Design Criteria and Guidelines For Surface Infrastructure Mechanical and Structural

IMPLEMENTATION 11/22/2013
AATC DESIGN CRITERIA AND GUIDELINES FOR SURFACE

INFRASTRUCTURE - MECHANICAL & STRUCTURAL
DOC NO AATC000859
CONTENTS
Page
AIM
DEFINITIONS
PROCESS DESIGN CRITERIA
3.1
Material Characteristics
MECHANICAL DESIGN CRITERIA
4.1
Design Codes and Standards
4.2
Surface materials handling systems General requirements
4.3
Environmental Aspects
13
4.4
Standardisation
13
4.5
Belt Conveyors
14
4.6
Chutes
30
4.7
Mechanical Design General Requirements
32
4.8
Fire protection
36
4.9
Pipework and Valves
36
4.10
Platework and Lining
47
STRUCTURAL DESIGN CRITERIA
52
5.1
Plant Buildings and Structures
52
5.2
Conveyor Structures
53
5.3
Walkways, access, platforms and flooring
54
5.4
Cladding of structures
55
5.5
Civil
57
5.6
Corrosion Protection
57
INTERFACES
60
6.1
Civil
60
6.2
Electrical Engineering
60
6.3
Instrumentation
61
REFERENCES
62
7.1
62
AA Standards and Specifications:
Refer to the AATC Document Management System for the latest version of the document. Copyright resides with the
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7.2
DOC NO AATC000859
National Standards and Specifications
63
REVISION HISTORY
64
APPENDICES
65
9.1
Appendix A: Preferred Vendor List
65
9.2
Appendix B: Standard Drawings
66
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DOC NO AATC000859
AIM
The purpose of this document is to provide generic design criteria and guidelines for AATC
surface infrastructure projects related to the Mechanical and Structural Steel Engineering
disciplines. Certain basic civil aspects which directly impact on the mentioned disciplines are
also covered but not from a design perspective.
Underground systems are covered under the AATC Underground Conveyor Design Guide
document number AATC000860.
The intent of the document is not to present detailed design information for each component and
system, but rather to outline guidelines and certain mandatory requirements not contained in
specifications. Any particular information not contained herein must be developed during
detailed design stage to support equipment and erection specifications.
This document shall be read in conjunction with the relevant Anglo American Specifications as
quoted, which shall be issued as part of the equipment and/or contract enquiry documents.
In project specific cases where the need arise to deviate from any item in this document a
concession must be submitted to and approved by the Engineer in writing.
Where an item is specified with a note stating or equivalent, the Engineer shall be requested in
writing to grant permission to use such an alternative.
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DOC NO AATC000859
DEFINITIONS
Term
Definition
AATC
Anglo American Thermal Coal
AFRS
Anglo American Fatal Risk Standard
APW
Anglo Projects Way
Approved
Approved by the Engineer in writing or signature
BMH
Bulk Materials Handling
BS
British Standard
BS EN
British Standard European Norm
CEMA
Conveyor Equipment Manufacturers Association
CMA
Conveyor Manufacturers Association
DMR
Department of Mineral Resources
Engineer
AATC Discipline Engineer assigned to the project
ESS
HAZOP
Electronic Soft Starter

Front End Loading of Project
documentation)
Hazard And Operability Study
ISO
International Standards Organisation
MCC
Motor Control Centre
OEM
Original Equipment Manufacturer
PFD
Process Flow Diagram
P & IDs
Piping And Instrument Diagrams
PLC
Programmable Logic Controller
PSD
Particle Size Distribution
SANS
South African National Standard
SIB
Stay in Business
ROM
Run of mine
VSD
Variable Speed Drive
FEL
Phases
(Refer
company.
to
APW
Page 5 of 68

PROCESS DESIGN CRITERIA
3.1
Material Characteristics
3.1.1
General design parameters
DOC NO AATC000859
The table below indicates the design parameters to be used in all material handling
systems. Material flow tests should ideally be conducted during FEL 2 so that the design
data is available when FEL 3 commences.
Duty
The plant and equipment shall be designed to operate 24 hours a day, 7

days a week; with one 8 hour maintenance shift a week.
The nature of the reserve must be understood i.e. virgin reserves versus
previously undermined areas.
ROM material
Consideration must be given to previously undermined operations where

the top size of lumps cannot be accurately controlled and instantaneous
slugs of 100 % stone may occasionally occur in the feed stream. Where
weathered coal exists, the total instantaneous throughput tonnage may
be fine material.
When designing systems, the scale of the operation must be considered
since design approach and methodology are not the same for a 0.5 MTA
mini-pit as opposed to a 20 MTA operation.
Contamination
Previously undermined reserves may contain a considerable amount of

timber and tramp metal.
Raw coal PSD
The particle size distribution can be considered typical of open cast

operation but confirmation from metallurgy is prudent. It is not uncommon
to encounter 2 m top size lumps.
Bulk density
(volumetric)
Volumetric calculations to be based on lowest anticipated bulk density

unless a correction factor is applied in the calculations.
Bulk density (mass)
Power calculations to be based on highest anticipated bulk density unless

a correction factor is applied in the calculations.
Total moisture
content
Average
12 %
Dry season 8 %
Wet season 15 %
(Guideline only, reserve specific)
Angle of repose
38 (Guideline only project specific data required for detail design)
Bulk densities
Raw coal
Product
Discards
: 900 to 1300 kg/m

3
: 900 to 1100 kg/m
3
: > 1100 kg/m
Guideline only - For specific project information refer to the bulk solids
flow reports or confirm with AATC metallurgy.
Table 1 General Design Parameters
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MECHANICAL DESIGN CRITERIA
4.1
Design Codes and Standards
DOC NO AATC000859
4.1.1.1 The design and construction of all works shall be carried out in accordance with all
applicable laws, regulations and standards. This document is regarded as a guideline
with certain mandatory requirements. Applicable standards which are not listed must be
included by the designer or supplier.
4.1.2
Anglo American Specifications
4.1.2.1 The list of Anglo American Specifications referred to in this document is provided in
Section 7 References.
4.1.3
Applicable Codes, Standards, Acts and Regulations
4.1.3.1 Unless specifically stated otherwise, designs shall be based on the applicable parts of
the latest revision of the Codes, Specifications, Standards, Regulations and other
documents. The list of the codes, specifications, standards and regulations referred to
in this document provided in Section 7 References. In addition, the design must comply
with local legislation and regulations as stipulated by the DMR.
4.1.3.2 In the event of conflicting requirements, the most stringent will apply.
4.1.3.3 For conveyor designs, ISO 5048 will take preference over CEMA requirements.
4.1.3.4 The following protocol will be used where specifications are required:
1) Available Anglo American specifications must be used.
2) If no Anglo specifications are available, refer to the most relevant SANS
specification.
3) If no SANS specifications are available, international specifications recognised
within the industry may be applied.
4.2
Surface materials handling systems General requirements
4.2.1
General
The layout of materials handling systems must be conducted in view of an optimal
balance between operational costs and capital expenditure.
Where the implementation of new technology is considered viable, a trade off study
must be done against the conventional approach.
Designs must be carried out with consideration for the reduction of fines generation.
4.2.2
Tips General
The layout of tips must be such that free access with mobile cranes is possible from both
sides.
The topography of the location can often be used to minimise the ramp height and excavation
depth. However, free drainage is mandatory.
On certain large and more complex tip configurations, typically associated with previously
undermined reserves, an overhead crane may be required. On these installations only roof
sheeting will be required.
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4.2.3
DOC NO AATC000859
Dust hood
Passive dust suppression is mandatory on all new tip installations. The passive system
may be aided by the intermittent use of a spray system as and when required.
The volumetric design of the hood structure is somewhat specialised but essentially it
needs to provide enough volume so that the displaced air, as a consequence of the
tipping operation, can settle down such that dust pollution is minimised.
Installations must be equipped with used fire retardant conveyor belt installed in a
specific internal baffle arrangement to enable dust particles to settle out.
The ratio of the dust hood width/truck width must fall within a range of 1.8 to 2 in order to
ensure easy truck manoeuvrability and to avoid mechanical damage. Columns must
ideally be integrated with the wing walls and bin structure to eliminate structural damage.
The walls of the bin must be raised to prevent damage to the sheeting by large rolling
lumps when the bin is full or where grizzly cleaning operations are anticipated.
Safe access to the roof is required for the maintenance of lighting etc.
The orientation of the hood must ideally be such that the prevailing wind direction is
towards the tipping face i.e. into the hood.
4.2.4
Jockey Slab
The jockey slab must be equipped with cast-in rail liners to facilitate cleaning operations.
The ideal height of the wheel stopper must be 67% of the wheel diameter. Special
consideration is required where different truck types are anticipated. The steel cover
plate must be submerged well into the concrete such that it cannot be lifted during
cleaning operations by a front end loader. Avoid any ledges that can initiate material
build up.
Where a concrete bin is utilised, the jockey slab will be integrated with the wing walls
and bin structure. For a steel bins however, the jockey slab will be independent.
4.2.5
Tip static grizzly

The viability of using a static grizzly depends on the specific operations. The guideline is
to equip mini-tips with low throughput tonnage with a static grizzly to ensure that smaller,
cost effective equipment can be selected.
The consideration for a grizzly must be done within the context of downstream
equipment selection.
The grizzly aperture is reserve specific but within AATC 1.2m x 1.2m is commonly used.
Static grizzlies are not permitted on large operations where previously undermined areas
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DOC NO AATC000859
will be mined. The philosophy is that large lumps can be removed safer at an inspection
feeder at a lower level in the tip, which is equipped with an overhead crane.
Grizzly bars and support structures must be designed to safely withstand the impact
energy associated with the tipping operation and where applicable, the hydraulic rock
breaker.
4.2.6
Tip static grizzly cleaning operations

It is not permitted to use a fixed pecker in conjunction with a dust hood.
The use of a TLB may be functional on mini-pit operations but on larger tips, the reach
may be insufficient. A track mounted excavator, equipped with a hydraulic hammer may
be required.
On mini-pit operations, it may be more efficient to remove and stockpile oversize rock
instead of attempting it through the grizzly.
4.2.7
Tip bin
The volume of the tip bin is generally taken as 2 to 3 times the capacity of the hauling
trucks but must be justified by simulation or calculation.
Steel bins should only be considered for an anticipated mining life of less than 15 years
because of corrosion considerations. All other installations must be constructed out of
concrete.
Concrete bin constructions can be integrated well with the dust hood, wing walls and
wheel stoppers.
Concrete bins must be equipped with casted in rail liners.
Discharge arrangement designs should be based on mass flow system. Appropriate
material release angles to be applied.
4.2.8
Tip feeders
The draw off pattern achievable is a function of the geometry of the interfacing plate
work. The design must be such that tipping space is continuously created at the tipping
face of the bin.
Big lumps must specifically be catered for on large operations. However, at small
operations, a trade off is required to ensure that capital cost remains at an acceptable
level.
Where previously undermined areas are included in the mining plan, the preference is to
use a conventional apron feeder. Apron feeders are generally orientated in line with the
tipping face such that dribbling is collected on the clearance conveyor.
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DOC NO AATC000859
Flight bar feeders may be used on mini-tips and larger operations where virgin areas are
mined but the bin interface requires careful consideration.
The orientation of these feeders i.e. parallel or perpendicular to the tipping face is project
specific.
A perpendicular arrangement provides good maintenance access but the tail end of the
tip clearance conveyor cannot be utilised as a spillage conveyor. A parallel configuration
is therefore preferable when using a conventional apron feeder.
A perpendicular arrangement is usually preferable when using a flight bar type feeder
but not mandatory.
4.2.9
Grizzly and observation feeders

Grizzly feeders are generally associated with tips used at previously undermined
reserves where jaw crushers are installed. Large tramp metal chunks, oversize lumps
and timber can be removed with an overhead crane from the observation feeder deck.
Safe access onto the observation feeder deck is a key design consideration. The
decision to utilise these feeders are project specific.
4.2.10 Rock breaker

Rock breakers are generally associated with tips equipped with observation feeders
such that large lumps can also be broken at sizer or crusher feed-ends.
The guideline rating for the hydraulic hammer is 2000 Joule.
4.2.11 Primary crushing
Jaw crushers are considered more robust than mineral sizers and are therefore
preferred where previously undermined reserves are mined. The large lumps associated
with this type of operation generally lead to the selection of the largest crusher available
on the market i.e. 80 x 60
Where virgin reserves are mined, mineral sizers are preferred.
The preferred feed configuration is such that the feed stream lands parallel to the sizer
shafts such that fines can easily pass through the sizer without being scrolled to the
sides. A perpendicular feed arrangement is also possible but will result in uneven wear
and may lead to throughput constraints when the sizer is operating close to its capacity
limit.
4.2.12 Secondary crushing
A scalping operation between the primary and secondary crushers or sizers will usually
enable the selection of a smaller secondary machine with reduced wear and
maintenance.
The removal of tramp metal is problematic where the secondary sizer is positioned
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DOC NO AATC000859
directly below the primary sizer. This configuration must be avoided.

4.2.13 Tertiary crushing
Although the throughput tonnage processed by the tertiary crushers is often lower than
upstream crushing operations, tertiary crushers often work the hardest and are often
where excessive wear, throughput and oversize problems occur.
Special consideration must be given to the nature of the operation. During the rainy
season, when wet material is processed, throughput problems may occur if the sizer is
marginally selected.
It must be noted that where a guaranteed product size must be delivered i.e. Eskom
product, mineral sizers are not suitable on its own without a final screening operation. As
internal wear occurs, oversize material will be encountered. Granulators are generally
utilised where stringent final product size specifications is stipulated.
4.2.14 Tramp metal removal
The most effective tramp metal removal configuration is where the magnet is positioned
above a material trajectory. Conventional overband magnets are however often
sufficient. Where excessive amounts of tramp metal are anticipated, the magnet should
be positioned at a perpendicular transfer. This configuration will also make the removal
of long rails and timber logs possible. Where magnets are positioned above a transfer,
stainless steel pulleys are usually only required for belt speeds below 2 m/s.
4.2.15 Rotary breakers
A rotary breaker should not be used as a primary crusher on opencast applications. The
impact energy associated with large lumps is problematic.
A concrete support structure is preferred. A conservative structural design approach is
advisable.
A scalping operation upstream of the rotary breaker should be avoided unless the use
thereof can be justified.
4.2.16 Silos and bins
The general guideline is to use steel for the construction of bins with a capacity of less
than 500 ton and concrete for silos in excess of 1000 ton. The range between 500 and
1000 ton may be constructed out of steel or concrete based on economical or other
considerations.
Where the anticipated life of the project exceeds 20 years, concrete construction is
preferable.
Silo diameters commonly used includes 13, 16, 20 and 22 m.
Where concrete roofs are used on silos, dust explosions must be catered for by means
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DOC NO AATC000859
of explosion panels.
Silos and bins are generally designed for expandable flow conditions in the upper region
with mass flow conditions at the discharge hopper.
4.2.17 Silo and bunker trade-offs
Although several project specific considerations will influence the selection, Table 2
below is to be used as a guideline.
Surge / storage structure
Approx capacity range (m3)
Comment
Up to 1 000
Project requirements may

dictate concrete construction.
Silo
1 000 to 6 000
Consider bunker for > 5 000

m3
Silo, rail load out
up to 10 000
Bunker with rail load out bin

must be evaluated.
2 500 to 15 000
Project specific constraints

may rule (RE) option out.
Bin, steel
Bunker, (RE C)
Bunker, longitudinal
> 6 000
RC / RC P / RE L
Where:
RC = Reinforced concrete
RC P = Reinforced concrete with pre-cast elements
RE C = Reinforced earth, circular
RE L = Reinforced earth, longitudinal
Whenever the required surge or storage capacity is close to the threshold values indicated
above, a trade-off study would be required unless an option can be ruled out because of
specific project requirements or constraints.
Table 2 Selection guideline for silos & bunkers
4.2.18 Stockyards and equipment

