Hard Rock Miner's Handbook

Hard Rock Miner's

Handbook

HARD ROCK MINER'S HANDBOOK

STANTEC CONSULTING

Hard Rock Miner's Handbook

by Jack de la Vergne

TITLE Hard Rock Miner's Handbook, Edition 5 Copyright ? 2008 Stantec Consulting Ltd. 10160 ? 112 Street ? Edmonton, Alberta ? Canada Phone (780) 917-7000 ? Fax (780) 7330

Hard Rock Miner's Handbook, Edition 3 Copyright ? 2003 McIntosh Engineering Limited 147 McIntyre St. West, Suite 200 ? North Bay, Ontario ? Canada Phone (705) 494-8255 ? Fax (705) 474-2652 Copyright ? 2003 McIntosh Engineering Inc 1438 West Broadway Road, Suite 101 ? Tempe, Arizona ? USA Phone (480) 831-0310 ? Fax (480) 831-0317

AUTHOR J.N. de la Vergne

SPONSOR Scott L. McIntosh

EDITOR Susan L. Andersen

PUBLISHER* Stantec Consulting *Also published in CD format and available for download from mining

PRINTER AND BOOKBINDER O'Neil Printing (Phoenix, Arizona), Roswell Bookbinding (Phoenix, Arizona)

ISBN ISBN 0-9687006-1-6

RIGHTS All rights reserved. No part of this publication may be reproduced, stored, or transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior written permission of the author.

EDITIONS Edition 1 ? June 2000 ? Hard Copy Edition 2 ? July 2000 ? CD and Web Edition 3 (CD/Web) ? May 2003 ? CD and Web Edition 3 (Hard Copy) ? August 2003 ? Hard Copy Edition 4 (CD/Web) ? September 2012 ? CD and Web Edition 4 (Hard Copy) ? September 2012 ? Hard Copy Edition 5 (CD/Web) - January 2014 - CD/Web

2008 Stantec Consulting Ltd.

Foreword

Edition 5, January 2014 by Scott McIntosh, Stantec

TABLE OF CONTENTS

John (Jack) de la Vergne's Hard Rock Miner's Handbook is a work of the heart. Jack--whose 40+ year career spanned engineering, construction, and operation of mining projects worldwide--conceived of and wrote the first edition of the Handbook, published in June 2000, to assist miners and engineers in the difficult world of hard rock mining. It was his gift to an industry that provided him with employment, challenges, and fascination.

The Handbook is a not-for-profit publication intended to help the mining companies we serve, as well as the mining community at large--students, teachers, consultants, contractors, manufacturers, salespeople, media representatives, financial institutions, mining associations, and government officials. Although it emphasizes metal mining, much of the information is also valuable to our friends mining soft and other not-so-soft industrial mineral and energy resources.

I personally know the lifetime of effort that Jack put into Edition 1. Although I helped him with sponsorship and encouragement, Jack did all of the real work and I never believed we would consider publishing an update, let alone a fourth edition twelve years down the road. A lot has changed since Edition 1--Jack retired and McIntosh Engineering was acquired by Stantec in 2008--but Jack's legacy lives on in Edition 4 of a book that continues to serve the mining community.

RULES OF THUMB: THE "ART" (EXPERIENCE) OF THE MINING INDUSTRY One attraction of the mining industry is the fact that, although our business is based on sound scientific principles, there is still significant "art" to the work we do. This art is the exciting part of our business. We don't truly know what the ground will be like until it is mined, and by then, if the art has not been prudently applied, it is too late for the application of scientific principles. Because of the unknowns, we often rely on the experience of others and good rules of thumb to guide us.

Rules of thumb and comparable data are often sufficient to provide immediate, approximate answers to kick-start the problem solving process. Consequently, mining industry experts initially compiled and published many rules of thumb, which we delivered at mining conventions across North America. The mining community's strong response provided many new rules and encouraged us to pursue this Handbook as a separate project. Although certain contents in the Handbook may be controversial, its "Rules of Thumb" and "Tricks of the Trade" sections capture the art (experience) of the mining industry. I encourage you to use the Handbook, and use it wisely.

