ISSUED MASTER SPECIFICATION

Originated by Larry Faught on 17/06/1999

SPECIFICATION DETAILS Status: Issued

Discipline: Design Criteria

Equipment: Design Codes
Title: Corrosion Protection Of Steelwork In Mine Shafts
Description: Design Code Mines

MASTER SPECIFICATION NUMBER

Specification No: ADC001
Specification Rev No: 01

- ADC001-01~1.doc
 ANGLO PLATINUM MANAGEMENT SERVICES (PROPRIETARY) LIMITED
ENGINEERING TECHNOLOGY DIVISION

SPECIFICATION No.: ADC 001

SPECIFICATION TITLE: CORROSION PROTECTION OF STEELWORK

IN MINE SHAFTS

PROJECT TITLE: -

BUSINESS UNIT: -

AREA: -

EQUIPMENT No.: -

DISCIPLINE: DESIGN CODE

Rev No Date Description Orig. Project Site Eng. CM&EE M.E.T

Man.
01 10/06/99 Into new Anglo Platinum WvdO - - - KBF
Format
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Revision Notes
Master Specification No.- ADC 001 Rev.- 01

Site Specification No.- Title.- Corrosion Protection of Steelwork in Mine Shafts

Date Rev No Description Revised By
10/06/99 01 Into New Anglo Platinum Format WvdO

INDEX
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SECTION TITLE

1.0 SCOPE

2.0 CORROSIVE CONDITIONS IN A SHAFT

2.1 General Corrosive Conditions

2.2 Type of Shaft
2.3 Shaft Water

3.0 CORROSION PROTECTION PHILOSOPHY FOR SHAFTS

4.0 CORROSION PROTECTION PROCEDURES

4.1 Buntons
4.2 Guides
4.3 Station Support Steelwork
4.4 Station Auxiliary Steelwork
4.5 Service Columns
4.6 Service Column Flange Areas
4.7 Ore Loading Facility
4.8 Fasteners
4.9 Brackets, Supports, etc
4.10 Headgears

APPENDIX 1

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1. Scope
This Design Code covers the corrosion protection of shaft steelwork in corrosive conditions.
Items covered in the specification include buntons, guides, station steelwork, columns, ore
loading arrangements and all associated fasteners, supports, brackets, etc.

The code covers both the permanent shaft situation as well as short period situations such as
sinking and mid shaft loading.

2. Corrosive Conditions
2.1 General Corrosive Conditions
The conditions within a shaft are corrosive on account of the wet and humid
atmospheres and the abrasive action of falling particles of ore and water.

As the temperature and humidity levels increase towards the lower regions of the shaft,
the conditions become increasing more corrosive. The shaft bottom area, which
generally includes the ore loading facilities and drainage arrangements, may be
regarded as the most corrosive section of a shaft.

2.2 Type of Shaft

Vertical shafts are classified as upcast, downcast or combined upcast and downcast.
From the corrosion viewpoint, upcast shafts are markedly more corrosive than downcast
as the corrosive environment is continually swept upwards throughout the entire shaft.
Sub-vertical shafts are more corrosive than vertical shafts as the upper portion of the
shaft is contained within a highly corrosive area.

2.3 Shaft Waters

The major cause of corrosion in shafts is the presence of mine waters which contain
high concentrations of dissolved species and have high hardness values. These waters
normally have a high scaling tendency which results in accelerated corrosion at crevices
or other areas where solid deposition takes place.

Of particular importance from the corrosion aspect is the presence of dissolved chloride
ions (C1 -) which causes high rates of localised corrosion eg. Pitting, and is harmful
towards stainless steels (304, 316, etc) and 3CR12. Free State shafts generally have
waters with very high chloride levels (typically 1 000 – 2 0000 ppm) whereas Gauteng
shafts have markedly lower values (eg. 100 ppm).

Sulphate ions (SO4) are always present in shaft waters owing to the leaching effect of
water on sulphidic ore bodies. In general as shaft and haulage development proceeds,
the level of sulphate ions increases due to the opening up of the ore body.

Although mine service water is generally neutralised by lime additions, the pH values
can be low (acidic) owing to poor control over liming procedures or shaft circuiting of
some fissure waters which can be highly acidic. Alkaline waters (above pH 7) have
little effect on the overall corrosion rates of steel.

