-
MWH Job No. 1005795
Prepared for:
Freeport McMoRan Copper & Gold Inc. One North Central
Avenue
Phoenix, AZ 85004
TENKE FUNGURUME MINE TAILING STORAGE FACILITY AND RETURN WATER
POND
PHASE 1 CONSTRUCTION COMPLETION REPORT
August 2009 Prepared by:
1801 California Street Suite 2900 Denver, Colorado 80202 (303)
291-2222
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x TOC-i
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * 303 291 2222
TABLE OF CONTENTS Section No. Page No. 1.0 INTRODUCTION
.............................................................................................................................
1
1.1 GENERAL
......................................................................................................................................
11.2 PURPOSE AND SCOPE OF WORK
.............................................................................................
21.3 PROJECT DOCUMENTS
..............................................................................................................
31.4 DISCLAIMER
................................................................................................................................
41.5 REPORT ORGANIZATION
..........................................................................................................
5
2.0 PROJECT OVERVIEW
...................................................................................................................
6
2.1 GENERAL
......................................................................................................................................
62.2 PROJECT COMPONENTS
............................................................................................................
72.3 DESIGN MODIFICATIONS
.........................................................................................................
82.4 SEQUENCE OF CONSTRUCTION
..............................................................................................
92.5 PART 1: CONTRACTING APPROACH ORGANIZATION
..................................................... 13
2.5.1 Owner
.......................................................................................................................................
152.5.2 EPCM
.......................................................................................................................................
162.5.3 Designer
...................................................................................................................................
172.5.4 Construction Manager
..............................................................................................................
172.5.5 Contractor
................................................................................................................................
18
2.6 PART 2: SELF-PERFORM APPROACH ORGANIZATION
..................................................... 202.6.1
Owner, Construction Manager, and Contractor
......................................................................
202.6.2 Construction Quality Assurance
...............................................................................................
202.6.3 Subcontractors
..........................................................................................................................
21
PART 1 CONSTRUCTION COMPLETION
3.0 FIELD DOCUMENTATION
.........................................................................................................
24
3.1 SUMMARY
..................................................................................................................................
243.2 SUBMITTALS
.............................................................................................................................
24
3.2.1 General
.....................................................................................................................................
243.2.2 Schedule
...................................................................................................................................
26
3.3 FIELD REPORTS
.........................................................................................................................
283.3.1 Correspondence
........................................................................................................................
283.3.2 Construction Quality Assurance Reports
.................................................................................
29
3.4 RECORD DRAWINGS
................................................................................................................
29
4.0 EARTHWORKS
.............................................................................................................................
32
4.1 SUMMARY
..................................................................................................................................
324.2 CLEARING AND GRUBBING
...................................................................................................
334.3 TOPSOIL REMOVAL
.................................................................................................................
334.4 BASIN CONTOURING
...............................................................................................................
344.5 SUBGRADE PREPARATION
....................................................................................................
354.6 EMBANKMENT EXCAVATION
...............................................................................................
41
4.6.1 North Embankment
...................................................................................................................
414.6.2 Return Water Dam
....................................................................................................................
424.6.3 West Embankment
....................................................................................................................
43
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x TOC-ii
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * 303 291 2222
4.7 EMBANKMENT STRUCTURAL ROCKFILL ZONE 1
......................................................... 434.7.1
Test Fill
....................................................................................................................................
434.7.2 North Embankment
...................................................................................................................
464.7.3 Return Water Dam
....................................................................................................................
484.7.4 West Embankment
....................................................................................................................
51
4.8 EMBANKMENT BACKFILL GRAVEL ZONE 1A
................................................................
534.9 EMBANKMENT ENGINEERED FILL ZONE 2 AND 2A
..................................................... 54
4.9.1 Borrow Source
..........................................................................................................................
544.9.2 North Embankment
...................................................................................................................
554.9.3 Return Water Dam
....................................................................................................................
614.9.4 West Embankment
....................................................................................................................
65
4.10 PERIMETER ROADS
..................................................................................................................
694.11 PERMANENT STORMWATER CONTROLS
...........................................................................
70
4.11.1 SPILLWAY
...........................................................................................................................
704.11.2 Drainage Culverts
................................................................................................................
71
4.12 TEMPORARY STORMWATER CONTROLS
...........................................................................
714.12.1 Return Water Dam Stormwater Drain
.................................................................................
714.12.2 North Embankment Stormwater Drain
................................................................................
724.12.3 Other Temporary Stormwater Controls
...............................................................................
74
5.0 UNDERDRAINS
.............................................................................................................................
75
5.1 SUMMARY
..................................................................................................................................
755.2 DELIVERY, STORAGE, AND HANDLING OF MATERIALS
................................................ 75
5.2.1
Geotextile..................................................................................................................................
755.2.2 Zone 4 Drain Gravel
................................................................................................................
765.2.3 Piping
.......................................................................................................................................
76
5.3 MATERIAL QC/QA DATA
........................................................................................................
765.3.1
Geotextile..................................................................................................................................
765.3.2 Zone 4 Drain Gravel
................................................................................................................
765.3.3 Piping
.......................................................................................................................................
77
5.4 UNDERLINER DRAIN INSTALLATION
.................................................................................
785.5 EMBANKMENT DRAIN INSTALLATION
..............................................................................
78
6.0 GEOSYNTHETICS
........................................................................................................................
79
6.1 SUMMARY
..................................................................................................................................
796.2 DELIVERY, STORAGE, AND HANDLING
..............................................................................