The possibility of future expansion must be considered when conducting layouts.
Stockyards should, where possible, not be located within a rail loops unless sufficient
space is available for future expansions.
Where possible, stockyard by-pass conveyors must be included.
4.2.19 Escape access
The need for escape access, cross overs at conveyors and especially parallel
conveyors where personnel can be entrapped in case of fire, must be determined by risk
assessment.
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4.3
DOC NO AATC000859
Environmental Aspects
4.3.1.1 Environmental aspects are regulated by local Legislation. Items listed below merely
highlights some important considerations directly related to designs.
4.3.1.2 All designs shall be carried out such that the impact that mining operations have on the
environment is minimised. Of particular concern are water, dust and noise pollution.
4.3.1.3 All water that arises within the conveyor area shall be contained and channelled to the
polluted water handling system.
4.3.1.4 Overland conveyors transporting material outside the boundaries of the polluted area
must be equipped with belt turnovers at the head and tail to avoid material carry back
along the conveyor. Turnovers are problematic on wide conveyors. Overland conveyors
used for AATC projects are generally less than 1500 mm wide such that turnover
designs are possible.
4.3.1.5 Generation of dust shall be strictly controlled by avoiding degradation of the coal and
the dust that is generated shall be controlled by both passive and active means.
4.3.1.6 The noise generated by the plant shall be minimised by selecting inherently quiet
equipment and processes and, where unavoidable, acoustic enclosures.
4.3.1.7 Special note shall be taken for electrical drives that are electronically controlled which
have an inherent noise generation through the motor drive shaft. This shall be taken
into account with respect to noise abatement. Noise abatement technical information
shall be obtained from the drive manufacturer. Resonance points, if applicable, shall be
provided in the ramp-up to full speed.
4.4
Standardisation
4.4.1
General
The selection of major equipment must not be done in isolation. Equipment already used
within AATC must be considered.
When selecting conveyor belting for purposes of an FEL 3 Study or Detail Design,
belting already used at AATC operations must be considered.
For SIB type project designs, it is essential to stick to standard equipment and supplier
brands which are already used at the specific Operation unless the deviation can be
motivated.
A preferred vendors list is provided in Appendix A: Preferred Vendor List. Vendors not
listed are not necessarily excluded nor are vendors tabulated in order of preference.
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4.5
Belt Conveyors
4.5.1
Conveyor Design Criteria
DOC NO AATC000859
Conveyor designs are to be in accordance with the latest ISO 5048 Standard,
Continuous mechanical handling equipment and guidelines prepared by Conveyor
Equipment Manufacturers Association (CEMA).
Conveyors must be designed for continuous operation and starting under full design
load.
4.5.2
Standardisation
4.5.2.1 The conveyor designer is to give consideration to economical design while rationalising
mechanical components for optimum spares holding and interchangeability. The
process shall be based on component priority selection as follows:
Priority 1 belting
Priority 2 - drives
Priority 3 - pulleys
Priority 4 other
In view of power savings, right-sizing must be traded off against standardisation.
4.5.3
Vertical inclination
4.5.3.1 The maximum permissible angle of inclination shall be dictated by the material, particle
size distribution, type of loading, belt speed etc. of the particular design.
4.5.3.2 The maximum inclination angle shall however not exceed 13.
4.5.3.3 Where material run-back on the conveyor is expected e.g. conveyors exclusively
handling screened oversize or spherical type lumps, conveyor inclinations will be kept
below 10.
4.5.3.4 For stacker boom belts, the inclination angle, and subsequently the angle at which
material is loaded, will be limited to 14.
4.5.3.5 For normal loading conditions, with the tail pulley positioned for full trough, the conveyor
incline should be 0.5 to provide effective drainage.
4.5.3.6 The maximum incline at loading shall not exceed 5
4.5.4
Vertical curves
Dynamic calculations must be performed for all vertical curves to ensure safe and
reliable conveyor operation. Calculations must be based on the worst case combination
of conveyor loading and geometry.
A suitable factor, taking cognisance of the start-up device, must be applied to the
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DOC NO AATC000859
calculated dynamic start-up tensions when calculating the required concave radius.
4.5.4.1 For concave curves, the following criteria should be met:
On all conveyors featuring trippers (eg. stacker feed conveyors), the belt shall not lift off
the radius during start-up or normal running when loaded to 15 % of the conveyors
maximum design capacity in the curve only, with the rest of the belt fully loaded for the
load-case causing highest tension in the curve. The belt mass used for these
calculations shall be based on 50 % top cover wear. Belt-lift control must be considered
where it is not possible to satisfy these criteria.
For cases where the rear tangent point is close to the feed chute, the above calculation
shall be repeated with load up to the rear tangent point and no load on the belt in the
curved section to ensure that the belt will never lift into the chute or skirt sections.
On all other conveyors, the belt shall not lift off the radius during start-up or normal
running when empty. The belt mass used for these calculations shall be based on 50 %
top cover wear.
Centre tension in the curve area shall be limited to 115 % of the maximum rated tension
for the particular conveyor.
The edges of the belt shall not buckle in the curve area.
4.5.4.2 For convex curves, the following criteria should be met:
The additional stress imposed on the idlers as a result of the convex curve shall not
lead to idler shaft deflections and idler bearing lives that do not comply with Anglo
specifications.
Edge tension in the curve area shall be limited to 115 % of the maximum rated tension
for the particular belt.
The centre of the belt shall not buckle in the curve area.
4.5.5
Horizontal curves overland conveyors

Belt wander must be considered for all conditions of loading as well as for all weather
conditions and must be limited to approximately 100 mm as a guideline.
It is recommended to use stringer widths for the next belt size up within horizontal
curves. Throughing idlers will then be for the selected belt width while return idlers will
be for the next size up.
The layouts for horizontal curves must be based on a minimum radius of 4 km. Where
route requirements and existing infrastructure dictates otherwise, a smaller radius may
be allowed on concession provided that the design can be justified.
4.5.6
Conveyor Dynamics
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4.5.6.1 All conveyors shall be analysed for behaviour during starting (for vertical curves),
coasting and where applicable, braking.
4.5.6.2 For conveyors >1 km, or where special profiles are encountered, dynamic transients
and the application of torque prior to starting must be considered.
4.5.7
Conveyor Capacities, Widths and Loading
4.5.7.1 Conveyor design capacities shall be calculated from the Life of Mine plan and recorded
on a flow sheet. Only the approved flow sheet capacities shall be used for detail
conveyor designs.
4.5.7.2 The width of belt shall be selected as follows:
For a maximum lump size up to 180 mm: Flow sheet peak capacity and the standard
recommended edge distance shall be used according to the latest ISO 5048 Standard,
Continuous mechanical handling equipment and CEMA.
The designer shall optimise belt speed and installed power by achieving as close as
possible a belt loading of 80 % full at the installed power. Where designs incorporate
trippers and multiple feed points, the belt loading must be reduced.
For maximum lump size over 180 mm: As a minimum requirement, the belt width shall
be maximum lump size x 4 and then selecting the closest standard belt width above this
value. Thereafter, the criteria above for a maximum lump size below 180 mm shall
apply.
4.5.8
Feed factors
4.5.8.1 In order to cater for fluctuations in feed to the conveyors, the following feed factors shall
be used as a guideline:
Application
Feed factor
Belt and apron feeders where steady

stream controlled feed is expected.
1.1
Vibrating, table feeders etc. where surges

and significant short term flooding may
occur on the receiving conveyor belt
1.15 - 1.25
Reciprocating feeders
1.7
Where there is no feed control e.g.

Langlaagte chutes under hoppers / box
fronts.
2.0
(depending on the feeder type)
* The above factors will be incorporated in the conveyor designs but will not be reflected in
the flow sheet capacity.
Table 3 Feed Factors
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4.5.9
DOC NO AATC000859
Conveyor belt speeds
4.5.9.1 The general philosophy of wide and slow belts shall be adopted with the following
recommended speeds:
Incline conveyors
< 4 m/s
Plant surface transfer conveyors
2 to 3 m/s
Overland conveyors
< 4.5 m/s
4.5.9.2 For typical transfer heights in the chutes, a nominal 250 mm lump will produce up to
900 Joules on impact with the receiving belt, which is the upper limit of the allowable
impact energy. It therefore follows that the initial kinetic energy of the lumps entering the
transfer chutes be minimised by way of conservatively slow belt speeds.
4.5.9.3 Where multiple feed points are required, lower speeds must be considered to reduce
spillage.
4.5.10 Conveyor artificial friction factor f

4.5.10.1 The guideline design values for the coefficient of friction f for idler resistance and flexure
of the material and the belts, are as follows:
Overland conveyors
:fc = .019
fr = .017
Curved overland conveyors
:fc = .0195
fr = .018
In-plant conveyors
:fc = .02
fr = .022
In-plant ROM conveyors
:fc = .022
fr = .022
4.5.10.2 A friction factor of 0.022 should be used for both underground and surface conveyors
with an adjusted length factor Lo of 60m for all conveyors longer than 100 m.
4.5.10.3 In extremely cold conditions during winter mornings a load factor of between 1.1 and
1.2 should be applied when selecting the sizes of the drives.
4.5.10.4 The above factors serve only for static analysis. Visco-elastic friction, indentation
resistance and idler resistance calculations shall be included in the design of long
overland conveyors.
4.5.11 Conveyor Drive Systems

4.5.11.1 The design, selection and layout of the drive systems for conveyors shall be determined
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DOC NO AATC000859
by the power, tension and wrap requirements.

4.5.11.2 The absorbed power at the drive pulley is calculated in accordance with the latest ISO
5048 standard, Continuous mechanical handling equipment, using the artificial friction
factors f being selected from section 4.5.10.
4.5.11.3 The absorbed power at the motor is that calculated at the pulley shaft, divided by the
combined gearbox and fluid coupling efficiency, approximately 0.94, depending on
selection, where fitted above 22 kW.
4.5.11.4 For VSD units, the efficiency is taken as 0.97, unless otherwise certified by the OEM.
4.5.11.5 The absorbed power at the motor is then multiplied by a factor of 1.1 for conveyors with
single drives. Thereafter, the next most suitable motor size up is selected in each case
as well as considering standardisation. For multiple drives, load sharing must be
considered. Although a factor of not less than 1.1 is to be applied, specific consideration
is required to ensure that large drives are not oversized.
4.5.11.6 The drives for incline, surface transfer and main overland conveyors shall be sized for
the full length of conveyor as per the conveyor route profiles and design capacity.
4.5.11.7 Single head drive configurations may be considered for large conveyor drives (> 250
kW) where the head is elevated one floor level only. Special consideration must be
taken to ensure that proper maintenance can be done on scrapers and that facilities are
available for the change out of pulleys, motors and reducer. A trade-off must be done
against a ground level installation.
4.5.11.8 Where drive sizes are 250 kW and smaller, elevated drive installations (in excess of a
single floor) may be considered provided that provision is made to remove the drive and
drive pulley to a conveniently located platform which can be accessed via mobile
cranes.
4.5.11.9 Head pulley drives up to 90 kW is permitted on cantilevered conveyors, such as over
stockpiles.
4.5.11.10
If the drive is at the head end of the conveyor, the head/drive pulley shaft should
be extended so that a clearance of approximately 500 mm is obtained between drive
and conveyor steelwork.
4.5.11.11
Right-angled, bevel helical gearbox units are to be used in a torque arm
configuration. The output shaft of the gearbox will be fitted with a rigid Bikon-type
coupling for mounting onto the drive pulley coupling.
4.5.11.12
The drive station layout shall be such that torque arms are always under
compression.
4.5.11.13
The drive station layout shall be such that the belt is always driven on the clean
side.
4.5.11.14
The selection guideline table for drive preference on various conveyor
applications is shown below.
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Page 18 of 68

DOC NO AATC000859
VSD
Fluid
Coupling
Electronic
Soft Start
U/G Section
No
1st
No
Dusty, Low tech
U/G Trunk 1500 m
1st
2nd
No
Variable Speed (load)
Shaft > 50 m lift
1st
2nd
No
Start-up and inspection
Overland > 2 km
1st
2nd
No
Start-up and inspection
Plant < 2 km
2nd
1st
No
F cplg Start time OK
Plant Single drive
No
1st
No
Plant < 110 kW
No
1st
2nd
Type conveyor
Remark
ESS more cost effective
No Not permitted, 1st Preferred choice, 2nd Alternative option

Table 4 Drive preference for various conveyors
4.5.12 Couplings
4.5.12.1 Fluid couplings will be fitted on the high speed side of all drives exceeding 22 kW where
VSD or Electronic starters are not provided.
4.5.12.2 All couplings shall be complete with guards.
4.5.12.3 All low speed couplings shall be of the rigid flange type, accurately aligned and fitted to
shafts via locking elements (no keyways allowed on shafts). The drive supplier shall fit
the rigid couplings to the pulley at the pulley suppliers premises.
4.5.12.4 Drives with an installed power exceeding 22 kW shall be fitted with a soft starter i.e.
fluid coupling or electronic.
4.5.12.5 For long overland conveyors with high inertia where the start-up times would be in
excess of 50 seconds (which is the limit of the capability of fluid couplings), Variable
Speed Drives (electrical VSDs) are selected.
4.5.12.6 The overhung on motor output shafts must be checked when using large fluid coupling
sizes. Jack shafts may be required to support the fluid coupling.
4.5.13 Belting
4.5.13.1 Steel cord conveyor belting shall comply with the latest AA Specifications, Steel cord
reinforced conveyor belting (AA_SPEC_377022) and Steel cord reinforced conveyor
belting (SANS 1366).
4.5.13.2 All fabric conveyor belting shall comply with the latest SANS Specification, General
purpose textile reinforced conveyor belting (SANS 1173).
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DOC NO AATC000859
4.5.13.3 PVC impregnated solid woven conveyor belting shall comply with the latest SANS
Specification, Fire retardant textile reinforced conveyor belting (Solid woven PVC,
SANS 948 and SANS 971).
4.5.13.4 All conveyor belting shall be selected with consideration of the standardised list of
belting already in use at Anglo Coal plants.
4.5.13.5 Ply belting to be natural rubber, minimum 3 ply with suitable top and bottom covers,
minimum 3 mm and 2 mm respectively. The top to bottom cover ratio is not to exceed
3:1.
4.5.13.6 Conveyor belt final selection shall be based on the calculated tension taking
standardisation into consideration.
4.5.13.7 In determining the length required allowance shall be made for hot vulcanized splicing.
4.5.13.8 Mechanical clips may be used in emergency situations only.
4.5.13.9 During belt and cover selection, consideration must be given to minimise the risk of
igniting flammable gas during installation and operation. Belt selection must also be
done considering the possibility of burning coal to minimise the risk of fire and noxious
gasses.
4.5.13.10
In selecting the belt type, the following table must be used as a guideline:
Area application
Belt type
Ply belts where impact permits.
Solid woven to be considered on tip clearance
belts and where significant steel contamination
is anticipated.
Tip, raw coal
Sacrificial belts and applications where high

abrasion is expected are generally equipped
with ply belts.
Evaluate the possibility of burning coal /
spontaneous combustion.
Plant
Ply belts
Stock yards
Ply belts
Interconnecting
overland
conveyors
shorter than 1 km
Ply belt
Overland conveyors
Tensions normally require steel cord

consider solid woven where possible.
but
Tensions normally require steel cord

consider solid woven where possible.
but
Shaft
&
conveyors
high
lift
Solid woven where justified, avoid steel cord.
Table 5 Belt type selection

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Page 20 of 68

DOC NO AATC000859
4.5.14 Belt service factors

4.5.14.1 The following minimum service factors shall be applied to all conveyors based on the
normal steady state tensions:
Solid woven belting : 10
Fabric ply belting : 10
Steel cord belting : 6.67
4.5.15 Belt Jointing

4.5.15.1 Conveyor belts will be joined in accordance with the latest Anglo American
Specifications (Cold splicing of plied (textile) conveyor, AA_SPEC_377010), (Splicing
of solid woven conveyor belting, PVC & PVG(Nitrile), AA_SPEC_377088) and (Splicing
of steel cord reinforced conveyor, AA_SPEC_377033) whichever is applicable to the
selected conveyor belting.
4.5.15.2 The conveyor belt splicing shall be done in consultation with the conveyor belt
manufacturer.
4.5.16 Belt installation Winch/Splice station/Replacement and maintenance of belting

4.5.16.1 Provision shall be made to provide easy access for replacement and repair of belting. A
belt replacement study is to be conducted.
4.5.16.2 A belt reel holder will be installed at the head end or tail end of every conveyor belt on
surface. In cases where the reel cannot be accommodated at the head or tail, provision
will be made at the take-up section.
4.5.16.3 A belt maintenance station shall be provided such that:
The belting to be replaced may be easily pulled off the conveyor.