3. Corrosion Protection Philosophy for Shafts

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The major factors in determining corrosion protection for shaft equipment are safety, minimum
maintenance requirements and cost effectiveness. Since the shaft steel provides the mechanism
for the continual transport of men, material, machinery and ore, it is essential that all items of
equipment be fully functional for extended periods of time. Corrosion of shaft steelwork can
destroy the functionality of the shaft, lead to early maintenance with large losses of revenue
and become unsafe. Due to the nature of shaft operations, opportunities for maintenance are
limited and accordingly it is important that all applied corrosion protection be effective for as
long as possible and ideally, for the full service life of the shaft, which is normally between 25
and 30 years.

Although successful in many other areas, eg. Surface plants, protective paint coatings are of
limited use in shafts. The coatings are easily damaged during erection and service and they
cannot be effectively maintained in the corrosive shaft condition. Access within a shaft for
maintenance is also extremely difficult. Since paint coatings offer very little by way of
effective corrosion protection, the steel undergoes rapid corrosion which is generally of a
pitting nature, and performation of the steel. Hot dip galvanising provides a hard abrasion and
corrosion resistant surface which, in addition, provides protection to the base steel at points of
damage. The nature of the corrosion on galvanised surfaces is also uniform and the risk of
pitting corrosion is reduced.

In order to cater for the very corrosive conditions in upcast shafts and in the lower regions of
downcast shafts, use is made of Duplex coatings which comprise of a hard durable paint
coating over hot dip galvanised surfaces.

In the conditions that prevail at the shaft bottom loading facilities (very severe corrosion and
abrasion ) the use of 3CR 12 may be considered instead of hot dip galvanised coatings or
Duplex coatings. In the very abrasive situations, eg. Loading chutes, abrasion resistant steels
such as Roq-Last are more effective. Both 3CR12 or the abrasion resistant steels would not be
expected to last for the full service life of the shaft and would require replacement at fairly
frequent intervals.

For temporary shaft situations, eg. Sinking and mid shaft loadings, the corrosive conditions
would be present for a shorter period of time, eg. 2 to 4 years compared to 25 to 30 years for
permanent shaft fittings. Accordingly the applied corrosion protection is also of a temporary
nature and in general protective paint coatings will suffice. As a guide, temporary steelwork
required for less than two years may be installed without any protection while steelwork for a
period longer than two years may be protected using paint coatings and PS 106 and AGS 011
would be recommended for this purpose.

4. Corrosion Protection Procedures

4.1 Buntons
All buntons shall be hot dip galvanised in accordance with the specification provided in
AGS 030. Buntons shall be designed in such a way that the hot dip galvanising can be
effectively performed.

As outlined in AGS 030, all buntons shall be provided with drain holes to allow for the
zinc coating on the internal surfaces.

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Buntons situated in the lower regions (typically below 500m for some corrosive shafts
and in the vicinity of and below the loading areas) and all buntons in upcast shafts shall
be further protected by the application of Duplex coatings in accordance with PS 122 of
AGS 011. Buntons in combined upcast/downcast shafts shall be hot dip galvanised as a
minimum form of protection with the application of the Duplex coating being subject to
the particular design.

4.2 Guides

Guides, which are normally of the top hat section type, shall be hot dip galvanised in
accordance with the specification provided in AGS 030. Hot dip galvanising shall be
carried out prior to the accurate cutting to length of the guides and the drilling of holes
in them. After the cutting and drilling operations, the damaged areas of galvanising
shall be repaired by either the application of zinc sprayed coatings or zinc rich epoxy
paints in accordance with the procedures given in AGS 030.

It shall be the responsibility of the galvaniser to ensure that any distortion during and
after galvanising is kept to a minimum by specific attention to handling of the guides
during galvanising and post galvanising procedures. Should unacceptable distortion
occur, the galvaniser shall be responsible for straightening the guides to acceptable
limits and shall repair any damaged sections (in accordance with repair procedures
given in AGS 030) that arise as a result of straightening. Guide splice plates shall be
hot dip galvanised in accordance with AGS 030.

4.3 Station Support Steel

All station steelwork (kingposts, beams, etc.) shall be hot dip galvanised in accordance
with AGS 030. The steelwork shall be designed to facilitate hot dip galvanising with
attention being paid to uniform section thickness, symmetrical stress loading and quality
of welding.