RESPONSE Mining industry response to the book continues to be incredible. Thanks in large part to the efforts by John Chadwick of the Mining Journal, , and many other members of the mining community, the Hard Rock Miner's Handbook has been distributed to over 113 countries worldwide. Web hits and downloads continue as students and professors, miners, engineers, and mining executives embrace the Handbook as an invaluable source of practical mining information.

After the first edition was published as a hard copy, we received significant encouragement from the many readers of the book, who provided new additions to the "Rules of Thumb" section. Therefore, Jack decided that a complete update was warranted, and I was on board. The original publication was published as a hard copy. The CD and web version, with minor changes, were published as Edition 2. Two hundred hard copies were distributed to customers and close friends of Stantec (then McIntosh Engineering) and thousands of electronic copies were freely distributed via CD and our website. Edition 3 consisted of two versions, a CD (May 2003) and hard copy (August 2003).

And now we have completed Edition 4, which provides a visual "refresh" to acknowledge Stantec's acquisition of McIntosh Engineering. As it has been for 12 years, the Handbook is available as a free download from our website (mining) and the CD version is free by request (marketing@). We are also printing copies of this new edition, available for a nominal charge to cover printing costs.

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ACKNOWLEDGMENTS Stantec gratefully acknowledges everyone who contributed to the development of the Hard Rock Miner's Handbook. Many people are listed as contributors of specific "Rules of Thumb" or "Tricks of the Trade." In addition, we are grateful to everyone who advised Jack on a personal basis through his years of writing the text. I am also personally grateful to the many employees of Stantec and others outside of our company who contributed time to the section-by-section internal review process and updates. Thank you!

In closing, I would like to express my sincere appreciation to John (Jack) de la Vergne for his dedication to this project. I have known and worked with Jack for nearly 30 years and thoroughly enjoyed the opportunity to participate with him in publishing this Handbook. To all of our mining industry friends, please feel free to use this Handbook wisely and share it with others. I hope that by publishing this Handbook, we have somehow made your jobs easier or helped you in some way to be competitive in a tough but fun and interesting industry. We look forward to any comments you have.

Scott McIntosh, September 2012 Stantec Consulting

DISCLAIMER The Handbook is intended as an educational resource that provides information to its readers. Use of the Handbook is not intended as a substitute for the standard of care, skill and diligence that would normally have to be provided by an experienced and prudent engineer supplying services in any mining project. The author and the publisher were not engaged to render any type of professional opinion or advice. The content of each rule or tip is the expression and opinion of its author and not necessarily that of the publisher. No warranties or guarantees are expressed or implied by the publisher's choice to include any of the content in this volume. Neither the publisher nor the authors shall be liable to any person or entity for any damage to property, losses, physical, emotional, financial or commercial damages, including but not limited to special, incidental, consequential or other damages. The author and publisher are providing you with information so that you can chose, at your own risk, how to apply and use that information. Every mine or mining project is different and the information contained herein may not be suitable for all particular circumstances.

Where practical, direct quotes of the individuals referenced are provided; however, some were translated from a foreign language, others are recalled from memory, received by word of mouth or do not represent word for word quotes. Every effort was made to ensure that the quotes are accurate. However, the author and publisher are not liable for any errors, omissions, misinterpretations or incorrectly referenced quotes.

Although the author and publisher have made every effort to ensure that the information in this book was correct at the time of first publication, the author and publisher are not liable to any person or entity for any loss, damage, or disruption caused by errors or omissions, whether such errors or omissions result from negligence, accident, or any other cause.

References are provided for informational purposes only and do not constitute endorsement of any websites or other sources. Certain links within the book lead to resources maintained by third parties over whom the author and publisher have no control, and the author and publisher make no representations or warranties as to the accuracy of those resources. Readers should be aware that the websites listed in this book may change and the author and publisher are not liable for any missing or broken links.