79
6.2.1
Geotextile..................................................................................................................................
796.2.2 Geomembrane
..........................................................................................................................
80
6.3 MATERIAL QC/QA DATA
........................................................................................................
816.3.1
Geotextile..................................................................................................................................
816.3.2 Geomembrane
..........................................................................................................................
82
6.4 GEOSYNTHETIC INSTALLATION EQUIPMENT
.................................................................
846.4.1
Geotextile..................................................................................................................................
846.4.2 Geomembrane
..........................................................................................................................
84
6.5 GEOTEXTILE INSTALLATION
................................................................................................
856.5.1 Underliner and Embankment Drain
.........................................................................................
856.5.2 Embankment Filter
...................................................................................................................
86
6.6 GEOMEMBRANE INSTALLATION
.........................................................................................
876.6.1 Deployment
...............................................................................................................................
876.6.2 Field Seaming
...........................................................................................................................
906.6.3 Non-Destructive Testing
...........................................................................................................
936.6.4 Destructive Testing
...................................................................................................................
93
6.6.4.1Sampling Procedure
.............................................................................................................
936.6.4.2Laboratory Destructive Tests
...............................................................................................
946.6.4.3Field Destructive Test and Statistical Analysis
....................................................................
95
6.6.5 Liner Leak Location Survey
......................................................................................................
98
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x TOC-iii
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * 303 291 2222
7.0 WELL ABANDONMENT
..............................................................................................................
99
8.0 ROCK QUARRY
..........................................................................................................................
101
8.1 SALABWE ROCK QUARRY
...................................................................................................
1018.2 FWAULU ROCK QUARRY
.....................................................................................................
102
9.0 CONSTRUCTION MATERIAL VOLUMES
............................................................................
103
9.1 SUMMARY
................................................................................................................................
1039.2 DESIGN AND MEASURED VOLUME COMPARISON
........................................................ 1039.3
FINAL SURFACE COMPARISON BETWEEN WBHO AND KWA SURVEYS
.................. 105
10.0 PART 1 SUMMARY AND CONCLUSIONS
.............................................................................
106
PART 2 CONSTRUCTION COMPLETION
11.0 FIELD DOCUMENTATION
.......................................................................................................
108
11.1 SUMMARY
................................................................................................................................
10811.2 SUBMITTALS
...........................................................................................................................
10811.3. CORRESPONDENCE
................................................................................................................
10911.4 RECORD DRAWINGS
..............................................................................................................
109
12.0 EARTHWORKS
...........................................................................................................................
110
12.1 SUMMARY
................................................................................................................................
11012.2 SITE
PREPARATION................................................................................................................
11112.3 EMBANKMENT BACKFILL GRAVEL ZONE 1A
..............................................................
11112.4 EMBANKMENT ENGINEERED FILL ZONES 2 AND 2A
................................................. 11312.5 ANCHOR
TRENCHES
..............................................................................................................
117
13.0 GEOSYNTHETICS
......................................................................................................................
118
13.1 SUMMARY
................................................................................................................................
11813.2 DELIVERY, STORAGE, AND HANDLING
............................................................................
11813.3 GEOSYNTHETIC INSTALLATION EQUIPMENT
................................................................
118
13.3.1 Geotextile
...........................................................................................................................
11813.3.2 Geomembrane
....................................................................................................................
119
13.4 GEOTEXTILE INSTALLATION
..............................................................................................
11913.5 GEOMEMBRANE INSTALLATION
.......................................................................................
120
13.5.1 Liner Deployment
...............................................................................................................
12013.5.2 Field Seaming
....................................................................................................................
12113.5.3 Trial Seams
........................................................................................................................
12113.5.4 Non-destructive Testing
.....................................................................................................
12113.5.5 Destructive Testing
............................................................................................................
122
14.0 CONSTRUCTION MATERIAL VOLUMES
............................................................................
123
15.0 PART 2 SUMMARY AND CONCLUSIONS
.............................................................................
124
16.0 REFERENCES
..............................................................................................................................
125
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x TOC-iv
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * 303 291 2222
LIST OF TABLES Table No. Description Page No.
1.1 Breakdown of Construction Oversight Responsibilities
......................................... 2 2.1 Summary of Design
Modifications
.........................................................................
8 2.2 Sequence of Work Summary
...............................................................................
12 2.3 Project Roles and Responsibilities for TSF and RWP Project
............................ 14 2.4 Owners Personnel and Roles
.............................................................................
16 2.5 Designers Personnel and Roles
.........................................................................
17 2.6 Construction Managers Personnel and Roles
.................................................... 18 2.7 Part 1:
Contractors Personnel and Roles
........................................................... 19 2.8
Part 2: Self-perform Personnel and Roles
........................................................... 20 2.9
CQA Personnel and Roles
..................................................................................
21 2.10 Part 2: Subcontractors Personnel and Roles
..................................................... 22 3.1 Owner
and Contractor General Submittals
......................................................... 25 3.2
Construction Schedule Submittal Sequence
....................................................... 28 3.3 List
of New Drawings for Record of Construction
................................................ 30 4.1 RWP and TSF
Basin Subgrade Soil Properties
.................................................. 36 4.2 North
Embankment Engineered Fill Properties
................................................... 56 4.3 Return
Water Dam Engineered Fill Properties
.................................................... 62 4.4 West
Embankment Engineered Fill Properties
.................................................... 66 6.1 Grade
A-7 Geotextile Physical Properties
........................................................... 81 6.2
Grade A-10 Geotextile Physical Properties
......................................................... 82 6.3
Geomembrane Resin Physical Properties
.......................................................... 82 6.4
Geomembrane Physical Properties
.....................................................................