The replacement belting may be easily pulled onto the conveyor without the risk
of damaging the belting.
Splices may be easily and accurately made.
4.5.16.4 The splicing area is protected from the elements.

4.5.16.5 Provision will be made to install suitable winches to facilitate the initial and any
subsequent pulling-in of a new belt. These will be located to pull the belt up from the tail
end as well as to pull the return side down from the head end.
4.5.16.6 Sheaves may be permanently mounted but the winches will be installed on prepared
mounts and connected as required.
4.5.16.7 The belt maintenance station for overland conveyors shall be provided with outdoor
industrial power outlets for 220 volts (2x) and 550 volts (1x) and water. The floor of the
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DOC NO AATC000859
belt maintenance station shall be concrete and shall be bunded.

4.5.16.8 Belt clamps shall comply with the CMA specification MC-01.
4.5.17 Holdbacks
4.5.17.1 A full risk assessment per conveyor belt shall be carried out prior to selection of the
holdback considering:
Material loading combinations on conveyor.

Drive loading conditions during startup, abort start, normal running and jammed
take-up or belt.
Abnormal conditions such as wash down.
Stored energy.
Repair of conveyor components with a fully loaded incline.
Maintenance belt clamp of 60 kN capacity.
Assistance from anti-runback idlers.
Load release.
4.5.17.2 Where the design dictates the need for a holdback, external or reducer integrated units
may be considered.
4.5.17.3 Slow speed backstops, mounted directly onto the drive pulley shaft or the intermediate
reducer shaft, are preferred.
4.5.17.4 High speed holdbacks, fitted between the motor and the reducer, may be considered for
conveyors equipped with single drives.
4.5.17.5 Where it is desired to have a high speed holdback installation on a multiple drive
configuration, torque limiting type devices are required to ensure load sharing.
4.5.17.6 For external holdbacks, a horizontal mounting configuration will reduce bearing loading
and is therefore preferred.
4.5.17.7 Although stiff support steel is required to transfer the holdback reaction forces, the
torque arm end of an external unit must not be rigidly attached. This will prevent
damage to the bearings of the device.
4.5.17.8 The mounting of the torque arm must not permit any slack between the device and the
support steel. Cushioning between load contact surfaces is precluded.
4.5.17.9 Holdback selection must be based on the calculated runback load of the belt in
conjunction with a dynamic impact factor. The holdback rating shall not be less than the
maximum torque capacity of the gearbox.
4.5.17.10
Where required, turn down of the shafts may be considered to accommodate
maximum bore for selected backstop, provided that permissible shaft stresses, as
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DOC NO AATC000859
provided in AA_SPEC_371001, are not exceeded.
4.5.17.11
For standardization purposes, the selection of the internal holdbacks shall be
based on the highest torque requirement across the range of affected conveyors.
Standardised reducer units must be interchangeable, hence internal holdbacks must be
fitted for all these units unless economical considerations dictates otherwise in which
case clear visual identification must be provided.
4.5.18 Anti-runback idlers

4.5.18.1 Anti-runback idlers shall be installed to satisfy the requirements of the DMR.
4.5.18.2 Anti-runback idlers are generally not required on conveyor belts which have a lift of less
than 7 m. Special cases may however occur. Calculations and a risk assessment are
therefore still required.
4.5.18.3 In designing new steep incline conveyors, consideration must be given to increase the
carry idler spacing to enhance the friction breaking force should a belt failure occur.
4.5.18.4 In determining the number of anti-runback idlers required, a conservative friction factor
of no more than 0.3 must be used. This value caters for wet belts, condensation
associated with temperature change and build up of coal dust on contact surfaces.
4.5.18.5 The following design parameters must be considered when selecting anti-runback
idlers:
3-roll idler sets are preferred
The installation pattern, which formed the basis of the design calculations, must
be adhered to.
Clear marking is required.
Emergency conditions such as the jamming of the tail pulley or feed chute
blockage must be considered.
Where conveyors are equipped with 5 roll idler sets, the wing rolls should never
be fitted with anti-runback idlers since the contribution to braking friction is
negligible
4.5.18.6 Anti-runback idlers can never be installed in place of a positive holdback.
4.5.19 Pulleys and shafts

4.5.19.1 Pulleys and shafts shall be strictly in accordance with the latest AA Specification,
conveyor pulleys and shafts, AA_SPEC_371001 and SANS Specification, conveyor belt
pulleys, SANS1669.
4.5.19.2 Drive pulleys will be lagged using 6 mm thick smooth ceramic tiles epoxy bonded using
a high bond epoxy, directly to the pulley shell. Rubber lagging is acceptable for nondrive pulleys.
4.5.19.3 No conveyor pulleys shall be crowned. However, where reversible belts have been
approved by concession, crowning may be required.
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DOC NO AATC000859
4.5.19.4 The lagging philosophy of the operation shall be considered when conducting SIB
designs and projects.
4.5.19.5 Plummerblocks should be the split type.
4.5.19.6 Spherical roller bearings with an adapter sleeve should be used.
4.5.19.7 Plummer blocks with its bearings to be fitted with an easily accessible grease nipple.
Inaccessible grease point must be equipped with a hydraulic hose and grease block to
facilitate safe remote manual lubrication.
4.5.19.13
Plummer block orientation shall be such that the bearing force acts through the
base of the plummer block. Cap bolts shall never be under tension.
4.5.19.14
Bearing temperatures on critical belts will be monitored at the head, tail, drive and
take-up pulleys using resistance temperature detector. (RTD)
4.5.19.15
All pulley approach points will be fitted with nip protection.
4.5.19.16
The number of pulleys must be kept to a minimum when designing new
conveyors.
4.5.20 Idlers
4.5.20.1 Idlers shall be in accordance with the latest AA Specification, belt conveyor idlers and
rolls (AA_SPEC_373001) and shall bear the SANS certification mark to the latest SANS
Specification, conveyor belt idlers.
4.5.20.2 Idler spacing selection must be done by balancing the capital expenditure with
operational costs.
4.5.20.3 The maximum allowable idler shaft deflection is limited to 8 minutes at the designed
throughputs.
4.5.20.4 For the average operating throughputs, the minimum idler life is 40 000 hours.
4.5.21 Troughing idlers

4.5.21.1 All troughing idlers shall comply with the latest Anglo American specification, Belt
conveyor idlers and rolls (AA_SPEC_373001).
4.5.21.2 Carry idlers shall be specified individually for each conveyor, based on the material,
particle size distribution, etc.
4.5.21.3 Carry idlers shall be designed based on the peak capacity.
4.5.21.4 The 3 roll idler configurations are preferred. 5 roll idler configurations may be
considered for belt widths exceeding 1200 mm.
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DOC NO AATC000859
4.5.21.5 The preferred troughing angle is 35 although 45 and higher may also be used when
justified.
4.5.21.6 The head frame or the stringers leading up to the head frame shall include a transition
section to flatten the belt in accordance with the CEMA recommendations, precautions
shall be taken to prevent spillage at this point.
4.5.21.7 Head and tail transitions are to be designed to run out to 0 by installing the appropriate
transition idlers. 3 idler sets are generally required.
4.5.21.8 When required, the tail pulley may be positioned at half or third trough to reduce the
transition distance. This is however not preferred.
4.5.21.9 Standardization across designs remains to be an important consideration.
4.5.21.10
High angle troughing idlers should be considered to eliminate long and high
maintenance skirting on conveyors with multiple loading points typical for coal plant
product and discard belts.
4.5.22 Impact idlers

4.5.22.1 Impact resulting from the transfer of material shall be absorbed by impact idlers.
4.5.22.2 Standard steel rolls can however be used on -20 mm material. Idlers located in impact
areas are generally series 30 or 35 with 152 mm diameter.
4.5.22.3 Impact idlers shall be 45 trough, 159 mm rubber disk rolls to be used for coarse
material.
4.5.22.4 Where impact is abnormally high, a torsion rubber mounting system is to be considered
in conjunction with rubber disk idlers. The rubber torsion mounting arrangement is to be
approved by the Engineer.
4.5.22.5 Idlers located within the skirted area at loading points will be mounted on quick release
mountings which will allow the complete idler frame to be lowered for idler roll
replacement.
4.5.22.6 Solid SKEGA beds should not be used.
4.5.23 Return idlers

4.5.23.1 Return idlers shall be specified individually for each conveyor, based on length, belt
width, tracking difficulties, etc.
4.5.23.2 All conveyors 1200 mm wide and above should be 10 vee, 2 roll return idlers, subject
to belt troughability and the specific detail design.
4.5.23.3 As a guideline, conveyors below 1200 mm wide should be fitted with single roll flat
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DOC NO AATC000859
return idlers unless troughability calculations prove otherwise.
4.5.24 Take-up units

4.5.24.1 All conveyors with horizontal pulley centres 30 metres and longer will be provided with
gravity take-ups, either vertical or horizontal to suit the design.
4.5.24.2 For short conveyors (less than 30 m) mechanical screw take-ups may be used.
4.5.24.3 All take-ups shall be designed to accommodate the elastic and permanent stretch of the
belt, calculated from the belt modulus as specified by the belting Supplier.
4.5.24.4 In addition to belt stretch, the take-up must make provision for belt storage such that
five splices in case of overland conveyors and three splices in the case of shorter plant
conveyors is catered for.
4.5.24.5 Allowance shall also be made for sufficient movement for splicing, and where
applicable, for rope tie offs on horizontal take-up trolleys.
4.5.24.6 On vertical gravity take-ups, deflector plates, with adjustable rubber scrapers, are
required to prevent ingress of spilled material between the belt and the take-up pulley.
4.5.24.7 The take-up shall include the counterweight or winch, sheaves, steel wire rope,
attachments, etc. to maintain the required belt tension under all operation conditions.
4.5.24.8 The take-up trolley longitudinal wheel centres will have a ratio of :1 in relation to the
width of the trolley as a minimum. This aspect ratio shall apply to vertical gravity take-up
carriages as well.
4.5.24.9 The take-up trolley must have locating wheels on one side and floating wheels on the
opposite side of the carriage.
4.5.24.10
Provision shall be made for the take-up trolley to be locked in position, and the
two belt strands entering and exiting the horizontal take-up to be clamped during
maintenance activities.
4.5.24.11
A manually operated electric winch with local starting controls shall be provided
on all horizontal take-up towers to facilitate raising and lowering of the counterweight
box under controlled conditions.
4.5.24.12
Vertical take-up counter weight shall be provided with suitable guide channels to
ensure positive location of the counterweight in the guides.
4.5.24.13
The desired counterweight mass should be made up with plate packs in a support
cradle. Consideration may be given to properly drained counterweight boxes in order to
facilitate the use of steel punchings or similar material, given the high cost of steel
plates.
4.5.24.14
Steelwork, walkways, stairs platforms, etc. to afford safe and adequate
operational and maintenance access shall be provided.
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DOC NO AATC000859
4.5.24.15
For vertical gravity take-up, over 6m in height, belting flap to be restrained with
flat return idler guides. This configuration should however be avoided.
4.5.24.16
Vertical gravity take-up should have a clearance between frame and guides of
approximately 10 mm per side.
4.5.24.17
Gravity take-up towers shall be of sufficient height to accommodate the change in
the length of the conveyor belting under all operating conditions with a minimum of
500mm travel distance before any object will be encountered.
4.5.24.18
Ny-lock (prevailing torque) nuts to be used on take-up frames.
4.5.24.19
Gravity take-up towers shall have a buffer at the bottom. This buffer shall be able
to absorb the impact of the free falling take-up weight to prevent damage to the
structural components. The preference is to use a sand box with screed closure.
4.5.25 Belt scrapers and duff chutes

4.5.25.1 A double bladed secondary belt scraper shall be fitted at all head pulleys. Scrapers
shall be adjustable and self-compensating for wear. Sufficient space for servicing is to
be allowed. Belt scrapers must be easily and safely accessible for maintenance
purposes.
4.5.25.2 Primary scrapers are occasionally used at certain applications with success and
therefore not prohibited.
4.5.25.3 All scrapings from the belt cleaner shall be deposited onto the receiving conveyor by
means of a dribbling chute. The side angles of the duff chute shall be inclined such that
a valley angle of not less than 70 degrees is obtained. All the corners shall be rounded
such as to allow the free flow of duff material to the receiving conveyor. A chute impact
angle of less than 20 degrees shall be maintained.
4.5.25.4 Dribble chutes will be lined with UHMW liners with a 6mm thick rubber backing or
manufactured from stainless steel polished on the sliding surfaces.
4.5.25.5 Chutes must ideally be designed such that duff can be removed by the main material
stream.
4.5.26 Belt ploughs

4.5.26.1 V-return ploughs shall be installed on the following positions:
Clean side of the return belt at tail pulleys

Approach to bend pulley on vertical gravity take-ups.
At drive stations prior to the HT snub pulley
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DOC NO AATC000859
4.5.26.2 Care must be taken to position tail scrapers such that material is not scraped into the
tail guard area.
4.5.26.3 Where V-return idlers are used, the positioning of the plough must be such that proper
contact between the belt and plough is maintained. Flat return idlers must be provided.
4.5.26.4 Where access to one side of the belt for cleaning purposes is not available, bias
ploughs shall be installed so that material is scraped off to the side where access is
readily available.
4.5.26.5 Where ploughs are installed on elevated conveyors, safety precautions due to falling
material shall be taken. Easily cleanable catchment boxes should be installed.
4.5.27 Skirting
4.5.27.1 Continuous skirting is to be used for multiple load points onto a single belt. Flared
skirting or spaced skirting shall only be incorporated into the design with the prior
approval of the Engineer.
4.5.27.2 Skirting rubber shall be 40 shore hardness or below. Used conveyor belting in skirt seal
locations is prohibited.
4.5.27.3 AATC standard skirts will be installed at all single loading points.
4.5.27.4 All conveyor feed chutes shall be equipped with steel skirting to contain material at the
feed point. Skirts shall extend a minimum distance of 1 m past the stabilized material on
the belt. Chute skirt covers to be easily removable.
4.5.27.5 All discharges below crushers, centrifuges etc. shall be fully enclosed to eliminate
spillage completely.
4.5.27.6 High angle troughing idlers may be considered to eliminate long and high maintenance
skirting on conveyors with multiple loading points typical for coal plant product and
discard belts.
4.5.28 Safety and guarding