2008 Stantec Consulting Ltd.

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TABLE OF CONTENTS

Hard Rock Miner's Handbook

Rules of Thumb Tricks of the Trade

Case Histories Example Problems

Long before science and engineering evolved, Rules of Thumb constituted the sole body of mining knowledge. In 1891, the Royal Commission on mineral resources in Ontario, Canada stated that we had been "mining by rules of thumb for long enough." The Royal Commission probably never imagined that over 100 years later we not only continue to employ these tools, but we lend more value to them then ever before.

Exploration Geology and Ore Reserves Rock Mechanics Mining Methods Mine Layout

Environmental Engineering Feasibility Studies Mineral Economics Cost Estimating Shaft Design Shaft Sinking

Lateral Development and Ramps Collars and Portals Drum Hoists

Koepe / Friction Hoists Wire Ropes, Sheaves, and Conveyances

Headframes and Bins Conveyors and Feeders Ventilation and Air Conditioning

Compressed Air Mine Dewatering

Backfill Explosives and Drilling

Electrical Passes, Bins, and Chutes Crushers and Rockbreakers

Mineral Processing Infrastructure and Transportation

Mine Maintenance Project Management

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HARD ROCK MINER'S HANDBOOK

Table of Contents

1.0 EXPLORATION GEOLOGY AND ORE RESERVES .................................................................................. 2

1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10

INTRODUCTION ........................................................................................................................................ 2 RULES OF THUMB.................................................................................................................................... 2 TRICKS OF THE TRADE............................................................................................................................. 3 DIAMOND DRILLING ................................................................................................................................. 4 ORE RESERVES ...................................................................................................................................... 5 EVALUATING EXPLORATION PROPERTIES.................................................................................................. 6 ESTIMATING ORE RESERVES ................................................................................................................... 6 UNDERGROUND EXPLORATION ENTRIES................................................................................................... 7 MINE ENTRY COMPARISONS .................................................................................................................... 9 TABLES................................................................................................................................................. 11

2.0 ROCK MECHANICS................................................................................................................................... 13

2.1 2.2 2.3 2.4 2.5

2.5.1 2.5.2 2.6 2.7 2.8 2.8.1 2.8.2 2.8.3 2.8.4 2.9

INTRODUCTION ...................................................................................................................................... 13 RULES OF THUMB.................................................................................................................................. 13 TRICKS OF THE TRADE........................................................................................................................... 15 THE ROLE OF ROCK MECHANICS ........................................................................................................... 16 ROCK STRESS ...................................................................................................................................... 17

Virgin (in situ) Ground Stress ......................................................................................................... 17 Induced Ground Stress .................................................................................................................. 18 GROUND CONTROL ............................................................................................................................... 20 STABILITY OF EXCAVATIONS................................................................................................................... 23 ROCKBURSTS........................................................................................................................................ 26 Causes of Rockbursts .................................................................................................................... 26 Combating Rockbursts................................................................................................................... 27 Simple Truths about Rockbursts .................................................................................................... 28 Anecdotes of Rockburst Experiences ............................................................................................ 34 ACKNOWLEDGEMENT............................................................................................................................. 34

3.0 MINING METHODS .................................................................................................................................... 35

3.1

INTRODUCTION ...................................................................................................................................... 35

3.2

RULES OF THUMB.................................................................................................................................. 35

3.3

TRICKS OF THE TRADE........................................................................................................................... 36

3.4

MINING METHOD SELECTION.................................................................................................................. 37

3.5

DILUTION .............................................................................................................................................. 38

3.6

MINE PLANNING .................................................................................................................................... 39

3.7

MINING METHODS FOR LARGE CAPACITY UNDERGROUND MINES ............................................................ 40

4.0 MINE LAYOUT ........................................................................................................................................... 42

4.1

INTRODUCTION ...................................................................................................................................... 42