83 6.5 Geomembrane Physical Properties Test Frequency
........................................... 84 6.6 Geomembrane
Quantity and Waste Factor
......................................................... 88 6.7
Summary of Welded Seam Length
......................................................................
91 6.8 Minimum Seam Strength Properties
....................................................................
91 6.9 Destructive Seam Test Result
Summary.............................................................
92 6.10 Field Destructive Seam Test Result Summary
.................................................... 95 7.1 Wells
Abandoned by Grouting
.............................................................................
99 9.1 Comparison Between Design and Survey Quantities
....................................... 104 12.1 North Embankment
Engineered Fill Properties
................................................. 114 13.1 Part 2
Field Destructive Seam Test Result Summary
....................................... 122 14.1 Part 2 Comparison
of Estimated and Final Quantities
...................................... 123
LIST OF FIGURES Figure No. Description Page No.
4.1 Relative Compaction in RWP Basin Subgrade Soils
........................................... 37 4.2 Relative
Compaction in TSF Basin Subgrade Soils
............................................ 38 4.3 Variation from
In-place and Optimum Moisture Content in RWP Basin
Subgrade Soils for Density Test Samples
........................................................... 39 4.4
Variation from In-place and Optimum Moisture Content in TSF
Basin
Subgrade Soils for Density Test Samples
........................................................... 40 4.5
Test Fill Layout
....................................................................................................
44 4.6 Test Fill Settlement Curves
.................................................................................
45 4.7 North Embankment Particle-size Distribution, Zone 1
(Rockfill) ...................... 47 4.8 Return Water Dam
Particle-size Distribution, Zone 1 (Rockfill)
....................... 49 4.9 West Embankment Particle-size
Distribution, Zone 1 (Rockfill) ....................... 52 4.10
Particle-size Distribution, Embankment Backfill Gravel - Zone 1A
...................... 54
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x TOC-v
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * 303 291 2222
4.11 North Embankment Zones 2 and 2A Relative Compaction Test
Results, 7 Sept. to 17 Sept. 2008
..................................................................................................
57
4.12 North Embankment Zones 2 and 2A Relative Compaction Test
Results (Cont.), 17 Sept. to 22 Sept. 2008
....................................................................................
58
4.13 Percent Variation from Optimum Moisture Content in North
Embankment Zones 2 and 2A Compacted Soils, 7 Sept. through 17 Sept.
2008 ................................... 59
4.14 Percent Variation from Optimum Moisture Content in North
Embankment Zones 2 and 2A Compacted Soils (Cont.), 17 Sept. through
22 Sept. 2008 ..................... 59
4.15 Return Water Dam Zones 2 and 2A Relative Compaction Test
Results ............. 63 4.16 Variation from In-place and Optimum
Moisture Content in Return Water Dam Soils
.....................................................................................................................
63 4.17 West Embankment Zones 2 and 2A Relative Compaction Test
Results ............ 67
4.18 Variation from In-place and Optimum Moisture Content in the
West Embankment Soils
...............................................................................................
68
5.1 Particle-size Distribution Zone 4 (Gravel Drain)
.................................................. 77 6.1 RWP Field
Versus Laboratory Seam Peel Strength
......................................... 96 6.2 TSF Field Versus
Laboratory Seam Peel Strength
.......................................... 96 6.3 RWP - Field
Versus Laboratory Seam Shear Strength
....................................... 97 6.4 TSF Field Versus
Laboratory Seam Shear Strength
........................................ 97
12.1 Embankment Backfill Gravel Zone 1A Particle-size
Distribution North Embankment Elevation 1,367 to 1,378 m
......................................................... 112
12.2 North Embankment Engineered Fill Zones 2 Relative
Compaction Test Results Elevation 1,367 to 1,380 m, Section 2
...............................................................
115
12.3 Percent Variation from Optimum Moisture Content in North
Embankment Engineered Fill Zones 2 and 2A Compacted Soils,
Elevation 1,367 to 1,380 m
................................................................................