4.5.28.1 All safety guards shall be in accordance with the latest Anglo American Best Practise
Guideline, AA_BPG_375001
4.5.28.2 In addition, guarding shall conform to the requirements of the Minerals Act, the Mines
Health and Safety Act and where these do not cover a particular condition, the
Occupational Health and Safety Act (85/1993) Incorporation of Safety Standards in the
Construction Regulations 2003.
4.5.28.3 Risk assessments, as envisaged by the Mines Health & Safety Act, of all operating and
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Page 28 of 68

DOC NO AATC000859
maintenance procedures shall be undertaken by the Contractor. Personnel nominated

by the Company shall be involved with these risk assessments. The outcomes of these
risk assessments shall be included in the appropriate operating or maintenance
manuals.
4.5.28.4 Shaft mounted power packs must be equipped with safety chains in view of a past fatal
accident. A standard AATC design concept is available on request.
4.5.29 Guarding design and mounting

4.5.29.1 In areas where maintenance access is required, guarding must be designed to swivel
along the vertical plane on bullet type hinges. The opposite end must be fixed with bolts
so that physical work must be done to gain access. This type of guards can typically be
used within horizontal take-up areas of conveyors. The swivel door must be removable
by two persons.
4.5.29.2 The above requirement does not apply when the removal of guarding is not required for
maintenance and change-out of equipment, belt replacements etc. This type of
guarding is considered to be fixed.
4.5.29.3 Fixed panels shall be mounted using M16 hot dip galvanised fixing bolts (min 4 bolts
per panel). Bolts and nuts shall be easily accessible for installation of the guard.
Suitably designed fixing brackets shall be used.
4.5.29.4 Where swivelling guards are not deemed possible or practical where access is required,
specific care must be taken to ensure that the removal of all panels can be safely done
by one person.
4.5.29.5 Guard lifting handles must not protrude into the walkways.
4.5.29.6 Greasing points must be safely accessible without the removal of guards. Inaccessible
points must be equipped with a hydraulic hose and grease block located at convenient
location.
4.5.29.7 Conveyor under-belt guards must be provided on elevated sections to provide a
working platform to replace return idlers and to prevent large objects e.g. idlers to fall to
the ground but not to cause material build-up. The preferred construction is to have
welded mesh panels, welded into a frame which is bolted into the gantry steelwork.
4.5.29.8 Guards shall be painted to AA_SPEC 164050_Corrosion Protection of steelwork with
coatings and colour coding to AA_SPEC 164051_Plant Colour Coding.
4.5.29.9 Materials of construction and panel mass to comply with the table below:
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DOC NO AATC000859
Guard panel type
Frame construction
Guard mesh
Total mass (kg)
Fixed
50x50x6L
Flatex type 348 / Eq
50
Swivel
50x50x6L
Flatex type 348 / Eq
50
Light weight removable
None
100x20x3 Specimesh M389 / Eq*
25
Under-belt
50x50x6L**
100x100x10 welded mesh
Not restricted
*Aperture size subject to specific application.

**Span dependent, serviceability may be relaxed on concession.
Table 6 Guarding design and mounting
4.6
Chutes
4.6.1.1 The minimum width of the conveyor feed chutes (measured inside of liners) shall be 2,5
x the particle size. The width of such feed chutes shall not exceed 2/3 of the conveyor
belt width.
4.6.1.2 Chutes shall be designed to pass the peak load continuously, without spillage or buildup, and to transfer it to the receiving equipment smoothly and equally distributed across
the receiving equipment. The chute shall also pass the maximum lump size without
blocking, hanging-up or spilling or excessive wear, and shall transfer it to the receiving
equipment such that the possibility of damage is minimized.
4.6.1.3 Chute design shall accommodate dust extraction and suppression requirements where
applicable (on transfers within buildings, chutes carrying dry coal). The velocity of dust
shall be kept to a minimum regardless of whether dust extraction or suppression is
applied. Connection flanges shall be supplied for dust suppression or extraction
equipment where such systems are required.
4.6.1.4 The impact pressure on the chute and on the receiving equipment shall be kept to a
minimum and shall not exceed 8 kPa.
4.6.1.5 The angle of impact, i.e. the angle between the material stream and the impacting
surface, shall be minimised and shall preferably be less than 20.
4.6.1.6 Suitable support for the chute shall be provided. In designing the chutes, the forces
likely to be encountered as a result of large lumps passing through the chute shall be
taken into account.
4.6.1.7 Where appropriate, deflector chutes must be provided at ploughs, take-up and drives.
4.6.1.8 When chute plates have to be stiffened, care must be taken in positioning stiffeners so
that no water traps occur.
4.6.1.9 Although chutes need to be suitably stiffened in line with the liner selection, over
stiffening must be avoided.
4.6.1.10 New ceramic tiles have a high co-efficient of friction, which must be considered when
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DOC NO AATC000859
conveying fines.
4.6.1.11 Light weight chute inspection doors must be provided with welded hinges. To prevent
finger injuries, these doors shall always open sideways, never to the top or bottom.
4.6.1.12 Where possible, the head snub pulley must be located within the main chute so that the
fines can be carried away with the main flow of material. The chute back plate must be
positioned such that there will be no build-up of the fine material.
4.6.1.13 The guideline for the required clearance between the belt and chute is obtained by the
ratio of the selected belt width divided by 12.
4.6.1.14 In order that degradation of material and belt wear may be minimised, all transfer
chutes shall be designed in accordance with the following principles:
All chute designs shall be based on friction characteristics obtained from bulk solids
flow test for material on material and material on liner surfaces,
In determining chute angles, the co-efficient of friction between the wear material and
the coal shall be taken into account.
The functional design of transfer chute arrangements shall prevail over mechanical and
structural considerations,
Material velocity throughout the entire chute shall be designed in accordance with
measured friction characteristics for direct sliding and sliding under impact conditions,
Material transferred to chutes shall impinge on the chute at the least practical angle of
impact,
Where unavoidable and to eliminate impact wear in the top section of the chute, in-line
dead boxes will be permitted.
Where a chute transfers material onto a belt conveyor, the difference in the velocities of
the material in the direction of the conveyor, and the belt shall be within 10% of the belt
velocity for average friction characteristics of the material on the chute liner surface,
The kinetic energy of the largest particle reasonably anticipated on a receiving conveyor
belt shall not exceed 500 joules,
Where the stopping time of a conveyor is such that it may deliver more material to the
receiving equipment than the receiving equipment can absorb without the possibility of
spillage or blockage overloading, provision shall be made for the conveyor head chute
to accommodate the overrun material. The amount of overrun material to be
accommodated shall be based on the peak capacity of the conveyor,
The chute angle at the bottom of the chute shall be minimum 5 steeper than the friction
angle for direct sliding.
4.6.1.15 Transfer point arrangements must be designed to minimise the fragmentation of coal.
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DOC NO AATC000859
4.6.1.16 Blocked chute detection will be installed at all conveyor discharge ends in accordance
with the latest AA Specification, Conveyor belt protection systems (AA_SPEC_673018).
4.6.1.17 Also refer to general plate work and lining requirements under section 4.10 Platework
and Lining.
4.7
Mechanical Design General Requirements
4.7.1
Design
4.7.1.1 All equipment shall be designed:

To be intrinsically safe and easy to operate and maintain,
To facilitate inspection, maintenance, cleaning and repairs,
To ensure satisfactory operation under the conditions prevailing at the site of the works,
To run without undue vibration or excessive noise,
To prevent undue stress being produced by temperature changes.
4.7.2
Design factors
4.7.2.1 Service factor shall be in accordance with the latest AA Specification, Mechanical
Standards (AA_SPEC_999022).
4.7.2.2 Where specific manufacturer or other requirements exist, these will be stated in the
relevant equipment specification.
4.7.3
Transmissions
4.7.3.1 Chain drives (Not preferred)

4.7.3.2 Chain drives shall be in accordance with the latest AA Specification, Mechanical
4.7.3.3 Chain drives shall not be specified unless application is essential to the satisfactory
operation of the equipment.
4.7.3.4 V-Belt Drives (Not preferred)
4.7.3.5 V-belt drives shall be in accordance with the latest AA Specification, Mechanical
4.7.3.6 Gearing
4.7.3.7 Gearing shall be in accordance with the latest AA Specification, Mechanical Standards
(AA_SPEC_999022).
4.7.3.8 Speed reduction units shall be in accordance with the latest AA Specification,
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DOC NO AATC000859
Mechanical Standards (AA_SPEC_999022).
4.7.4
Bearings
4.7.4.1 Bearings shall be in accordance with

(AA_SPEC_999022).
the latest
AA Specification, Mechanical Standards
4.7.4.2 All bearings must be SKF with the exception for conveyors pulleys (only) where FAG
may be used as an alternative where SKF bearings are not available.
4.7.4.3 The L10 life shall be calculated at the maximum speed and radial and axial loads
resulting from rated motor power.
Mechanical Equipment
Cranes, trolley and hoists

(maintenance)
Minimum L 10 Life (hours)

3,000
(Service Class below H3 only)
Gear drives combination drives
60,000
Pumps
60,000
Agitators
80,000
Conveyor pulley plummer blocks
100,000
Conveyor idlers
40,000
Screens
80,000
Compressors, blowers, process

fans
100,000
Table 7 Minimum L-10 Bearing life
4.7.4.4 Plummer blocks shall be designed and installed such that the belt load acts through the
mounting base. Stored energy within the conveyor belt must not result in an unsafe
condition when the bearing cap is removed.
4.7.4.5 Greasing points shall be provided for all plummer blocks.
4.7.4.6 All electric motors used on VSD installation above 90 kW, must be equipped with
insulated bearings at either the drive or non drive end to mitigate the effect of stray
currents.
4.7.4.7 Bearing sole plates must be supplied loose for site welding to ensure that bearing
housings can be aligned. Galvanising must be grinded off locally prior to site welding
and repaired according to CPS41 A after installation.
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4.7.5
DOC NO AATC000859
Brakes
4.7.5.1 Brakes are generally not required on conventional conveyors.

4.7.5.2 Brakes shall be in accordance with the latest AA Specification, Mechanical Standards
(AA_SPEC_999022).
4.7.5.3 Where required, brakes shall be fitted to the high-speed input shaft of the speed
reducers and on the reducer side of the coupling, fail safe, with automatic wear
compensation, and adjustable brake torque.
4.7.5.4 Disc callipers shall be mounted on rigid supports attached to the same base frame as
the drive.
4.7.5.5 Brake pivots shall be provided with self-lubricating bushings and hardened alloy steel
pins on all pivoting joints.
4.7.5.6 Brake rated torques shall be at least 150 % of specified braking torque.
4.7.5.7 Brakes used on out-of-balance loads shall be capable of arresting the load in the event
of a trip of the motor in the maximum out-of-balance condition.
4.7.5.8 The rated heat dissipation shall allow for the specified stops per hour without fade or
loss in holding.
4.7.5.9 Brakes shall use asbestos-free shoes and pads.
4.7.6
Lubrication
4.7.6.1 Lubricants and lubrication shall be in accordance with the latest AA Specification,
Mechanical Standards (AA_SPEC_999022).
4.7.6.2 All equipment which normally contains lubricant and is despatched without such
lubricant shall have their interior sprayed with a suitable moisture inhibitor, to prevent
corrosion during transport and storage. Such equipment shall carry clear legible tagging
indicating that it does not contain lubricant. All machinery and equipment shall be
checked for cleanliness and lubrication prior to testing or start-up.
4.7.6.3 As far as possible a centralised lubrication system shall be considered for multiple items
of equipment supplied. Where a centralised lubrication system is not justified, multiple
lubrication points in close proximity shall be plumbed to a central manifold block
accessible without removing safe guards. Lubrication plumbing shall be neatly run and
supported as required. Lubrication points shall be labelled to indicate the point supplied.
4.7.6.4 All oil lubricated equipment shall be provided with a valve at the outlet (where practical)
so that samples for oil analysis may be easily taken.
4.7.6.5 First fill of lubricants shall be agreed by project team and included in the Capex or SIB
costs.
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4.7.7
DOC NO AATC000859
In-plant Maintenance Facilities
4.7.7.1 In designing or selecting the equipment, attention shall be given to the ease of
operation and maintainability of the plant as well as operational costs.
4.7.7.2 The design and selection of equipment shall be directed towards minimizing
maintenance and maintenance durations.
4.7.7.3 Steelwork, walkways, stairs, platforms, etc. must allow safe and adequate operational
and maintenance access shall be provided.
4.7.7.4 Crawl beams, equipped with crawls but not lifting tackle, strategically placed so that all
heavy lifts required to maintain the plant and equipment may be safely and easily
carried out shall be provided.
4.7.7.5 Equipment must be arranged so that overhead crawl or lifting beams provide simple
and adequate suspension for in situ stripping and/or removal to an external workshop.
4.7.7.6 Electrical overhead travelling cranes will be provided in the main plant and plant
workshop. Cranes shall be in accordance with the latest BS 466 standard.
4.7.7.7
The plant crane will be sized to lift the heaviest piece of equipment within the cranes
reach.
4.7.7.8 Crawl beams will be fitted over equipment that is not accessible by the overhead crane
including all transfer towers, bins and the discard silo.
4.7.7.9 Crawl beams will be fitted with manual trolleys.
4.7.7.10 Stop blocks will be fitted to both ends of the crawl beams.
4.7.7.11 The safe working load, SWL, must be stencilled onto both sides of crawl beam web
after passing load test certification.
4.7.7.12 No lifts, including construction activities, shall take place on a new crawl beam prior to
passing load test certification.
4.7.8
Cleaning operations
4.7.8.1 All floors in wet areas should be concrete and easily accessible for skid steer loaders
(bobcat) without obstacles.
4.7.8.2
Skid steer loaders (bobcat) access is required around conveyor tail end areas and
inside tunnels.
4.7.9
Dust suppression and extraction
4.7.9.1 All materials handling facilities will be designed to minimise, and where possible, to
prevent the generation and liberation of dust.
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DOC NO AATC000859
4.7.9.2 Methodologies will vary from passive e.g. tip dust hood and active systems e.g. water
spray systems.
4.7.9.3 Ducted dust extraction systems and filters are not preferred. These may be used in
limited quantities where required by an analysis of an experienced dust control
specialist.
4.7.9.4 Water sprays will be used to suppress dust escaping from enclosures. Each water
spray system will be designed for the optimised droplet size and velocity. The objective
will be to balance the system requirements in terms of water consumption,
maintainability, dust suppression efficiency, water quality requirements and simplicity.
4.7.9.5 Where fine droplet sizes are preferred, the spray systems will make use of suitable
atomizing nozzles (using either by pneumatic or high pressure hydraulic
methodologies). Water supply systems to atomising dust spray systems will include fine
filtration and possibly reverse-osmosis treatment, as required by an analysis of the
quality of the water supply system.
4.7.9.6 Water sprays, where used will be specified in a manner which avoids caking and buildup on materials handling equipment. Sprays must ideally be directed towards the
conveyed material.
4.8
Fire protection
4.8.1.1 Fire suppression and detection to be provided in accordance with the latest
Specifications:
AATC000168
Fire protection for buildings and structures
AATC000169
Fire protection for conveyors and coal transfer
4.8.1.2 Risk assessments will be required to finalise the project scope.
4.9
Pipework and Valves
4.9.1
General
4.9.1.1 Piping covered in this document specifically addresses plant related environments. Bulk
supply and services to the plant are covered by civil engineering.
4.9.1.2 All piping systems, equipment and design shall comply with the latest relevant
standards, regulations, codes and statutory requirements. (Refer to Reference
Documents)
4.9.1.3 Piping systems shall be designed to facilitate reliable and continuous operation, as well
as easy accessibility for operation, maintenance, equipment replacement, handling,
cleaning and inspection.
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DOC NO AATC000859
4.9.1.4 All pipe work, equipment and apparatus supplied and installed shall be designed to
ensure satisfactory operation under the atmospheric, ambient and other conditions
prevailing at the plant/site.
4.9.1.5 The Contractor shall ensure that all piping and components stored on site are placed on
sleepers or pallets. All open ends of piping, valves and fittings shall be provided with
plastic or wooden end caps to prevent ingress of dirt and other foreign matter.
4.9.2
Piping Categories
4.9.2.1 Piping is classified under the following categories:

Slurries &
moderately acidic
fluids
Clarified water,
Raw water, potable
dilute medium,
water, plant air,
magnetite solutions,
Fluids
instrument air, air for
polluted water,
the filter plant,
effluents, correct
flocculent, coagulant.
medium
Spray bars in
Pump suctions and
Special
abrasive
other high wear
Category
environments, gland
items
seal water (GSW)
Table 8 Piping Categories
General Purpose
4.9.3
Alternate of
aggressive
slurries
Correct medium
distribution
Design of Piping Systems

In designing a piping system the following design parameters shall apply:
4.9.3.1 All pipe and fittings supplied shall be new and unused.
4.9.3.2 Pipe routes shall be as short and straight as possible using 45 and 90 bends.
4.9.3.3 Consideration shall be given to the overall piping system behaviour under dynamic
conditions. 90 bends do not lend itself to being self-draining; 85 are preferred.
4.9.3.4 Relevant pipe routes shall be self-draining. Drain valves shall be fitted on any pipelines
which do not self drain, however this should be avoided. No dead legs are
acceptable.
4.9.3.5 Pipe deliveries into sumps and tanks shall be directed away from the suction inlet to
avoid air entrainment, instrumentation and towards the centre of the sump or tank to
minimise wear and vortex generation.
4.9.3.6 Flushing points shall be provided to assist drainage and cleaning where necessary.
4.9.3.7 The number of connectors shall be minimised wherever possible.
However the
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DOC NO AATC000859
following opposing factors shall be considered: handling of pipe sections in confined

spaces, application of corrosion protection linings to bends, future extensions or
branches to the pipeline and the need for closer sections. Sacrificial spools,
approximately 1000 mm long shall be installed on the downstream side of bends.
4.9.3.8 Pipe routes shall not interfere with walkways or maintenance access. Where pipes are
routed over walkways a minimum of 2300 mm headroom is required under the lowest
obstacle. For example the lower edge of a flange or the lowest edges of a pipe support.
4.9.3.9 Valves and instrumentation shall be located in readily accessible positions for operation
and maintenance. Special platforms must be provided if necessary.
4.9.3.10 Water and air piping up to 50 NB shall have threaded connections with sufficient
number of unions for easy replacement of valves, instruments etc. and shall be hot
dipped galvanised.
4.9.3.11 Water and air piping larger than 50 NB shall be a combination of flanged and butt
welded construction and shall be hot dipped galvanised.
4.9.3.12 Flanges shall be to the latest SANS Specification, Pipe flanges (SANS 1123). Flanges
shall be table 1000/3 flat face except for tailings lines or any other medium or high
pressure line which shall be rated to the required design pressure.
4.9.3.13 In flanged pipe runs, flanges are to be provided at all changes in direction and all
pipework is to be in reasonably lengths for ease of handling and maintenance. The
maximum distance between flanges shall be 6m for in-plant piping and 18m on tailings
lines. All flanges shall be accessible as far as possible and positioned 1,0 m above
the floors.
4.9.3.14 Piping will be designed with adequate flexibility for thermal expansion and where
required be analysed to ensure compliance with the applicable code(s). Either
expansion loops or expansion joints shall address thermal expansion and contraction.
4.9.3.15 Standard lengths of pipes and fittings should be used where possible.
4.9.3.16 Pipe supports and hangers shall comply with the latest requirements of BS 3974.
Attention shall be given to the support system in order that external loads acting on
pump suctions, discharge nozzles and branches may be minimized.
Expansion/compression on HDPE lines shall be taken into consideration.
4.9.3.17 Wear resistant pipes or lining to be used with abrasive fluids.
4.9.3.18 Suctions on slurry pumps to be lined with 25 or 13 mm hi-alumina tiles and or 6 mm
epoxy all as per requirements outlined under item 4.10.9, Lining philosophy.
4.9.3.19 Abrasive and non-abrasive pump suctions to have eccentric reducers (flat top), drain
and flush valves and tapered breakout piece. The reducer shall be designed to suit the
flow requirements.
4.9.3.20 300 NB and larger process and clean water pump suctions and discharges will not be
fitted with flexible Bellows.
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DOC NO AATC000859
4.9.3.21 Axial bellows units shall comply with the requirements of the Expansion Joint
Manufacturers Association (USA). Further guidance on the design and specification of
bellows and bellows installation is detailed the latest British Standard, Code of practice
for the selection and application of bellows expansion joints for use in pressure
systems.
4.9.4
Line Sizing
4.9.4.1 Line sizing shall be calculated considering the effects of friction drop, erosion, solids
settling, product degradation, water hammer, NPSHr, process flow variations, provision
for future capacity increases. The following velocity ranges are a guide:
Fluid Type
Pipe Velocity Guide m/s

DN50
to DN150
to DN300 to DN400
DN100
DN250
Min
Max
Min
Max
Min
Max
DN450
DN750
Min
Max
Pump Suction
0,6
0,9
1,2
1,6
1,3
1,7
1,8
2,3
Pump
Discharge
1,2
2,1
2,4
2,5
3,1
3,2
4,6
to
Liquids
Pump
Discharge
flocculent
1,2
1,5
1,8
Pump suction &

dischargeorganic
1,0
1,0
1,0
1,0
Pump
discharge
fuel/lube oil
0,5
1,0
0,5
1,0
0,5
1,0
0,5
1,0
Gravity
1,0
1,0
1,0
1,0
Slurries
Pump Suction
1,2
1,4
1,2
1,5
1,3
1,7
1,8
2,3
Pump
Discharge
1,5
1,6
1,8
2,4
2,0
2,6
3,8
Gravity-non
settling
Gravity-settling
slurry
1,0
1,0
1,0
1,0
Settling velocity + 15%
Table 9 Pipe velocity guide
4.9.4.2 The above guide is not applicable for two phase flow or pressure relief lines.
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4.9.5
DOC NO AATC000859
HDPE Pipes and Fitting
4.9.5.1 For all slurry applications HDPE pipes to comply with the latest SANS Specification,
Polyethylene (PE) pipes for water supply (SANS 4427). The nominal pressure rating
shall be PN 6 or higher if pressure dictates.
4.9.5.2 HDPE slurry piping shall be flanged throughout or a combination of fusion welds and
flanges, depending on the system length and duty.
4.9.5.3 All fittings are to be fabricated from HDPE pipe.
4.9.5.4 All fittings to be provided with weld on stub-ends and backing rings on both sides.
Backing rings to latest SANS Specification, Pipe flanges (SANS 1123), table 1000/ 3
and hot dip galvanized.
4.9.5.5 Maximum pipe lengths to be 9 meters. Shorter lengths shall be used as necessary
inside buildings for installation purposes.
4.9.5.6 Correct Medium feed box and HM cyclone feed piping will be Basalt lined.
4.9.5.7 HDPE pipe bends to be seamless and pulled to have a radius of minimum 3D for all
slurry lines.
4.9.5.8 Bends to be standardized with regard to bend degrees and centre to face dimensions.
4.9.5.9 Fittings and pipes which have misalignment on welded joints due to ovality will not be
accepted.
4.9.5.10 Welding of HDPE joints shall conform to the Manufacturers procedures.
4.9.6
Steel Pipes
4.9.6.1 150NB and below to be mild steel to the latest SANS Specification, Steel pipes: Part 1,
Pipes suitable for threading and of nominal size not exceeding 150mm. Pipes shall be
heavy wall hot dip galvanized.
4.9.6.2 Pipe 200NB and above to be mild steel to the latest SANS Specification, Electric
welded low carbon steel pipes for aqueous fluids (large bore). Pipes shall be grade "A",
6mm thick wall hot dip galvanized.
4.9.6.3 Steel pipe bends shall have a radius equal to 1 x nominal bore (i.e. long radius) and
constructed to steel pipes material specification.
4.9.6.4 Lined pipes are painted on the outside as per specifications.
4.9.6.5 Pump suctions to be mild steel as per the above relevant SANS Specifications and
coated as per the latest Anglo American corrosion prevention specification.
4.9.6.6 Maximum working pressures:
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Slurry
Raw, process or gland service water
Compressed air
Tails lines
Spray water pipes
Wedged blank flanges
DOC NO AATC000859
650 kPa
1000 kPa
1000 kPa
As per Engineers design
Rated to run @ 450 kPa
Knock-off flanges to be installed on
selected
tanks,
sumps
and
platework to provide instant
emergency drainage
Table 10 Maximum Working Pressures
4.9.7
Compressed air pipework
4.9.7.1 Compressed air piping and distribution headers will be galvanised and provided with
suitable filter/lubricator sets, air pressure gauge, isolating valve and water drainage
valve. Headers will be installed at approximately 5 to the horizontal for water collection
and drainage.
4.9.7.2 Compressed air and instrument airlines shall be sized so the pressure at the end of the
most resistant branch line does not drop below minimum requirements with full flow in
that line
4.9.7.3 Compressed air and instrument air branches shall be taken off the top of the respective
header.
4.9.7.4 Compressed air systems shall have a moisture trap at the low point in the air system for
each major plant area.
4.9.8
Spray bars in abrasive environments and gland seal water (GSW)
4.9.8.1 Schedule pipe to ASTM A106 Gr.B and pipe fittings to BS 3799 screwed to BS 21 ISO
R7 and EN10226-1, are to be used for spray bars below 50 NB. All items are to be hot
dip galvanised to ISO 1461 Heavy duty.
4.9.8.2 In the event of GSW pipework having an operating pressure in excess of 600kPa (two
stage pumping) then schedule pipe and fittings to BS EN 10241 shall be used.
4.9.8.3 Single stage pumps will have GSW fabricated to General Purpose Pipework
specification.
4.9.9
Slurry pipes
4.9.9.1 Slurry pipes are to be routed as directly as possible, with the minimum, least angled
bends possible. Head box nozzle orientations shall where possible aid in the elimination
of pipe bends.
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DOC NO AATC000859
4.9.9.2 Slurry pipes shall be routed in such a way that self drainage will occur. Dead legs may
only be installed when there is no alternative. In such cases a drain valve must be
installed at the lowest point.
4.9.9.3 Slurry piping shall be arranged and supported to facilitate dismantling, flushing and
descaling. Straight lines shall be flanged to permit rotation and bends should be
flanged to permit replacement. Pipes shall be self-draining, preferably back to a tank or
vessel. Where this is not practical, provision shall be made for dumping the slurry at
low points.
4.9.9.4 The process engineer shall advise the minimum allowable angle for slurry, which will
normally be between ten and twenty degrees fall from the horizontal.
4.9.9.5 Selection of pipe sizes for slurry service shall ensure that line velocities are kept above
solids settling velocities.
4.9.9.6 Steel slurry pipelines (including rubber-lined) shall be flanged at every fitting and
branch.
4.9.9.7 Slurry lines shall have a maximum flanged length of 6 m within the process plant and a
maximum length of 9 m outside of process plant areas. Rubber lined slurry lines shall
have a maximum flange length of 6 m for all process applications.
4.9.9.8 The first pipe spool immediately after the pump discharge reducer shall be a minimum
of three meters long to reduce wear created by the pump discharge velocity and
turbulence.
4.9.9.9 Sacrificial spools, approximately 1000 mm long shall be installed on the downstream
side of bends.
4.9.9.10 Long radius swept bends shall be utilised for all slurry piping. No lobster back bends
shall be permitted.
4.9.9.11 Flushing water and drain connections will be provided at pump boxes and sumps and at
vertical piping as required.
4.9.9.12 Pipes shall be either rubber lined, materials handling hose or high-density polyethylene
or similar as per the piping specification and P&IDs.
4.9.9.13 Slurry pump suction lines shall reduce according to the requirements of the P&IDs.
Reductions shall be made with eccentric reducers with the bottom flat.
4.9.9.14 Slurry pump suction lines will be kept as short as practically possible.
4.9.10 Pump Suction Lines

4.9.10.1 Pump suction lines shall be short and shall not be smaller in diameter than the pump
nozzle.
4.9.10.2 Any reduction in diameter shall be made gradually through a tapered eccentric reducer
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DOC NO AATC000859
with the flat on top; except for slurry lines where the flat shall be on the bottom.
4.9.10.3 Elbows or bends shall not be placed within 4 pipe diameters of the pump suction
nozzle.
4.9.10.4 Isolating valves are to be accessible and in the case of Knife Gate Valves, are to be
orientated with the hand wheel or actuator as vertical as possible.
4.9.10.5 Drain valves must drain the suction completely.
4.9.10.6 Pump suctions smaller than 300 NB shall be installed with a bellows.
4.9.10.7 Pumps shall be mounted on an integral pump support frame designed to enable pump
alignment and pump drawback to facilitate removal of suction piping and pump internals
replacement.
4.9.10.8 Pump suctions will be designed to allow for ease of maintenance of the pump
4.9.10.9 Steel Pipes Bends (Water & Air Lines) to have radius equal to 1 x nominal bore (i.e.
long radius) and constructed to steel pipes material specification.
4.9.10.10
Bends in high wear regions to have a minimum radius of 5 x diameter.
4.9.10.11
The ratio of the mean bend radius to the outer diameter of the pipe shall be not
less than 2. Bends in unlined steel pumped lines > 80 NB and in gravity lines where the
vertical fall before the bend is greater than 3 metre shall be white cast iron complying
with the latest British Standard, Founding. Abrasion resistant cast irons.
4.9.11 Threaded steel pipes

4.9.11.1 Small bore screwed fittings 50 NB and below shall comply with BS 21 ISO R7 and EN
10226. Lines 50 mm and below will be threaded instead of flanged.
4.9.11.2 Threaded pipes and all the fittings to be hot dipped galvanised.
4.9.11.3 Small bore 50 NB and below service pipelines may be site run with screwed
connections having at least one union every two changes of direction. The route for
such pipelines shall be indicated on drawings and shall be approved by the Engineer.
4.9.11.4 Threaded joints may be made with suitable tape or sealing compound, except where
fragments of tape may block down stream equipment, e.g. fine spray nozzles, and joints
to be seal welded.
4.9.12 Steel pipe flanges

4.9.12.1 Flanges to be mild steel HD galvanized, flat face, drilled off-centre (two holes top) to the
latest SANS Specification, Pipe flanges. The flanges shall be table 1000-3 as specified,
continuously welded to pipe, both internal and external.
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DOC NO AATC000859
4.9.13 Fittings and gaskets

4.9.13.1 Fittings 65/80 NB up to and including 150 NB to be butt-weld fittings to BS 1640 AND
BS EN 10253-2 Schedule 40 and ANSI B16.9
4.9.13.2 Fittings 200 NB and above to ANSI B16.9 or fabricated from pipe.
4.9.13.3 Threaded wrought steel fittings to be to BS EN 10241.
4.9.13.4 Screwing to ISO/R7.
4.9.13.5 Gaskets to be 3 mm thick, klinkerite or equivalent. No asbestos permitted.
4.9.13.6 Full face gaskets shall be used on flat face flanges, ring type gaskets shall be used on
raised face flanges. For high pressure steel pipelines gaskets shall be spiral wound
metallic to the latest British Standard, Specification for spiral wound gaskets for steel
flanges.
4.9.14 Slurry rubber hoses