4.2

RULES OF THUMB.................................................................................................................................. 42

4.3

TRICKS OF THE TRADE........................................................................................................................... 44

4.4

STRATEGY FOR UNDERGROUND MINES .................................................................................................. 45

5.0 ENVIRONMENTAL ENGINEERING .......................................................................................................... 47

5.1

INTRODUCTION ...................................................................................................................................... 47

5.2

RULES OF THUMB.................................................................................................................................. 47

5.3

TRICKS OF THE TRADE........................................................................................................................... 48

5.4

PROCEDURES ....................................................................................................................................... 49

5.5

ENVIRONMENTAL IMPACT STATEMENT .................................................................................................... 49

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TABLE OF CONTENTS

5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13

SCHEDULE ............................................................................................................................................ 50 ACID ROCK DETERMINATION.................................................................................................................. 50 DRAINAGE DITCHES AND CULVERTS....................................................................................................... 51 WATER DEMAND ................................................................................................................................... 52 CHLORINATION OF POTABLE WATER ...................................................................................................... 52 RECYCLING MINE WATER ...................................................................................................................... 53 SMELTER EMISSIONS............................................................................................................................. 53 CYANIDE ............................................................................................................................................... 53

6.0 FEASIBILITY STUDIES.............................................................................................................................. 54

6.1

INTRODUCTION...................................................................................................................................... 54

6.2

RULES OF THUMB.................................................................................................................................. 54

6.3

TRICKS OF THE TRADE........................................................................................................................... 55

6.4

ORDER-OF-MAGNITUDE FEASIBILITY ESTIMATE ...................................................................................... 56

6.5

PRELIMINARY FEASIBILITY STUDY .......................................................................................................... 57

6.6

DETAILED FEASIBILITY STUDY ................................................................................................................ 57

7.0 MINERAL ECONOMICS............................................................................................................................. 66

7.1 7.1.1 7.1.2 7.1.3 7.1.4

7.2 7.3 7.4

7.4.1 7.4.2 7.4.3 7.4.4 7.5 7.6

INTRODUCTION...................................................................................................................................... 66 Accounting Practice ....................................................................................................................... 66 Commodity Market ......................................................................................................................... 66 Financing........................................................................................................................................ 66 Economic Evaluation...................................................................................................................... 66

RULES OF THUMB.................................................................................................................................. 67 TRICKS OF THE TRADE........................................................................................................................... 68 ECONOMIC EVALUATION ........................................................................................................................ 68

Cash Flow ...................................................................................................................................... 68 Rate of Return on Investment ........................................................................................................ 70 Payback ......................................................................................................................................... 70 Competitive Cost............................................................................................................................ 71 OPERATING MINE ECONOMICS............................................................................................................... 71 APPENDIX ............................................................................................................................................. 72

8.0 COST ESTIMATING ................................................................................................................................... 73

8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16

INTRODUCTION...................................................................................................................................... 73 RULES OF THUMB.................................................................................................................................. 73 KEY DEFINITIONS AND ABBREVIATIONS................................................................................................... 74 PROCEDURE ......................................................................................................................................... 75 TOOLS OF THE TRADE ........................................................................................................................... 75 TRICKS OF THE TRADE........................................................................................................................... 76 CATEGORIES AND CONFIDENCE LEVELS OF ESTIMATES........................................................................... 76 VALUE ENGINEERING............................................................................................................................. 77 CALCULATION OF INTEREST COSTS ........................................................................................................ 77 THE "SIX-TENTHS RULE" ....................................................................................................................... 78 JACK'S FACTORS................................................................................................................................... 78 LANG FACTORS ..................................................................................................................................... 78 CALCULATION OF EPCM COSTS ............................................................................................................ 79 OPERATING COST BREAKDOWN............................................................................................................. 80 CALCULATION OF PRODUCTIVITY ? TYPICAL VALUES ............................................................................... 80 CALCULATION OF CONSUMPTION ? TYPICAL VALUES............................................................................... 81

