.
Road width for two lane traffic shall not be less than 6000 mm plus shoulder width of 500
mm each side. Special road wide requirement could be necessary for erection &
maintenance purposes.
For one way, road minimum wide must be 5000 mm, and 500 mm shoulders to each side.
Vertical roadway clearance shall be 5 meters.
10.2 CONCRETE
Either the strength design or working stress design method may be used for structural
concrete.
Concrete cover for reinforcing steel shall be as follows:
Unformed concrete cast against and permanently exposed to soil 75 mm

Formed concrete exposed to weather 50 mm
Formed concrete exposed to soil with waterproofing membrane on
50 mm
soil side
Formed concrete in contact with soil 65 mm
Beams, girders and columns exposed to wet process area 65 mm
Beams, girders and columns not exposed to weather nor contact
40 mm
with soil
Slab and walls exposed to wet process area 50 mm
Slab and walls not exposed to weather nor contact with soil 25 mm
Splicing of reinforcing bars shall be in accordance with section 12 ACI 318. All splices
shall be Class B unless specified otherwise.
10.3 MASONRY (NOT APPLICABLE)

2
14 of 16
Project No. C560
Rev. 2
10.4 STEEL
In general, ASD (Allowable Stress Design) or LRFD (Load Reduction Factor Design) could
be used for all structural steel design, according Steel Construction Manual AISC
Thirteenth edition.
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,
Thirteenth edition, Part 7, Tables 7-1 at 7-6, using the minimum row of bolts listed below,
unless otherwise indicated on the drawings or in this specification.
Depth of Beam (d) Min. Row of Bolts (n)

125 mm – 175 mm 1
200 mm – 250 mm 2
300 mm – 400 mm 3
450 mm – 525 mm 5
600 mm – 675 mm 7
750 mm 8
825 mm 9
900 mm 10
Single-plate shear connections, conforming to Table X-A, may be used for 200 mm and
250 mm beams in platform framing.
All welded beam connections shall conform to the AISC Manual of Steel Construction,
Thirteenth edition, Part 8, Table 8-1 at 8-11, 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 6.5 tons for single angles and not less than 13 tons for double
angles and structural tees. End connections for wide flange shape bracing members shall
be claw angle type per AISC Vol. II, Connections.
20 mm 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 shall be excluded from the shear plane.
15 of 16
Project No. C560
Rev. 2
16 mm diameter machine bolts may be used for connecting purlins, girts, handrail and
miscellaneous steel.
10 mm 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.
16 of 16

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PROJECT No.

MINERA CHINALCO PERU S.A.

General Specification N° 000-GD-C-002

Civil and Structural Design Criteria

Aker Solutions Owner Approval: J. Wigle

REV DATE BY CHK APPROVAL DESCRIPTION

A 22 Apr 08 LGM CSH A. Ibarra Issued for Internal Review

Note: Signed originals on file

2 APPLICABLE CODES AND STANDARDS.......................................................................3

3 CLIMATIC INFORMATION OF JOBSITE..........................................................................6

6 DESIGN LOADS ................................................................................................................7

2 APPLICABLE CODES AND STANDARDS

AASHTO American Association State Highway and Transportation Officials

AISC American Institute of Steel Construction

AISE Association of Iron and Steel Engineers

AISI American Iron and Steel Institute

API American Petroleum Institute

ASCE American Society of Civil Engineers

ASTM American Society for Testing and Materials

AWS American Welding Society

AWWA American Water Works Association

CFR Code of Federal Regulations

IBC International Building Code

MSHA Mine Safety and Health Administration

NFPA National Fire Protection Association

OSHA Occupational Safety and Health Administration

RNE Reglamento Nacional de Edificaciones, Perú

SJI Steel Joist Institute

E.030 Diseño sismorresistente

E.050 Suelos y Cimentaciones

E.060 Concreto Armado

E.090 Estructuras metálicas

GE.030 Calidad de la Construcción

RNE Reglamento Nacional de Edificaciones

OSHA Occupational Safety and Health Standards, 29 CFR

MSHA Mine Safety and Health Standards, 30 CFR

AASHTO HB-17, Standard Specifications for Highway Bridges

AASHTO GD-2, A Policy on Geometric Design of Rural Highways

ACI 318, Building Code Requirements for Structural Concrete and

AISC 325, Steel Construction Manual, Thirteenth Edition

AISC 360, Specifications for Structural Steel Buildings

AISC Seismic Provisions for Structural Steel Buildings

SJI Standard Specifications for Open Web Steel Joists

AWS D1.1/D1.1M, Structural Welding Code Steel

AISI Cold-Formed Steel Design Manual

API Std. 620, Design and Construction of Large, Welded, Low-Pressure

API Std. 650, Welded Steel Tanks for Oil Storage

AWWA D100, Welded Steel Tanks for Water Storage

ASTM Technical Standards for Materials specified in these codes

AS Document 000-GD-T-001, Process Design Criteria

Golder Doc-100 Version 4, Seismic Hazard Analysis – Basic Engineer

Golder Doc-305 Version 4, Mine Site Geotechnical Design Recommendations –

In general arrangement drawings, the elevations and coordinates must be in meters.

The units in the calculation sheets must be in metric system.

3 CLIMATIC INFORMATION OF JOBSITE

Density for weight 2.16 t/m3

6.1 DEAD LOAD

6.2 PROCESS LOADS IN EMPTY OPERATION

6.3 PROCESS LOADS IN NORMAL OPERATION

6.4 PROCESS LOADS IN TESTING OPERATION

6.5 LIVE LOADS

6.6 WIND LOAD

6.7 SNOW LOAD

000-GD-C-002 R.2 Civil & Structural Design

000-GD-C-002 R.2 Civil & Structural Design