116
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x TOC-vi
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * 303 291 2222
LIST OF APPENDICES Appendix Description PART 1 APPENDICES A
(Vol. 2) Design Changes B (Vol. 2) Submittals
B.1 Owner Supplied Material B.1.1 HDPE Geomembrane Liner B.2
Contractor Supplied Material B.2.1 Geotextile B.2.2 HDPE Pipe B.3
Contractor General B.3.1 Organization Chart B.3.2 WBHO Safety
Documents B.3.3 WHBO On-site QC and Laboratory Equipment B.3.4 WBHO
Method Statements B.3.5 Foundation Preparation Method Statements
B.3.6 HDPE Geomembrane Installation Method Statements B.3.7
Grouting and Well Abandonment Method Statements B.3.8 Topsoil
Stockpile Location B.3.9 Quality Control Plan B.3.10 Field Office
Location B.4 Contractor Construction Schedule B.4.1 WBHO Tenke TSF
Rev 12 Dec 2007 Schedule B.4.2 WBHO Tenke TSF Rev 16 Apr 2008
Schedule B.4.3 WBHO Tenke TSF Rev 05 May 2008 Schedules B.4.4 WBHO
Tenke TSF Rev 03 Nov 2008 Schedule
C (Vol. 3) Field Documentation C.1 Site Instructions C.2
Selected Correspondence C.2.1 Correspondence C.2.2 Meeting Minutes
C.3 Construction Progress Reports C.3.1 Client Weekly Progress
Report C.3.2 TFM Mine Fleet Production Report
C.4 WBHO Final Punch List
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x TOC-vii
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * 303 291 2222
D (Vol. 4) Earthworks Quality Control Data
D.1 Clear and Grubbing D.2 Topsoil Removal D.3 Basin Subgrade
Preparation D.3.1 Summary of Test Results D.3.2 Test Location Map
D.3.3 Return Water Pond D.3.4 Tailing Storage Facility D.4
Embankment Foundation Preparation D.4.1 Summary of Test Results
D.4.2 Test Location Map D.4.3 North Embankment D.4.4 Return Water
Dam D.4.5 West Embankment
D (Vol. 5) D.5 Embankment Fill D.5.1 North Embankment D.5.1.1
Test Fill D.5.1.2 Test Results D.5.1.3 Zone 2 Test Results D.5.2
Return Water Dam D.5.2.1 Zone 1 Test Results D.5.2.2 Zone 2
Engineered Fill Test Results D.5.3 West Embankment D.5.3.1 Zone 1
Test Results D.5.3.2 Zone 2 Engineered Fill Test Results D.5.4 Zone
1A Rockfill Results D.6 Perimeter Road D.6.1 Return Water Pond
Perimeter Road D.6.2 North Road D.6.3 South Road D.7 Spillway
E (Vol. 6) Drainage Quality Control Data E.1 Drain and Gravel
Material E.1.1 Summary of Test Results E.1.2 Drain Gravel In-place
Density Test Results E.2 Underdrain Installation E.2.1 Pipe
Inventory E.2.2 Return Water Pond and Dam E.2.3 Tailing Storage
Facility and West Embankment E.2.4 North Embankment E.3 Temporary
Stormwater Drains E.3.1 Return Water Dam Stormwater E.3.1.1
Concrete Checklist E.3.1.2 Pipe Installation E.3.1.3 Pipe
Abandonment E.3.2 North Embankment E.3.2.1 Concrete Checklist
E.3.2.2 Pipe Installation
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x TOC-viii
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * 303 291 2222
F (Vol. 7) Geosynthetics F.1 Material Inventory F.2 Geotextile
Filter F.2.1 North Embankment F.2.2 Return Water Dam F.2.3 West
Embankment F.3 HDPE Geomembrane F.3.1 Not Used F.3.2 Not Used F.3.3
WBHO Quality Control Data
F.3.3.1 Return Water Pond F (Vol. 8) F.3.3.2 Tailing Storage
Facility F (Vol. 9) F.3.4 MWH Quality Assurance Data
F.3.4.1 Return Water Pond F.3.4.2 Tailing Storage Facility F.3.5
Laboratory Test Results F.3.5.1 Return Water Pond F.3.5.2 Tailing
Storage Facility F.3.6 Liner Leak Location Survey
G (Vol. 10) Well Abandonment
G.1 Well Locations G.1.1 Map and Coordinate Table G.1.2 Borehole
Completion Diagrams G.2 Abandonment G.2.1 Grouting Checklist G.2.2
MWH QA Report
H (Vol. 10) Rock Quarry H.1 Salabwe Rock Quarry H.1.1 Salabwe 2
and 4 Quarry Mine Plan H.1.2 Salabwe 5 Quarry Investigation H.2
Fwaulu Rock Quarry H.2.1 Original Mine Plan Memorandum H.2.2
Potential Pit Layout and Quantities Memorandum H.2.3 Drill Hole
Logs and Photos
I (Vol. 10) Survey Data
J (Vol. 11) Photographs J.1 2004 (Part 1) J.2 2005 (Part 1) J.3
2006 (Part 1) J.4 2007 (Part 1) J.5 2008 (Part 1 January through
May)
J (Vol. 12) J.5 2008 (Part 1 June through December) J (Vol. 13)
J.6 2009 (Part 1 and Part 2)
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x TOC-ix
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * 303 291 2222
PART 2 APPENDICES
K (Vol. 14) Submittals
L (Vol. 14) Field Documentation L.1 Meeting Notes and Engineered
Fill QC Report L.2 Construction Weekly Progress Reports
M (Vol. 14) Earthworks QC Data M.1 Site Preparation M.2 North
Embankment Fill Zone 1A Test Results M.3 North Embankment Fill Zone
2 Test Results M.4 North Embankment Fill Zone 2 Test Data M.5
Embankment Fill Soils lab Test Results
N (Vol. 14) Geosynthetics QC Data N.1 Geotextile Filter N.2 HDPE
Geomembrane Aquatan QC Data N.3 Geomembrane MWH QA Data
O (Vol. 15) TFM Final Survey
P (Vol. 15) MWH Calculation Check
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x TOC-x
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * 303 291 2222
LIST OF ACRONYMS ASTM American Society of Testing Materials CAT
CM
Caterpillar Equipment Company Construction Management
CQA Construction Quality Assurance CSI DRC
Construction Specification Institute Democratic Republic of
Congo
EPCM Engineering, Procurement and Construction Management
Contractor
FMI Freeport McMoRan Copper and Gold, Inc. Golder Golder
Associates Africa (Pty) Ltd. GRI HDPE
Geosynthetic Research Institute High-Density Polyethylene
HWL High Water Level ID LDPE
Identification Low-Density Polyethylene
mamsl Minproc
Meters above mean sea level GRD Minproc Ltd.