9.0 SHAFT DESIGN ......................................................................................................................................... 82

9.1 9.2 9.3 9.4

9.4.1 9.4.2

INTRODUCTION...................................................................................................................................... 82 RULES OF THUMB.................................................................................................................................. 82 TRICKS OF THE TRADE........................................................................................................................... 85 FUNCTION OF CONCRETE LINING IN A CIRCULAR SHAFT .......................................................................... 86

Curb Rings ..................................................................................................................................... 86 Continuous Lining .......................................................................................................................... 86

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9.4.3 9.4.4 9.5 9.6 9.7 9.8 9.8.1 9.8.2 9.8.3 9.9

Role of Lining ................................................................................................................................. 87 Concrete Lining Advantages .......................................................................................................... 87 STIFFNESS OF CONCRETE ..................................................................................................................... 87 STIFFNESS OF ROCK ............................................................................................................................. 87 CONCRETE LINER DESIGN ..................................................................................................................... 88 STEEL LINER DESIGN ............................................................................................................................ 89 Sandwich Liner............................................................................................................................... 89 Leaky Liners ................................................................................................................................... 90 Hydrostatic Liner ............................................................................................................................ 90 SHAFT DESIGN TOLERANCES ................................................................................................................. 91

10.0 SHAFT SINKING ........................................................................................................................................ 92

10.1

INTRODUCTION ...................................................................................................................................... 92

10.2

RULES OF THUMB.................................................................................................................................. 92

10.3

TRICKS OF THE TRADE........................................................................................................................... 94

10.4

TYPES OF SHAFTS................................................................................................................................. 95

10.5

PLANNING AND PREPARATIONS ? RECIPE FOR SUCCESS ......................................................................... 95

10.6

HOIST SELECTION FOR SHAFT SINKING .................................................................................................. 96

10.7

SHAFT CONCRETE................................................................................................................................. 96

10.7.1 Coriolus Effect ................................................................................................................................ 97

10.8

SOLVED PROBLEMS............................................................................................................................... 97

10.8.1 Coriolus Effect ................................................................................................................................ 97

10.8.2 Overbreak Measurement ............................................................................................................... 97

11.0 LATERAL DEVELOPMENT AND RAMPS ................................................................................................ 99

11.1 11.2 11.3 11.4 11.5 11.6

INTRODUCTION ...................................................................................................................................... 99 RULES OF THUMB.................................................................................................................................. 99 TRICKS OF THE TRADE......................................................................................................................... 100 TRACK VERSUS TRACKLESS................................................................................................................. 101 DESIGN AND FUNCTION OF LATERAL HEADINGS .................................................................................... 102 LASER CONTROLS ............................................................................................................................... 102

12.0 COLLARS & PORTALS ........................................................................................................................... 104

12.1

INTRODUCTION .................................................................................................................................... 104

12.2

RULES OF THUMB................................................................................................................................ 104

12.3

TRICKS OF THE TRADE......................................................................................................................... 105

12.4

WELL POINTS AND WELL PUMP DEWATERING....................................................................................... 108

12.5

BIG HOLE DRILLING ............................................................................................................................. 109

12.6

GROUND FREEZING ............................................................................................................................. 109

13.0 DRUM HOISTS ......................................................................................................................................... 114

13.1

INTRODUCTION .................................................................................................................................... 114

13.2

RULES OF THUMB................................................................................................................................ 114

13.3

TRICKS OF THE TRADE......................................................................................................................... 117

13.4

HOIST CYCLE TIME "T" ........................................................................................................................ 118

13.4.1 Stops ............................................................................................................................................ 119

13.4.2 Creep Times................................................................................................................................. 119

13.5

MAXIMUM LINE SPEEDS FOR DRUM HOISTS .......................................................................................... 120

13.5.1 Case Histories .............................................................................................................................. 120

13.6

PRODUCTION AVAILABILITY .................................................................................................................. 121

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