4.9.14.1 Heavy duty slurry rubber hoses shall be constructed with double layer of spring wire,
nylon fabric and 9 mm or 11 mm thick hard liner with a pressure rating 700 kPa.
4.9.14.2 Minimum radius of hose bends shall be 10D. For splitter boxes where hoses are used to
divert flow, the hose will be constructed without spring wire.
4.9.15 Closures
4.9.15.1 To be supplied 150 mm longer than installed length.
4.9.15.2 Flanges on stubs to be left loose and welded during erection.
4.9.16 Marking
4.9.16.1 All items to be clearly marked on pipes approximately 300 mm from fixed flange with
line number and item number. Rubber hoses to be securely tagged with item and line
number.
4.9.17 Colour Coding

4.9.17.1 All plant piping shall be colour coded in accordance with the latest Anglo American
Specification AA_Spec_164051_Plant colour coding
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DOC NO AATC000859
4.9.18 Fasteners
4.9.18.1 All pipe bolts, nuts and washers to be SANS 1700 Class 4.8 hot dip galvanised and
suitably bagged, labelled and dispatched to site together with pipes.
4.9.18.2 High pressure piping with flanges table 25/3 or higher to be bolted with Class 8.8 hot dip
galvanized fasteners.
4.9.19 Stainless Steel

4.9.19.1 Stainless Steel Pipe and fittings shall be to ANSI 316L.
4.9.20 Nozzles
4.9.20.1 To conform to pipework fabrication and platework lining requirements.
4.9.21 Supports
4.9.21.1 Pipe support to the requirements of BS 3974
4.9.21.2 This will generally take the form of U-bolts and angle or channel-iron brackets and
supports welded to the adjacent building steelwork during and after completion of pipe
installation. HDPE piping of 75 O.D. or smaller shall be provided with continuous
supports.
4.9.21.3 All pipe supports and U-bolts to be hot dip galvanized.
4.9.21.4 Galvanized steel structure surfaces damaged due to welding of the supports shall be
repaired as per the Anglo American procedure CPS 41A.
4.9.21.5 Pipelines shall be adequately anchored to withstand the reactions caused by changes
in pipe direction, temperatures, pressure, etc. Pipes connected to a fixed item of
equipment shall be anchored in such a way that no thrust forces are imposed on the
item to be connected.
4.9.22 Valves
4.9.22.1 Valves shall comply with the latest Anglo American Specification (General purpose
valves).
4.9.22.2 Valves shall be selected for the specific duty, rating and operation required.
4.9.22.3 In order to ensure a fit for purpose the expertise of the valve supplier must be sought
company.
Page 45 of 68

DOC NO AATC000859
and coupled with past experience gained from similar applications.

4.9.22.4 Information required, but not limited to for valve selection:
Maximum differential working pressure

Full details of medium to be carried including corrosiveness, abrasion, particulate
matter, line transport velocity and volume of flow.
Environmental conditions
Duty, e.g. isolation, regulating pressure control, together with closure time required.
Type of control, i.e. manual, automatic (local or remote) and any limitations of
access
Limitations of space for determining gearbox/actuator/handwheel orientation
Flange table
Line position
4.9.22.5 Valves and instrumentation shall be located in readily accessible positions for operation
and maintenance. Access platforms shall be provided where necessary.
4.9.23 Lifting lugs

4.9.23.1 Large pipe fittings which are removable for valve and pump servicing shall have
designed lifting lugs welded to them.
4.9.23.2 Where heavy equipment are furnished with lifting lugs for installation and maintenance
the following requirements shall apply:
Lifting lugs shall be:
Positioned to give maximum balance with an even weight distribution where

possible to minimize handling hazards.
Designed to have a safe working load of at least six times the design load
suspended by it.
Manufactured in accordance with drawings which have been approved by a
Professional Engineer.
Designed for use with standard shackles, Grade S.
Shown on drawings together with slinging details and load weight. Special
attention shall be given to lifts using more than three lugs to ensure proper load
distribution. Unequal sling and lug loads caused by differences in nominally
equal sling lengths and sling stacking arrangements on hooks shall be avoided.
Permanently fixed to all items requiring removal for inspection and maintenance.
4.9.23.3 For fabricated lifting lugs all welds shall be examined by NDT. Acceptance criteria shall
be in accordance with the registered Engineers approved design requirements.
4.9.23.4 The maximum allowable sling angle from the vertical shall be determined and marked at
all lifting points.
4.9.23.5 Removable lugs shall be bolted to each component in the shop prior to shipment and
company.
Page 46 of 68

DOC NO AATC000859
remain attached until erection work is completed.
4.10
Platework and Lining
4.10.1 General plate work requirements

All platework required to control and direct material, prevent spillage, contain fluids, etc. shall be
included in the scope of the contract and shall comply with the following general requirements:
4.10.1.1 Platework shall be fabricated from steel plate complying with S355JR or while
availability permits, SABS 1431, grade 300WA, no less than 6 mm thick. 3CR12 may be
considered in specific applications where approved by the Engineer.
4.10.1.2 Fabrication and erection shall be in accordance with AA Specification 114/2.
4.10.1.3 All welds shall be in accordance with AWS D1.1, shall be 6mm continuous fillet welds,
and shall be watertight.
4.10.1.4 Flanges and stiffeners shall be a minimum 65 x 6 thick flat bar.
4.10.1.5 Boltholes shall be 18 mm diameter for M16, Class 4.8 bolts, spaced at a maximum pitch
of 200 mm.
4.10.1.6 Joints shall be watertight.
4.10.1.7 Chute support brackets shall be fabricated from 10 thick plate and shall be drilled to 22
mm diameter holes for M20 Class 4.8 bolts.
4.10.1.8 Precautions shall be taken to prevent platework from distorting during transport and
erection. Platework and support steelwork shall not be put under strain in order to
erect the platework.
4.10.1.9 All nuts, bolts and washers shall be hot dipped galvanised.
4.10.1.10 In designing plate work, care must be taken to avoid dead boxes where water and
fugitive material can be trapped. Large cut-outs must be provided to allow drainage.
4.10.1.11 Corrosion protection shall be in accordance with AAC Specification 164/50 and the
following:
All new platework shall be painted on the outside in accordance with CPS 132.
Internal surfaces shall be prime painted after drilling and before liners are fitted.
The outside finish colour shall be Aircraft Grey Green (SABS 1091 D18).
4.10.1.12 Impact onto any platework shall be avoided (and high impact is unacceptable), but
where it cannot be entirely eliminated a suitable design shall be submitted to the
Engineer for an approval.
4.10.1.13 Internal surfaces below steel liners will be prime painted only.
company.
Page 47 of 68

DOC NO AATC000859
4.10.2 Platework subjected to normal impact and slide loading:

4.10.2.1 Minimum 8 mm thick plate with 10 mm support brackets, 80 x 8 minimum flanges and
stiffeners to SANS 1431-Grade S355JR designed to minimize plate deflections.
4.10.2.2 Platework shall be suitably stiffened when ceramic lining is required. The philosophy is
to use a thick plate with fewer stiffeners as opposed to an over stiffened thin plate.
4.10.3 Welding
4.10.3.1 Plate joints to be 6 mm (leg length) continuous fillets on both sides, unless otherwise
specified by the design engineer.
4.10.3.2 External stiffeners shall have a full 2 mm seal weld to prevent ingress of moisture. Stitch
welding to achieve the required structural strength is permitted.
4.10.4 Plate Packs

4.10.4.1 Where required to be laminated and wired to platework item for delivery.
4.10.4.2 Packs shall not exceed 30 mm.
4.10.4.3 On final assembly a single packer made to final dimension is preferred.
4.10.5 Joints
4.10.5.1 To be sealed with compri band strips on the full flange width where faces are not rubber
lined.
4.10.6 Fasteners
4.10.6.1 For platework, bolts, nuts and flat washers to conform to SANS 1700 Class 4.8 and to
be hot dipped galvanised.
4.10.6.2 Bolts on chutes where high impact is anticipated to be secured with Nylock, Cleveloc or
Huck fasteners. Electro plated galvanised bolts are permitted on these applications.
4.10.6.3 Taper washers to be fitted to steel sections with taper flanges.
4.10.6.4 Site bolts to be suitably bagged, labelled and wired to platework item for delivery.
4.10.6.5 Nylock nuts shall not to be used where burning coal is anticipated.
company.
Page 48 of 68

DOC NO AATC000859
4.10.7 Marking
4.10.7.1 All items to be hand stamped (min. size 12 mm) with drawing and item number. Hand
stamps shall be clearly visible after hot dip galvanising.
4.10.8 Painting
4.10.8.1 External and Internal: Refer to Corrosion Protection under section 5.6.
4.10.9 Lining Philosophy

General materials handling applications:
4.10.9.1 A project specific liner schedule must be developed for approval by the Engineer.
4.10.9.2 The life of mine, accessibility and standardisation of liners shall be considered when
selecting liners.
4.10.9.3 All surfaces that may be subject to wear shall be lined with a wear resistant material
suited to the nature of the wear, i.e. high impact or sliding. Where particle size of up to
50 mm is encountered, 25 mm ceramic hi-aluminium tiles on impact faces and 13 mm
tiles on sliding faces is considered the minimum.
4.10.9.4 Platework handling material where the particle size exceeds 50 mm, replaceable 400
Brinell liners must be used with minimum thickness of 12 mm on the sides, 25 mm thick
on the impact faces.
4.10.9.5 Although 500 Brinell liners are also commonly used, new projects should be designed
with 400 Brinell liners. Where higher wear occurs, the operation may do liner
replacements in these regions (only) with the higher specification.
4.10.9.6 Where extreme excessive wear is anticipated, special wear liners is to be considered.
4.10.9.7 Cast in rails shall be used for tip jockey slabs and concrete tip bins.
4.10.9.8 Specific consideration must be given to ROM and Raw Coal systems from previously
undermined open cast operations.
4.10.9.9 Lining will be carried out in the workshop and/or on site depending on the size of the
item and the assessed risk of damage during transport and erection.
4.10.9.10
Mass of any liner to be limited to 25 kg each and secured with 4 nibhead
countersunk bolts, nylock or cleveloc nuts and washers (i.e. retained torque nuts).
When determining the mass of liners consideration shall be given to wastage, sizing
and maintenance.
company.
Page 49 of 68

DOC NO AATC000859
Plant Applications:
4.10.9.11
Very high wear wet abrasive areas such as HM cyclones under flow boxes
(impact face) to be lined with 50 mm hi-aluminium tiles.
4.10.9.12
High wear wet abrasive areas containing raw materials (coals and discards) and
magnetite will be lined with 25 mm thick hi-alumina tiles, e.g. cyclone mixing boxes,
floats and sinks boxes as indicated on the drawings.
4.10.9.13
Wet abrasive areas containing coal water slurries or magnetite/coal suspensions
will be lined with 13 mm thick hi-alumina tiles, e.g. screen underpans, head boxes,
magnetic separator underpans and the conical portions of all process tanks (including
outlet nozzles). Split tiles.
4.10.9.14
Wet areas of relatively low abrasion will be lined with 6 mm thick hi-alumina
epoxy, e.g. vertical tank sides, tailings launders, etc.
4.10.9.15
Areas above hi-alumina tiles or epoxy will be lined with 1 mm thick brushable
wearing compound. Edge smoothing must be done.
4.10.9.16
Platework for wet and sticky fine material will be lined with minimum 8 mm thick
solidur or equivalent, e.g. fine coal centrifuge feed and discharge chutes, dewatering
screen discharge and conveyor dribbling chutes where material hang-ups could occur.
4.10.9.17
Drop boxes shall be used on certain platework items such as cyclone overflow
and underflow collection, distribution or feed boxes to prevent direct flow of the slurry
against the ceramic lined surfaces if practical. At the same time, the possibility of
blockages shall be considered.
4.10.10 Lining Specifications

4.10.10.1
Ceramic tiling application method, unless otherwise specified by liner supplier:

a) Preparation of substrate:
Steel surfaces shall be shot-blasted to SA 2, 50 - 75 microns profile
b) Laying of tiles:
Lay the tiles that joints are offset in direction of flow wherever practical.
Tile length shall be perpendicular to the main stream flow.
c) Gaps and Steps
Gaps between tiles in excess of 3 mm are not permissible.

Steps in excess of 3 mm are not permissible if against the flow.
Tiles must be overlayed in direction of flow only.
Tiles must overlap in corners
company.
Page 50 of 68

4.10.10.2
DOC NO AATC000859
Steel Lining
4.10.10.3
All steel liners to be 400 Brinell (minimum tensile strength 1340 MPa) or
equivalent. Also refer to 4.10.9.5 and 4.10.9.6
4.10.10.4
Standardised liner size and shapes must be used where possible.
4.10.10.5
Liners to be brick patterned in the material flow direction.
4.10.10.6
Gaps between steel liner plates not to exceed:
3 mm for up to including 16 mm thick liners

5 mm above 16 mm thick liners
8 mm for 50mm thick liners
4.10.10.7
For all steel liners, bolts are to be accessible from the outside of the chute or bin.
4.10.10.8
Liner plates are to be fastened by means of counter sunk nib bolts.
4.10.10.9
Fastening holes in liners must be drilled such that only 3 mm of liner thickness
below the counter sunk bolt head remains to ensure the maximum liner life.
4.10.10.10
UHMWPE Lining
4.10.10.11
All UHMWPE lining to be Solidur/TIVAR 88 or approved equivalent.
company.
Page 51 of 68

STRUCTURAL DESIGN CRITERIA
5.1
Plant Buildings and Structures
5.1.1
General
DOC NO AATC000859
5.1.1.1 Design of structural steelwork shall comply with the latest Anglo American
Specifications AA_SPEC_114/01 (Design of steel structures) and AA_SPEC_114/02
(Construction of structural steelwork)
5.1.1.2 AA_SPEC_114/01 requires that the latest versions of normative reference documents
are used. AATC nevertheless has a conditional concession to continue using the SABS
0160-1989, (amended 1993) loading code until the end of 2017.
5.1.1.3 When designing support structures for major equipment such as jaw crushers, rotary
breakers, screens, hydraulic rock breaker, apron feeder etc. the structural designer shall
initiate a clarification meeting with the OEM to ensure that certified equipment loads,
and the operation of the equipment is fully understood.
5.1.1.4 When designing crawl beams, it is acceptable to use BS2853:1957 for flange cross
bending calculations.
5.1.1.5 All steelwork shall comply with the following general requirements:All welds shall be in accordance with AWS D1.1 and shall be 6 mm continuous fillet
welds, unless otherwise specified by the design engineer.
All holes in structural members shall be 22 mm diameter for M20, Class 8.8 hot dipped
galvanised bolts unless otherwise specified by the design engineer.
Holes in lightly loaded components, e.g. purlins, girts, handrail fixings, ladders, etc.,
shall be 18 mm diameter for M16 grade 4.6 hot dipped galvanised bolts.
Care must be taken to orientate structural members toe down to avoid dead boxes
where water and material can be trapped.
Stiffeners on column bases must be positioned to avoid dead boxes. Where pockets do
occur, it needs to be filled with concrete and a non-shrink epoxy grout.
The use of high strength galvanized fasteners i.e. Class 10.9 and above, should be
avoided as far as possible.
The use of electroplated bolts is not permitted.
All bracing end connections must have a minimum of two bolts per connection.
Before fabrication of steelwork may commence the designs and drawings shall be
submitted to the Engineer for comment. This requirement shall in no way relieve the
Contractor of nor diminish his responsibility for the correctness and functionality of the
steelwork.
company.
Page 52 of 68