MWHA MWH Americas, Inc. MWH DRC MWH DRC, S.P.R.L. QA Quality
Assurance QC Quality Control RC Relative Compaction RCP Reinforced
Concrete PipeRQD Rock Quality Designation RWP Return Water Pond
SANS SDR SCS
South African National Standards Standard Dimension Ratio Soil
Conservation Service
TFM Tenke Fungurume Mining TSF Tailing Storage Facility TQ
Technical Queries USACE CRD USCS
United States Army Corps of Engineers Concrete Research Division
Unified Soil Classification System
WBHO Wilson Bayly Holmes-Ovcon Ltd
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 1
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
1.0 INTRODUCTION 1.1 GENERAL Tenke Fungurume Mining (TFM)
operates the Tenke Fungurume copper and cobalt mine in the Katanga
province of the Democratic Republic of Congo (DRC) in central
Africa. TFM is a company incorporated under the laws of the DRC for
the purpose of developing the deposits of copper, cobalt, and
associated minerals under a mining concession from the DRC Ministre
des Mines. TFM is a partnership of Freeport-McMoRan Copper &
Gold, Inc (FMI), the Lundin Mining Corporation, and the government
of the DRC through La Gnrale des Carrires et des Mines (Gcamines).
Currently, TFM is developing the mine site, which is located
approximately 180 km northwest of the provincial capital of
Lubumbashi and includes the towns of Tenke and Fungurume. The mine
site location is shown on Drawing 52018-0051-01-120-500. The
initial mine plan consists of mining and processing 100 million
tonnes of ore reserves with an average grade for copper and cobalt
of 2% and 0.3%, respectively. The Tenke Fungurume copper and cobalt
deposits are part of the central African copper belt and are found
near the surface in a series of hills within the mine concession.
TFM plans to mine and process ore from the Kwatebala, Goma, and
Kavifwafwaulu ore bodies over an initial 20-year period or more
using a conventional open pit mining method. Ore processing will
continue for a total mine life of 40 years or more. TFM began first
copper production from the Kwatebala hill ore in the first quarter
of 2009. The ore processing plant consists of a semi-autogenous
grinding (SAG) mill for producing a finely ground ore that will
undergo a solution extraction/electrowinning process to produce
electrolytic copper cathodes. A sulfuric acid plant provides
sulfuric acid and sulfur dioxide (SO2) for copper extraction and
cobalt recovery, respectively. The processing plant will also use
water, electricity, and raw materials such as lime, magnesium
hydroxide, and limestone to extract the metals from the ore and to
produce the final copper and cobalt products. The main wastes and
emissions from the processing plant are tailing and air emissions.
Tailing from the processing plant is deposited in a
geomembrane-lined tailing storage facility (TSF) supplemented by a
geomembrane-lined, return water pond (RWP). The TSF is a
cross-valley type repository that will be developed in several
stages to reduce the initial capital cost. The first (Phase 1)
state will have a capacity to provide tailing storage for
approximately one to one and a half years of mine production. The
second (Phase 2) stage will extend the life to about 5 years. The
TSF will need to be expanded and/or a new facility built to store
tailing for the remainder of the mine life. Construction of the TSF
and RWP began at the end of July 2007. The RWP and lower half of
the TSF, herein referred to as Phase 1, was completed and placed
into operation in the first quarter of 2009. Construction of the
remainder of the TSF (i.e., Phase 2) is scheduled to begin in
August 2009 with an anticipated completion date of September 2010.
This report provides the construction completion documentation for
the Phase 1 TSF and RWP project (project). The observations,
inspections, and testing performed during construction, as
described in this report, demonstrate that the TSF and RWP have
been constructed in accordance with the project drawings,
specifications, and design intent.
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 2
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
1.2 PURPOSE AND SCOPE OF WORK TFM retained MWH DRC S.P.R.L.
(MWH) to provide construction management and construction quality
assurance (CQA) services for the earthwork and liner construction
of the TSF and RWP. MWH mobilized a team consisting of a
combination of expatriates from MWHs global operations and local
DRC staff. The construction oversight team included both field and
home office engineering personnel who were familiar with the design
intent, specified materials, and construction techniques associated
with the geomembrane-lined TSF and RWP. The team worked closely
with TFMs on-site TSF construction management team throughout the
duration of construction. MWH was responsible for overseeing the
construction for compliance with the plans, specifications, and
approved design changes and for addressing technical issues that
were raised during construction. MWHs scope of work included CM,
CQA, construction progress monitoring, and reporting activities.
TFM was actively involved in the construction process and made
decisions that had an impact on the cost and schedule of
construction and other functions within the areas of responsibility
of the owner. TFM also self-performed some of the construction
activities. Table 1.1 provides the construction components of the
project that were MWHs responsibility and the components that were
the responsibility of other parties.
TABLE 1.1 BREAKDOWN OF CONSTRUCTION OVERSIGHT
RESPONSIBILITIES
MWH Other Parties
Year 2007 Design representation: MWH had a field engineer during
2007 who functioned as a design representative for the TSF and RWP.
Construction management and CQA were provided by GRD Minproc,
LTDC.