The steelwork shall be so designed to minimise the accumulation of solid ore particles
and water during service, and the recommendations given in Appendix I shall be
followed. In the event that accumulation cannot be avoided due to the particular design
of steelwork, drainage holes shall be provided.

4.4 Station Auxiliary Steelwork (Platforms, Gates, Fences, etc.)

4.4.1 Platforms
All platforms shall be hot dip galvanised in accordance with AGS 030.

4.4.2 Hand Rails, Barrier Rails, Guard Rails

These items shall be hot dip galvanised in accordance with AGS 030 or shall be
constructed from 3CR12. Where painting is required for colour coding purposes,
PS122 for galvanised steel and PS 107, of AGS 011, shall be used with the
required colour topcoats.

4.4.3 Guard Fences, Gate Fences, etc.

Expanded metal, using 3CR12 or hot dip galvanised (AGS 030) 6mm diameter
steel bar, shall be used.
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4.4.4 Stairs, Treads, etc.

Hot dip galvanising using AGS 030 or 3CR12 shall be used.

4.5 Columns
All columns (air, water, diesel fuel, etc) shall be hot dip galvanised in accordance with
AGS 030.

Columns for use in the lower regions of downcast shafts (typically below 500m) and all
columns in upcast shafts shall be further protected by the application of a Duplex
coating in accordance with PS122 of AGS 011. Columns in combined upcast/downcast
shafts shall be hot dip galvanised as a minimum form of protection with the application
of the Duplex coating being subject to the particular design of the shaft.

For sludge columns, or for any particular service which is abrasive in nature, eg.
Slurries, the internal surface shall be further protected by the application of a Duplex
coating in accordance with PS122 of AGS 011.

Where sleeved flange joints are used, the welding will destroy the hot dip galvanised
coating which shall be repaired by means of zinc metal spray, in accordance with the
repair specifications given in AGS 030.

Where sealing faces are present, the faces shall not be Duplex coated and the hot dip
galvanised finish shall be worked to obtain the correct finish for sealing.

4.6 Column Flanges

The upper and lower areas of flanged joints on columns (approximately 300mm above
and below the flange) are vulnerable to corrosion on account of the build-up of ore
particles and water. These areas on all columns (including the flanges) shall be further
protected by the application of a tape wrapping system or the application of an approved
epoxy tar mastic. Specification PS113 of AGS 011 shall be referred to for this purpose.

4.7 Ore Loading

The ore loading facility is normally situated at the shaft bottom and is subject to very
severe corrosion. On account of the very severe abrasion, the use of Duplex coatings
has limited value. For these applications 3CR12 may be considered with very high
abrasion areas being handled by Roq-Last or Roq-Tuf liner plates.

4.8 Fasteners
Fasteners (Bolts, hook bolts, nuts, etc.,) shall be hot dip galvanised in accordance with
AGS 030. Under no circumstances should electroplated coatings, etc. cadmium or zinc
plated fasteners, be used.

Although many types of locking bolts are available in the hot dip galvanised form,
certain types of locking bolts cannot be hot dip galvanised due to the presence of a non-
metallic insert in the bolt which would degrade during galvanising. This type of
locking bolt should be avoided.

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All bolts or any other type of fastener which is grouted into the wall or into a concrete
support plinth or base shall be hot dip galvanised prior to grouting.

4.9 Brackets, Supports, etc.

All brackets, supports, etc., shall be hot dip galvanised in accordance with AGS 030.
The items shall be designed to allow for hot dip galvanising without undue distortion.

4.10 Headgears
Headgears for sub-vertical shafts shall be hot dip galvanised in accordance with
AGS030. Particular attention shall be paid to the design of these headgears to prevent
unacceptable distortion during galvanising. In this regard, attention shall be paid to the
use of equal section thicknesses and symmetrical design to produce evenly distributed
stresses. The amount of welding should be minimised and all welding should be
uniform.

Surface headgears can be hot dip galvanised provided that very careful consideration is
given to all design features which may affect the structure during galvanising.

Where hot dip galvanising is not possible, the steel shall be protected by means of the
specification given in PS116 of AGS 011 (epoxy tar over inorganic zinc primer).

For concrete headgears, no further protection is required, provided that high quality off
shutter concrete has been used. Steel used in concrete headgears should be painted to
PS107 of AGS011 and all expansion and construction joints should be adequately
sealed to prevent moisture leaking through to steel/concrete interfaces.

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