5.2
Conveyor Structures
5.2.1
General
DOC NO AATC000859
5.2.1.1 All structures shall be designed for 100 % belt loading. The ultimate strength of the
structure must be validated for flooded belt conditions which will be treated as an
emergency load case. Serviceability requirements may be disregarded for this
condition.
5.2.1.2 The conveyor head frame shall be designed to withstand the forces imposed on it by
the conveyor under all operational conditions. The head frame shall be free standing
and shall not transmit any forces into the conveyor gantries. The head frame support
steelwork shall be designed to withstand the maximum head frame load.
5.2.1.3 The drive and take-up sections may be incorporated into elevated gantries provided the
gantry is designed to withstand the forces imposed on it.
5.2.1.4 Wherever a conveyor is elevated to the extent that maintenance or inspection will be
difficult or impossible from ground level, elevated or gantry sections with inspection and
maintenance walkways shall be provided. The elevated section shall adequately
support both the carrying and return strands of the conveyor belt. Idlers and idler
spacing on the elevated section shall be as for the run of conveyors section.
5.2.1.5 The elevated sections at the head end of conveyors shall be designed to tie-in with the
head frame, without transmitting or receiving any forces from the head frame.
5.2.1.6 Holes for pig tails to support a pull wire cable shall be provided on both sides of the
conveyor.
5.2.1.7 No deck plates to be used at any section of the conveyors, spilt material may burn
spontaneously.
5.2.1.8 Approximately 150 mm clearance between belt and structures are required.
5.2.1.9 Heavy duty conveyor modules and civil foundations must be considered at chute
discharge or material impact regions.
5.2.2
Gantries
For walkway requirements, refer to Section 5.3 Walkways, access, platforms and
flooring.
For sheeting requirements, refer to Section 5.4 Cladding of structures
5.2.2.1 Environmental gantries
Galvanized non-slip (vastrap) floor plates are permitted on horizontal

sections and on slopes of up to 5
Floors must be water tight.
company.
Page 53 of 68

DOC NO AATC000859
Suspended conveyors stringers are preferred.
36 m long span gantries are preferred where a considerable distance of

environmentally sensitive area must be crossed.
Constructability and crane access must specifically be considered.
5.2.2.2 Open gantries is generally used on all conveyor structures unless a specific need exist
to use a box type gantry.
5.2.2.3 Box gantries must be considered on conveyors significantly elevated above ground
level or where the use can be motivated.
5.2.2.4 Vehicle underpasses Gantries inclined below 5 may be equipped with vastrap
flooring. Solid concrete decks must be provided above underpasses where the
conveyor inclination exceeds 5. Provision must be made for wash down.
5.2.2.5 General gantry requirements
Gantries are to have welded side panels and bolted top and bottom lacing
to suit transport limitations.
Standard 12, 18, 24 and 36 meter gantries must be used wherever

possible taking cognisance of project standardisation.
Where substantial additional loads e.g. piping, cabling etc must be carried
by a gantry, the design must specifically cater for these. Minor loads such
as a 50 mm diameter pipe or small cabling may be disregarded subject to
the discretion of the designer.
Gantry support legs shall be mounted with slotted hole connections in

stool base plates for ease of erection.
5.3
Walkways, access, platforms and flooring
5.3.1
General
5.3.1.1 All landings, stair treads, walkways and handrails shall be in accordance to the latest
Anglo American Specification: Design, Fabrication, Installation and Maintenance of
open grid grating for floors, stairways and hand railing (ACSA_SPEC_114012).
5.3.1.2 Conveyors 900 mm wide or smaller shall have a single walkway 900 mm wide where
the belt line is elevated more than 1.5 m above ground level.
5.3.1.3 Conveyors wider than 900 mm shall have double-sided walkway access, 750 mm and
900 mm wide at main access side where the belt line is elevated more than 1.5 m
above ground level.
5.3.1.4 A sufficient clearance (400 mm minimum on wide walkway side) must be provided in
company.
Page 54 of 68

DOC NO AATC000859
area of take-up pulleys where the pulley guards restrict the walkway width.
5.3.1.5 Maintenance access must be provided to crawls, take-up towers etc. A 600 mm wide
stair case and 750 mm wide platform will suffice unless the risk assessment dictates
otherwise.
5.3.1.6 No cat ladders are permitted whatsoever.
5.3.1.7 Refer to 4.5.28 and 4.5.29 for guarding and conveyor underbelt guard requirements.
5.4
Cladding of structures
5.4.1
General
Plant structures will be provided with sheeting to the following guideline:

5.4.1.1 All coal handling and plant structures shall be sheeted from the 1st floor level up to allow
easy access.
5.4.1.2 Water treatment plant structures must however be fully sheeted.
5.4.1.3 For SIB projects, the sheeting philosophy of the existing operation must be taken into
consideration.
5.4.1.4 It is mandatory to utilise natural lighting wherever practical. The guideline is to allow for
approximately 25 % to 30 % of the floor area in translucent side sheeting per floor level.
5.4.1.5 No translucent sheeting is permitted on roof sheeting.
5.4.1.6 At fixture points, translucent sheeting must be sandwiched between 100 mm backing
strips cut from steel sheets to ensure durability.
5.4.1.7 Corrosion on hinged doors of old plants is problematic. The philosophy is to overdesign
door hinges by applying an impact factor of no less than 5 to ensure long term structural
integrity. Door frames and support steel need not be overdesigned although special
attention must be given to the attachment interface between hinges, door frames and
support steel.
5.4.1.8 All sheeting to be IBR profile, Chromadek pre-painted galvanised steel sheet or
approved equivalent.
5.4.1.9 ZincAlume or Chromadek Plus or equivalent may be considered for extremely corrosive
environments or where the project design life exceeds 30 years.
5.4.1.10 Regrettably no corporate specification is currently available. Good industry practice
must be followed.
5.4.1.11 On SIB projects, the colour of sheeting must match that of existing structures.
company.
Page 55 of 68

DOC NO AATC000859
5.4.1.12 Sheeting colour for new projects must be confirmed by environmental impact studies.
The following colour schemes are nevertheless standard within AATC:
Outside
Inside
Option 1
Aloe Green (close

match to D18)
Sandstone Beige,
C59
Option 2
Gemsbok Sand
Dove Grey, G22
Table 2 Sheeting Colours
5.4.1.13 Sheeting thickness standards are shown below:

Application
Main plant structures
Conveyor transfer
structures
All conveyors
including overlands
Pedestrian
underpasses
Roof sheeting (mm)
Side sheeting (mm)
0.8
0.6
0.8
0.6
0.6
0.8
0.6 (gantry walk

ways)
0.6 (where
applicable)
Table 3 Sheeting Thicknesses
5.4.2
Main plant structure
5.4.2.1 Roof and side sheeting must be reversed lapped. A full length gap must be provided
between the roof and the side sheeting to ensure a natural draft.
5.4.2.2 Ridge ventilators and louvers must be provided in line with the recommendations of a
sheeting specialist.
5.4.2.3 Plant structures housing large screens must specifically designed taking cognisance of
pressure pulsation phenomenon associated with big screens.
5.4.3
Conveyor gantries
5.4.3.1 To eliminate a natural draft and propagation of fire, approximately 30 % of the sides
must be left un-sheeted. Translucent sheeting is therefore generally not required on
environmental and boxed gantries.
5.4.3.2 Open gantries must be equipped with doghouse type roof sheeting which allows access
to idlers. Walkways must be side sheeted on the outside. Where wide cable racks are
affixed to the outside of handrails, side sheeting must be omitted on that specific side
only.
company.
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5.4.4
DOC NO AATC000859
Conveyors
5.4.4.1 Doghouse type sheeting must be installed on all conveyors such that the conveyed
material is shielded from the prevailing wind direction. Doghouse sheeting must allow
access from the enclosed side such that the sheeting line is terminated approximately in
the middle of the wing roll.
5.4.4.2 In close proximity of dwellings, it may be required to enclose the entire conveyor.
5.4.5
Pedestrians crossings
5.4.5.1 0.8 mm IBR sheeting protection will be installed at all areas where fall of material
could occur.
5.4.5.2 Dedicated pedestrian underpasses, integrated with the civil infrastructures designs, are
required beneath conveyors.
5.5
Civil
5.5.1
General
5.5.1.1 Design of civil works shall comply with the latest Anglo American Specifications
AA114/10 (Design of concrete structures) and AA114/11 (Construction of concrete
work)
5.5.1.2 Kerbs around buildings must be a minimum of 450 mm away from the sheeting
perimeter.
5.5.1.3 Column bases in processing buildings must be 1000 to 2000 mm above floor level.
5.5.1.4 The floor level must be elevated no less than 200 mm above the normal ground level.
5.5.1.5 The minimum kerb height around buildings and structures should be 200 mm above the
floor level and no less than 150 mm thick.
5.5.1.6 Drainage slopes of 1:75 are required within buildings.
5.5.1.7 Drainage soil slopes of at least 1:50 are required.
5.5.1.8 Trestle plinths must be elevated by 1000 mm above the natural ground level.
5.5.1.9 Where vehicle access bays or pass through are provided in plants or next to trestles,
plinths must be raised to 2000 mm.
5.5.1.10 Stockpile tunnels, tip areas etc. must be free draining.
5.6
Corrosion Protection
5.6.1
General
5.6.1.1 All corrosion protection systems to be in accordance with the latest Anglo American
Specifications, AA_SPEC_164000, Users guide for corrosion prevention and
AA_SPEC_164050, System selection and Corrosion Protection of Steelwork with
company.
Page 57 of 68

DOC NO AATC000859
Coatings.
5.6.1.2 Colour coding shall comply with the
AA_SPEC_164051, Plant colour coding.
latest
Anglo
American
Specification,
5.6.1.3 The following guide is applicable to components regularly encountered on mining

projects:
System
Galvanising
Painting
repair
CPS 132
Concession
AA_CPS_41A
only
Coating system
Specification
Hot dipped
galvanised unless
painting is specified
SANS 121 (SABS

ISO 1461 )
Hot dipped
galvanised
SANS 121 (SABS

ISO 1461 )
AA_CPS_41A
CPS 132
Hot dipped
galvanised
SANS 121 (SABS

ISO 1461 )
AA_CPS_41A
Cast in
plates/frames
Hot dipped
galvanised
foundation bolts,
fastening)
SANS 121 (SABS

ISO 1461 )
AA_CPS_41A
Stockyard
Equipment
Consult specialist
AA_SPEC_164000
and 164050
TBA
Mechanical,
electrical
equipment
OEM specification,
approval / review
on request of
Engineer
AA_SPEC_164000
and 164050
OEM
Structural steel*
Vastra floor
plates, all floors
horizontal and
inclined 5
Handrailing,
flooring &
stairtreads
Typical DMS
plant tanks,
cells,
distribution
boxes and
launders
Water & Air
piping
Piping
Paint, Consult
specialist
AA_SPEC_164000
and 164050
Hot dipped
galvanised
Paint, Consult
specialist
SABS ISO 1461

heavy pipe
AA_SPEC_164000
and 164050
Internal CPS 326,

External
CPS122
-
TBA
* All new steelwork shall be hot dipped galvanised in accordance with SANS ISO 1461 to
comply with SANS ISO 14713 Table 2 e, long (10 to < 20) maintenance years i.e.
minimum mean coating thickness of 85 micron (for steel > 6 mm thick). This requirement
must be reviewed where the design life of the operation exceeds 30 years.
Where exceptionally low acidity levels are anticipated, particularly at DMS washing plant
operations, a corrosion specialist must be consulted. Hot dipped galvanizing on its own is
not suitable for these conditions and a duplex system or paint system may be required.
Table 4 Coating System
company.
Page 58 of 68

DOC NO AATC000859
5.6.1.4 The Contractor shall be responsible for ensuring that he is fully conversant with the
specification requirements as detailed under the utilization of each system.
5.6.1.5 A qualified applicator shall be defined as a workman regularly engaged in the
application of protective coatings. Unqualified workmen shall be engaged in the
preparation and cleaning only, prior to coating.
5.6.1.6 The Contractor shall provide all the facilities necessary in order to ensure satisfactory
preparation and number and thickness of coats. All workmen shall at all times be under
the constant supervision of a qualified supervisor.
5.6.1.7 The Engineer or his duly authorised representative shall be provided access to inspect
the surface preparation and the application of any or all of the coats, to ensure that
these have been applied in accordance with the specifications. No steelwork, pipework
or items of plant and equipment shall be delivered to site until inspection has been
carried out and a release issued.
5.6.1.8 It shall be the contractor's responsibility to ensure that inspection is called for and the
necessary clearance certificates obtained prior to delivery of goods to site.
5.6.1.9 All equipment, motors, main plant, light fittings, etc. shall be suitably protected by
means of wrapping or covering before grit blasting or spray painting any steelwork after
the installation of the aforesaid equipment.
5.6.1.10 The Contractor must ensure that the correct materials are provided as designated in the
specifications.
company.
Page 59 of 68

INTERFACES
6.1
Civil
DOC NO AATC000859
6.1.1.1 AATC design and construction contracts are structured such that civil works which are
required to support materials handling systems are included under the mechanical
design and construction scope which also includes structural steel.
6.1.1.2 Battery limits are not always identical on all projects but defined during the early stages
of the project. Shown below are examples of typical battery limits:
Overland conveyor:
Route preparation
Civil contract
Transfer station civil works
Mechanical contract
Overland sleepers
Mechanical contract
Tip:
Tip ramp and retaining wall
Civil contract
Tip bin and support concrete

works
Mechanical contract
Silo:
Concrete works, all inclusive
Civil contract
Mechanicals, staircase, steel

roof
Mechanical contract
Table 5 Typical Contracts Battery Limits
6.2
Electrical Engineering
6.2.1.1 AATC design and construction contracts are structured in such a manner that electrical
equipment and associated infrastructure required for Bulk Materials Handling Systems
are designed according to an Electrical Load List provided by the Mechanical Designer
which details the required motor ratings and speed. Motor specifications shall be
according to AATC Specifications and shall be approved by the Electrical Discipline
Engineer.
6.2.1.2 Electrical design for Motor Control and associated infrastructure is normally contracted
in terms of a separate contract due to the nature of electrical bulk power supply. The
battery limit in terms of Bulk Materials Handling Systems is the terminals of the drive
motor/s associated with the BMH System. BMH Contractor responsible through AATC
Supply Chain for supply of motors.
company.
Page 60 of 68

6.3
DOC NO AATC000859
Instrumentation
6.3.1.1 The requirements for instrumentation and controls supplied as part of packaged
equipment is specified within document AA_REQ_673035, Packaged equipment and
plants discipline requirement.
6.3.1.2 The integration option and associated instrumentation to be approved by the AATC
Instrumentation engineer.
company.
Page 61 of 68

INFRASTRUCTURE - MECHANICAL & STRUCTURAL STANDARD
REFERENCES
7.1
AA Standards and Specifications:
Document No.
AA_SPEC_114001
AA_SPEC_114002
ACSA_114012
AA_SPEC_114005
AA_SPEC_114010
AA_SPEC_114011
AA_SPEC_164000
AA_SPEC_164050
AA_SPEC_164051
AA_SPEC_166005
AA_SPEC_166014
AA_SPEC_248002
AA_SPEC_254001
AA_SPEC_255004
AA_SPEC_371001
AA_SPEC_373001
AA_SPEC_373005
AA_BPG_375001
AA_SPEC_377002
AA_SPEC_377003
AA_SPEC_377005
AA_SPEC_377006
AA_SPEC_377008
AA_SPEC_377010
AA_SPEC_415003
AA_SPEC_421017
AA_SPEC_673018
AA_SPEC_999022
AATC000168
AATC000169
DOC NO AATC000859
Description / Title
Design of Steel Structures
Construction of structural steelwork
Design Fabrication, Installation and Maintenance of
Open Grid Grating for Floors, Stairways and Hand
railing
Steel and FRP Flooring, Stairs, Ladders and
Guardrails
Design of Concrete Structures
Construction of concrete work
Users guide for corrosion prevention: System
selection
Corrosion Protection of Steelwork with Coatings
Plant colour coding
Lubricants specific requirements for industrial gear
oils
Lubricants specific requirements for greases
Materials handling Machines Structural Components
Specification.
Stacking and Reclaiming Equipment Mechanical
and Structural
Apron Feeders
Conveyor pulleys and shafts
Belt conveyor idlers and rolls
Installation tolerances for belt conveyors and
structures
Conveyor guarding best practise guideline
Steel cord reinforced conveyor belting
Splicing of steel cord reinforced conveyor belting
Splicing of textile reinforced conveyor belting
Solid woven conveyor belting
Splicing of PVC and nitrile covered Solid Woven
Conveyor Belting
Cold Splicing of Plied (Textile) Conveyor Belting
High Pressure Mine Water Reticulation Systems
General Purpose Valves
Conveyor Belt Protection Systems
Mechanical Standards
Fire protection for buildings and structures
Fire protection for conveyors and coal transfer
Page 62 of 68
company.