Mobilization of the earthwork and liner contractor TSF and RWP
clear and grub Approximately 13% of the spillway excavation
Approximately 80% of the North Embankment foundation excavation
West Fwaula and Salabwe rock quarry geotechnical
investigations
HDPE liner laydown area construction Stormwater runon management
facilities Plant site earthworks and process ponds
Year 2008 TSF and RWP clearing and grubbing Salabwe rock quarry
haul road construction TSF and RWP topsoil stripping Salabwe rock
quarry mine plan TSF and RWP basin contouring Salabwe and Fwaulu
rock quarry management Remainder of the North Embankment foundation
excavation
Tailing slurry pumping and distribution system installation
Return Water Dam foundation excavation TSF water reclaim barge
access ramp construction West Embankment foundation excavation TSF
water reclaim barge installation Fwaulu rock quarry mine plan
development Return Water Pond return water pump platform and
piping Zone 1 and 1A rockfill for the North Embankment, Return
Water Dam, and West Embankment
Process and construction water wells
Geotextile filter installation for the Return Water Dam1, North
and West Embankments.
Village relocation Mine waste and ore storage facilities
Zone 2 and 2A engineered fill for the North Embankment, Return
Water Dam1 and West Embankment.
Safety berms
North Embankment and Return Water Dam temporary storm drains
Perimeter road excavation
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 3
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
MWH Other Parties HDPE liner installation for the TSF and Return
Water Dam Groundwater monitoring well abandonment
Year 2009 Demobilization of the original earthworks and liner
contractor
North Embankment temporary storm drain abandonment
Mobilization of the HDPE liner installation contractor who
installed the North Embankment liner from elevation 1367 to 1380
m
Liner ballast installation2
Security facilities Commissioning
Notes: 1. The engineered fill (Zone 2) for the downstream side
of the Return Water Dam was completed to
an elevation of 1,380 m under MWHs oversight responsibility. 2.
MWH oversaw the initial liner ballast installation that occurred
during the 1st and 2nd Quarters of
2009. MWH was responsible for the general construction
management (CM) and CQA services for the project components that
were within MWHs scope of work. MWHs primary responsibility was for
those project components. MWHs duties included coordinating site
activities, administering the contracts for construction,
monitoring the contractors performance, cost/schedule control and
reporting results from site inspection to TFM, responding to design
and technical submittals, managing changes during construction, and
preparing a construction completion report. TFM provided cost and
schedule control for the self-perform construction activities
performed in 2009. 1.3 PROJECT DOCUMENTS The observations and
testing conducted during the construction period were performed
according to the following plans and specifications:
MWH, 2007. Tenke Fungurume Mine: Tailing Storage Facility and
Return Water Pond PACKAGE 1: Site Clearing, Grubbing, and
Stripping, Construction Drawings and Engineering Specifications
prepared for Tenke Fungurume Mining, June.
MWH, 2007b. Tenke Fungurume Mine: Tailing Storage Facility and
Return
Water Pond PACKAGE 2 Phase 1A: Foundation Preparation,
Embankment Construction and Liner Installation, Construction
Drawings and Engineering Specifications prepared for Tenke
Fungurume Mining, October.
MWH, 2007c. Tenke Fungurume Mine: Tailing Storage Facility and
Return
Water Pond PACKAGE 2 Phase 1B: Foundation Preparation,
Embankment Construction and Liner Installation, Construction
Drawings and Engineering Specifications prepared for Tenke
Fungurume Mining, October.
MWH, 2008. Tenke Fungurume Mine: Tailing Storage Facility and
Return Water Pond PACKAGE 2 Phase 2: Foundation Preparation,
Embankment Construction and Liner Installation, Construction
Drawings and Engineering Specifications prepared for Tenke
Fungurume Mining, January.
Other project-related and guidance documents referenced during
the project include:
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 4
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
Daniel, David E. and Koerner, Robert M, 1995. Quality Assurance
and Quality Control for Waste Containment Facilities, U.S.
Environmental Protection Agency Research and Development:
EPA/600/SR-93/182, September.
Golder Associates and MWH, 2008. Tenke Fungurume Mine Tailing
Storage
Facility and Return Water Pond Final Design, prepared for GRD
Minproc LTD, August.
Golder Associates, 2007. Environmental Impact Assessment Tenke
Fungurume Project, prepared for Tenke Fungurume Mining S.A.R.L
(TFM), March.
GRD Minproc LTD, 2007. Tenke Fungurume Feasibility Study Feb
2007
Technical Report, prepared for Tenke Mining Corp, April.
International Finance Corporation, 2007. Environmental, Health
and Safety Guidelines for Mining, December.
MWH, 2008a. Request for Re-Pricing for the Tenke Fungurume Mine
Tailing
Storage Facility and Return Water Pond Earthworks and Liner,
prepared for Freeport McMoRan Copper and Gold, Inc, March.
MWH, 2008b. Tenke Fungurume Mine: Tailing Storage Facility and
Return
Water Pond PACKAGE 1: Site Clearing, Grubbing, and Stripping,
Construction Drawings and Engineering Specifications, March.
1.4 DISCLAIMER This document contains the expression of the
professional opinion of MWH as to the matters set out herein, using
its professional judgment and reasonable care. It is to be read in
the context of the agreement (the Agreement) dated June 19, 2008,
between TFM (the Client) and MWH (the Consultant), and the
methodology, procedures, and testing techniques used, the
Consultants assumptions, the circumstances, and constraints under
which its mandate was performed. This document is meant to be read
as a whole, and sections or parts thereof should thus not be read
or relied upon out of context. MWH has, in preparing the
as-constructed information, followed methodology and procedures,
and exercised due care consistent with the intended level of
accuracy, using its professional judgment and reasonable care.