7.2
DOC NO AATC000859
National Standards and Specifications
Document No.
SANS 14
SANS 62-1
SANS 121
SANS 719
SANS 971
SANS 1123
SANS 1173
SANS 1313
SANS 1669
SANS 1366
SANS 1431
SANS 4427
SANS 10083
SANS 10103
SANS 10400
ISO 1461
ISO 5048
AWS D1.1
DD CEN/TS
13001-3-2
PD 5403
BS 21
BS 436-5
BS466
BS 545
BS 1640
BS 3381
BS 3974
Description / Title
Malleable cast iron fittings threaded to IS0 7-1
Steel Pipes Part 1: Pipes suitable for threading and of
nominal size not exceeding 150 mm
Hot dip galvanized coatings on fabricated iron and steel
articles - Specifications and test methods
Electric welded low carbon steel pipes for aqueous fluids
(large bore)
Fire retardant textile reinforced conveyor belting (Solid
Woven PVC)
Pipe Flanges
General purpose textile reinforced conveyor belting
Conveyor idlers
Conveyor belt pulleys
Steel cord reinforced conveyor belting
Weldable structural steels
Polyethylene (PE) pipes for water supply
The measurement and assessment of occupational noise for
hearing conservation purposes
The measurement and rating of environmental noise with
respect to land use, health, annoyance and speech
communication
The application of the National Building Regulations
Hot dip galvanized coatings on fabricated iron and steel
articles -- Specifications and test methods
Continuous Mechanical handling Equipment Belt
conveyors with carrying idlers calculation of operating
power and tensile forces
American Welding Society - Structural Welding Code
Cranes General design - Part 3-2: Limit states and proof of
competence of wire ropes in reeving systems
Guidance on safe use of machinery
Pipe threads for tubes and fittings where pressure-tight
joints
are made on the threads (metric dimensions)
Spur and helical gears. Definitions and allowable values of
deviations relevant to radial composite deviations and
runout information
Specification for power driven overhead travelling cranes,
semi-goliath and goliath cranes for general use
Specification for bevel gears (machine cut)
Steel butt-welding pipe fittings
Specification for spiral wound gaskets for steel flanges to BS
1560
Specification for pipe supports. Large bore, high
company.
Page 63 of 68

BS 3799
BS 6129:
Part 1
BS EN
10226-1
BS EN 10241
BS EN
10253-2
BS EN 12513
BS2853
DOC NO AATC000859
temperature, marine and other applications. (Withdrawn but

still used in absence of alternative)
Specification for steel pipe fittings, screwed and socket
welding for the petroleum industry
Code of practice for the selection and application of bellows
expansion joints for use in pressure systems. Metallic
bellows expansion joints
Pipe threads where pressure tight joint are made on the
threads
Steel threaded pipe fittings
Butt-welding pipe fittings
Founding. Abrasion resistant cast irons
The design and testing of Steel Overhead Runway Beams
REVISION HISTORY
Version No.
Reason for Change
Date
Draft:
Distributed to DRA, FLSmidth, HATCH, PH Projects,

Taggart-JHDA, Taggart-LSL, and TWP for comment
(T Schmidt, May 2013)
May 2013
Final Draft:
Comments received from DRA, FLSmidth, HATCH,

PH Projects, Taggart-JHDA, Taggart-LSL, and TWP
incorporated (T Schmidt, August 2013)
August 2013
Published:
New template format & minor updates.
October 2013
company.
Page 64 of 68

APPENDICES
9.1
Appendix A: Preferred Vendor List
DOC NO AATC000859
Assizing
SKF
Belt Arrestors
ICO
Belt Ploughs
Belt Scrapers Primary and
Secondary
Hosch
Brelko
Scorpio
Hosch
Brelko
Scorpio/Mar
tin Eng
Process
Automation
Goodyear/V
eyance
Dymot
Thermo
Fisher
Schenck
Process
Dunlop
Fenner
Voith
Svendborg
Binder
Centrifuges
Malvern
Ludowici
Couplings - Fluid
Voith
Multotec
Seprotech
Transfluid
(BMG)
Belting (Existing
AATC contracts)
Brakes - Capstan
Brakes - High
Speed and Low
Speed
Cranes
Transmissio
n
Component
s
Morris
Cyclone
Multotec
Couplings - High
Speed and Low
Speed
Dust Suppression
and Extraction
Systems
Electro-hydraulic
actuators
Elemental Moisture
Density Analysers
Feeders - Apron
Feeders Observation
Feeders - Vibrating
Feeders - Grizzleys
Dustaway
Dabeb
Elram
Thermo
Fisher
Metso
Vendor 6
Vendor 5
Thermo
Fisher
FAG
(pulleys
only)
Bearings
Belt Weighers
Vendor 4
Atlas Copco
Process
Automation
Vendor 3
Air Compressor
Vendor 2
Equipment Type
Vendor 1
Equipment and Preferred Vendors
Phoenix
Andritz
Voith
Kone
Krebs FL
Smidth
Mikropul
Condra
Demag
Malvern
Air Cleaning
Equipment
Hytec
MMD
Bateman
Osborn
Osborn
Metso
Vibramech
Joest
Schenck
Vibramech
Joest
Schenck
Osborn
Magquip
Osborn
Vibramech
Joest
Schenck
company.
Vipro
Page 65 of 68

Fire Protection
Systems
Fire Control
Systems
Gearboxes
Hansen
Paramax
Hoists
Holdbacks External
Hydraulic Power
Packs
Idlers (Existing
AATC contracts)
Jaw Crushers
Morris
Kone
Falk
Marland
Denquip
Hytec
Hyflo
Melco
Lorbrand
Osborn
Osborn
FFE
Sandvik
Lubrication
Magnetic
Separators
Lincoln
Multotec/
Magquip
Overband Magnets
Eriez
Mineral Sizers
Motors
Siemens
Plate & Frame Filter

Press
Pulleys
TH (Tecnicas
Hydraulicas)
CPM
Weir
Warman
Pumps
Ring Roll
Granulators
Rock Breakers
Rotary Breakers
Sampling Plant
Packages
Screens
Stock
yard
Equipment
Stackers/
Reclaimers
Thickener
Winches,
Sheave
Wheels and Ropes
9.2
Bateman
SEW
Yale
David
Brown
Demag
Elco/ Ernest
Lowe
Malvern
Mechani
Mag
Process
Automation
MMD
Metal Detectors
Flender /
Siemens
Condra
DOC NO AATC000859
ABB
Sandvik
W.E.G /
ZEST
EET
Malvern
Multotec/Ma
gquip
Thermo
Fisher
FFE (Abon)
Alstom
CMG
Ishigaki
Bosworth
Krebs
MillMAX
MS Pulleys
Metso
Osborn
Atlas Copco
Rammer
CRM
Osborn
Metso
Osborn
Vibramech
Bateman
Thermo
Fisher
Schenck
Ludowici
ConnWeld
Linatex
Joest
Krupp
Metso
Tenova/
Takraf
Sandvik
Schade
FLSmidth
GKD Delkor
MIP
Outotec
FLSmidth
Dymot
Atlanta
Multotec
Appendix B: Standard Drawings
Drawing Number
0000-0000-MED-0001
0000-0000-MED-0002
0000-0000-MED-0003
0000-0000-MED-0004
0000-0000-MED-0005
0000-0000-MED-0006
0000-0000-MED-0007
Drawing Title
STANDARD HANDRAILING
*HOLD* GENERAL NOTES
ACSA - STANDARD A1 DRAWING SHEET
TEMPLATE
SCREW TAKE-UP DETAIL
EQUIPMENT SCHEDULE , PULLEY SCHEDULE
AND SOLE PLATE SCHEDULE
SLIDING JOINT DETAIL - 1500 WIDE BELT
BELT TURN-OVERS - 1200 WIDE BELT
company.
Page 66 of 68

0000-0000-MED-0008
0000-0000-MED-0009
0000-0000-MED-0010
0000-0000-MED-0011
0000-0000-MED-0015
0000-0000-MED-0016
0000-0000-MED-0017
0000-0000-MED-0018
0000-0000-MED-0019
0000-0000-MED-0020
0000-0000-MED-0021
0000-0000-MED-0022
0000-0000-MED-0023
0000-0000-MED-0024
0000-0000-MED-0025
0000-0000-MED-0026
0000-0000-MED-0027
0000-0000-MED-0028
0000-0000-MED-0029
0000-0000-MED-0030
0000-0000-MED-0031
0000-0000-MED-0032
0000-0000-MED-0033
0000-0000-MED-0034
0000-0000-MED-0035
0000-0000-MED-0036
0000-0000-MED-0037
0000-0000-MED-0038
0000-0000-MED-0039
0000-0000-MED-0040
0000-0000-MED-0041
0000-0000-MED-0042
0000-0000-MED-0043
0000-0000-MED-0044
0000-0000-MED-0045
0000-0000-MED-0046
0000-0000-MED-0047
0000-0000-MED-0048
0000-0000-MED-0049
0000-0000-MED-0050
DOC NO AATC000859
TAKE-UP CARRIGE - 1200 WIDE BELT

STANDARD INSPECTION DOOR DETAILS
HOOD AND SPOON CHUTE
ACSA - STANDARD A0 DRAWING SHEET
TEMPLATE
STANDARD SKIRTS PL. CLAMPS
RADIAL DOOR DETAIL
TYPICAL SCREEN UNDERPAN SHEET 1 OF 2
(SPLIT)
TYPICAL SCREEN UNDERPAN SHEET 2 OF 2 (
SPLIT)
CUT-OFF GATE FRAME
CUT-OF GATE G.A.
CUT-OFF GATE DETAILS
TYPICAL SCREEN UNDERPEN SHEET 1 OFF 2
TYPICAL SCREEN UNDERPEN SHEET 2 OFF 2
FLOPPER GATE DETAIL
SILO CAST-IN DISCHARGE CHUTE FRAME
SILO DISCHARDG CHUTE DETAIL
SILO BELT FEEDER FEEDCHUTE DETAIL
MAGNET INSTALATION
SILO BELT FEEDER DRIBBLE CHUTE
SILO BELT FEEDER
SILO BELT FEEDER MECHANICAL DETAILS
SILO STRUCTURE ABOVE SILO SHEET 1 OF 3
CONVEYOR GANTRY - 1500 WIDE BELT - 24M
LONG
CONVEYOR GANTRY - 1200 WIDE BELT - 24 M
LONG
LONG
LONG
CONVEYOR 1200 WIDE BELT STANDARD
OVERLAND MODULE
CONVEYOR 1200 WIDE BELT TURN OVER
TYPICAL DRIVE UNIT ARRANGEMENT
TYPICAL TRESTLES ARRANGEMENT
TYPICAL STOOL FOR TRESTLES
TYPICAL TAKE-UP TROLEY
TYPICAL TAKE-UP FRAME
LONG
LONG
TRUNK CONVEYOR GA
U/G BOX FRONT ONE FEEDER LAYOUT
U/G BOX FRONT TWO FEEDERS LAYOUT
company.
Page 67 of 68

0000-0000-MED-0052
0000-0000-MED-0053
0000-0000-MED-0054
0000-0000-MED-0065
0000-0000-MED-0066
0000-0000-MED-0067
DOC NO AATC000859
LOBSTER GATE DETAIL

WEIGH FLASK DETAIL
BOX FRONT FEEDED BY STATIC GRIZZLY
CONVEYOR GANTRY - 1050 WIDE BELT
PIPING - VALVE SCHEDULE
STANDARD ACCESS STAIRS FOR TAKE-UP
TOWER & SILOS - 600 WIDE STAIRS
company.
Page 68 of 68

Design Criteria and Guidelines For Surface Infrastructure Mechanical and Structural

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Design Criteria and Guidelines For Surface Infrastructure Mechanical and Structural

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IMPLEMENTATION 11/22/2013

AATC DESIGN CRITERIA AND GUIDELINES FOR SURFACE

PROCESS DESIGN CRITERIA

MECHANICAL DESIGN CRITERIA

Design Codes and Standards

Surface materials handling systems General requirements

Mechanical Design General Requirements

Pipework and Valves

Platework and Lining

STRUCTURAL DESIGN CRITERIA

Plant Buildings and Structures

Walkways, access, platforms and flooring

AA Standards and Specifications:

AATC DESIGN CRITERIA AND GUIDELINES FOR SURFACE

National Standards and Specifications

Appendix A: Preferred Vendor List

Appendix B: Standard Drawings

AATC DESIGN CRITERIA AND GUIDELINES FOR SURFACE

AATC DESIGN CRITERIA AND GUIDELINES FOR SURFACE

Anglo American Thermal Coal

Anglo American Fatal Risk Standard

Anglo Projects Way

Approved by the Engineer in writing or signature

Bulk Materials Handling

British Standard European Norm

Conveyor Equipment Manufacturers Association

Conveyor Manufacturers Association

Department of Mineral Resources

AATC Discipline Engineer assigned to the project

Electronic Soft Starter

International Standards Organisation

Motor Control Centre

Original Equipment Manufacturer

Process Flow Diagram

Piping And Instrument Diagrams

Programmable Logic Controller

Particle Size Distribution

South African National Standard

Variable Speed Drive

AATC DESIGN CRITERIA AND GUIDELINES FOR SURFACE

PROCESS DESIGN CRITERIA

General design parameters

The plant and equipment shall be designed to operate 24 hours a day, 7

Consideration must be given to previously undermined operations where

Previously undermined reserves may contain a considerable amount of

Raw coal PSD

The particle size distribution can be considered typical of open cast

Volumetric calculations to be based on lowest anticipated bulk density

Bulk density (mass)

Power calculations to be based on highest anticipated bulk density unless

38 (Guideline only project specific data required for detail design)

: 900 to 1300 kg/m

AATC DESIGN CRITERIA AND GUIDELINES FOR SURFACE

MECHANICAL DESIGN CRITERIA

Design Codes and Standards

Anglo American Specifications

Applicable Codes, Standards, Acts and Regulations

Surface materials handling systems General requirements

AATC DESIGN CRITERIA AND GUIDELINES FOR SURFACE

Tip static grizzly

AATC DESIGN CRITERIA AND GUIDELINES FOR SURFACE

Tip static grizzly cleaning operations

AATC DESIGN CRITERIA AND GUIDELINES FOR SURFACE