Unless expressly stated otherwise, assumptions, data, and
information supplied by or gathered from other sources (including
the Client, other consultants, contractors, testing laboratories,
and equipment suppliers, etc.) upon which the Consultants opinion
as set out herein is based has not been verified by the Consultant;
the Consultant makes no representation as to its accuracy and
disclaims all liability with respect thereto. MWH has, in preparing
the record of construction drawings, relied on the survey
information from others. Surveying was outside of MWHs scope of
work and, therefore, this information was produced by others. Since
MWH was not responsible for development of the surveys and has no
way to verify their accuracy, MWH assumes no responsibility or
liability for the surveys or their accuracy. It is recommended that
the accuracy of these surveys be confirmed if used in future design
work or construction.
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 5
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
MWH disclaims any liability to any third party with respect to
any reliance on this document by any third party without the prior
written consent of MWH. Although MWH prepared a design for Phase 2
of the TSF, FMI retained Golder of Lakewood, Colorado, to redesign
the Phase 2 portion and to oversee its construction. MWH has had no
involvement with the Phase 2 redesign and assumes no responsibility
for its construction, performance, or impacts to performance of
Phase 1 of the project that are impacted by Phase 2 design and
construction. 1.5 REPORT ORGANIZATION
This construction completion report provides the documentation
of the construction activities overseen by MWH for the TSF and RWP
Phase 1 construction. On-site activities began in 2007 under
oversight by GRD Minproc LTD (GRD Minproc); however, little
construction progress was made until the beginning of 2008. The
majority of the Phase 1 construction was performed by a single
earthworks and liner installation contractor, WBHO, in 2008
although TFM performed portions of the construction in 2008,
including managing the rock quarries, drilling, and blasting rock
in the quarries, hauling a portion of the rockfill, stripping of a
portion of the Phase 1 TSF footprint, and grouting to abandon the
storm drain pipe through the Return Water Dam. TFM completed the
remaining earthwork for Phase 1 with its own forces during the
first half of 2009, including grouting to abandon the North
Embankment temporary storm drain and completing the North
Embankment from elevation 1,367 mamsl to approximate elevation
1,380 mamsl. Part 1 of this report describes the construction
activities performed by the earthworks and liner installation
contractor, which occurred during 2007 through January 2009. Part 2
of the report describes the construction activities performed by
TFM from February to June 2009, including abandoning the temporary
stormwater drain. This report is divided into 15 volumes. Volume 1
contains the text and record drawings, Volumes 2 through 13 contain
the appendices associated with Part 1 of the construction
completion, and Volumes 14 through 15 contain the appendices for
Part 2 of the construction completion. Volume 2 contains design
changes and submittals (as Appendices A through B). Volume 3
contains field documentation, including site correspondence, and
construction progress reports (as Appendix C). Volumes 4 through 6
contain the completed construction documentation and quality
control data for earthworks, drainage material placement, and liner
placement (as Appendices D and E). Volumes 7 through 9 contain
geosynthetic quality control and quality assurance data (as
Appendix F). Volumes 10 through 13 contain information on well
abandonment, rock quarry, survey data, and photographs (as
Appendices G through J). Volume 14 contains information on the
North Embankment temporary storm drain abandonment and information
on the design changes, submittals and field documentation for Part
2 of the report (as Appendices K through M). Volume 15 contains the
completed construction documentation and quality control data for
the earthworks and liner placement and the survey data for Part 2
(as Appendices O through Q).
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 6
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
2.0 PROJECT OVERVIEW 2.1 GENERAL Construction of the Phase 1 TSF
and RWP began at the end of July 2007 and was completed in June
2009. Prior to the Phase 1 final completion, the TSF and RWP were
placed into operation by TFM in March 2009. TFM completed the
remainder of the Phase 1 work during the beginning of the
operation. Construction and operation of the TSF was divided into
Phase 1 and Phase 2. Phase 1 refers to the lower portion of the TSF
up to a perimeter crest elevation of approximately 1,380 mamsl with
some areas slightly higher in order to accommodate the required
grades of the roadway and tailing discharge pipeline. Phase 1
construction included the entire RWP except for a small portion of
the Return Water Dam, which will be completed during Phase 2
construction. Phase 2 refers to the upper portion of the TSF
finished to a perimeter crest elevation of approximately 1,396
mamsl. Although MWH prepared a design for Phase 2 of the project,
FMI retained Golder to redesign the Phase 2 portion of the TSF and
to oversee its construction. Phasing construction was necessary due
to the short construction season from May to September (i.e., dry
season) and the requirement to have the TSF and RWP operational by
the first quarter of 2009. The majority of the average annual
rainfall (1,137 mm) occurrs between October and April (i.e., rainy
season), limiting the work to placement of rockfill for the
embankments. Construction of the weather-sensitive components such
as the engineered fill and geomembrane were restricted to the dry
season. TFM retained a South African heavy civil contractor, WBHO
Construction (Pty) Ltd (WBHO), to perform the majority of the
construction. TFM performed the drilling and blasting for
developing the rock quarries and self-performed some of the work
later in the project. In December 2008, TFM notified WBHO that the
start of Phase 2 would be deferred due to the depressed global
economic conditions at that time. Subsequently, WBHO demobilized
from the project at the end of January 2009 and TFM terminated
their contract with WBHO shortly thereafter. Although the TSF and
RWP were substantially complete, the temporary stormwater drain
abandonment and a small portion of the North Embankment were items
left to complete the Phase 1 construction. In February 2009, TFM
abandoned the temporary stormwater drain and started construction
of the remainder of the Phase 1 North Embankment. TFM completed the
North Embankment to the Phase 1 crest height of approximately 1,380
mamsl in June 2009. The portion of the TSF below elevation 1,367
mamsl constructed by WBHO was commissioned in March 2009 with the
first tailing deposition on March 20, 2009. GRD Minproc managed the
TSF and RWP construction in 2007 and in the beginning of 2008. TFM
had retained GRD Minproc to provide engineering, procurement,
construction, and management (EPCM) services for building the mine
infrastructure that included the processing plant, roads, main
electric transmission lines, TSF, RWP, and logistic support during
construction. At the end of February 2008, TFM formally transferred
the construction management of the TSF and RWP to MWH, leaving some
smaller components of the TSF and RWP in GRDs EPCM scope, such as
the tailing delivery and distribution and water reclaim pumping and
piping systems.
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 7
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
The following sections provide a description of each key project
component built during the Phase 1 construction. A summary of the
design modifications made during construction, a description of the
construction sequence, and the organization and responsibilities of
the project team, are described in subsequent sections. 2.2 PROJECT
COMPONENTS The primary TSF and RWP components that were constructed
for Phase 1 include:
Zoned rock-fill embankments varying in height from approximately
30 m to approximately 12 m
Basin contouring Underliner drain Embankment drain High density
polyethylene (HDPE) geomembrane liner Perimeter roads Temporary
storm drains Stormwater diversion Spillway
The North Embankment is the largest of the embankments followed
by the Return Water Dam and West Embankment. The Return Water Dam
is located to the east of the TSF and separates the RWP from the
TSF. The West Embankment is located to the west of the TSF. The
spillway is located just northwest of the West Embankment outside
the TSF to divert stormwater runoff from the west drainage basin
around the TSF and RWP. The TSF and RWP basins were contoured and
the subgrade was compacted to a depth of 300 mm to provide a smooth
and firm foundation for the installation of a 1.5-mm-thick HDPE
geomembrane. An underdrain system was installed to drain
groundwater and reduce hydrostatic uplift pressures on the
geomembrane liner. An access road is located on the perimeter of
the TSF at an elevation of approximately 1,380 mamsl and at the
perimeter road of the RWP at an elevation of approximately 1,396
mamsl. Temporary storm drains were installed in the Return Water
Dam and North Embankment to help manage stormwater and protect the
facilities during construction. These drains were instrumental in
allowing construction activities to continue into the early part of
the wet season months. The Return Water Dam and North Embankment
temporary stormwater drains were abandoned on December 19, 2008,
and March 3, 2009, respectively. Stormwater diversion channels and
small embankments were also constructed to divert stormwater and
provide erosion control during and after construction. The spillway
is a large, valley-shaped excavation through an existing
topographic knob. It ranges up to approximately 34 m below the
existing ground surface at its deepest point. The spillway has
1H:1V (horizontal to vertical) side slopes in areas with rock and
2H:1V in soil areas. It is approximately 3 m wide at its base. Part
1 of the record of construction drawings shows the Phase 1
components constructed primarily by WBHO. Part 2 of the record of
construction drawings shows the remaining portion of the North
Embankment completed by TFM and North Embankment temporary storm
drain abandonment which was also performed by TFM. The general
arrangement of the TSF and RWP is shown on Drawing
52018-0051-01-120-502.
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 8
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
2.3 DESIGN MODIFICATIONS A number of design modifications were
implemented during construction. Design changes were either
initiated in the field by the owner or as a result of discussions
with the contractor. The design modification process included:
Technical review by the designer Schedule and cost implications
review by the construction manager and owner Technical
justification Designer and owner approval Submittal to the
contractor for execution
Table 2.1 provides a summary of the design modifications.
TABLE 2.1 SUMMARY OF DESIGN MODIFICATIONS
Design Revision
WBHO Change Order #
Date Implemented
1 Return Water Dam Temporary Stormwater Drain 1 8-Aug-08 2
Spillway Diversion Fill 2 5-Sep-08 3 North Embankment Modifications
3 10-Sep-08 4 Liner Ballast 4 25-Nov-08 5 North Embankment
Temporary Storm Drain Outlet Extension 5 29-Oct-08 6 West
Embankment Alteration and Spillway Diversion Fill Modification 6
9-Dec-08 7 Well Abandonment 7 12-Dec-08 8 Embankment
Instrumentation 8 15-Dec-08 9 Geotextile Specification Design
Change N/A 8-Apr-08
10 Filter Construction Method N/A 1-Jul-08 Note: To the
knowledge of MWH, the change orders were not executed, although the
work was performed. Finalization of the change orders during close
out of WBHOs contract between FMI and WBHO may have occurred, but
MWH was not informed of this.
A copy of each change order is included in Appendix A. A typical
change order package included a technical justification memo and
drawings relevant to the change. Design modification number 5 was
not implemented since a decision was made by FMI in November 2008
to suspend rockfill placement at the North Embankment in early
2009. Design modification number 10 required only a designer and
owner approval since it had been already included in the Drawings
as an optional method of constructing the embankment filter.
Drawing 52018-0051-01-120-915 shows details of two embankment
filter layer construction options. Option 1 allows the use of a
geotextile filter fabric. Option 2 allows the use of a graded
gravel filter. MWH recommended using the geotextile filter fabric
(option 1) based on the results of the engineered fill properties
determined during the geotechnical investigation.
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 9
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
2.4 SEQUENCE OF CONSTRUCTION TSF and RWP project activities
started with WBHO clearing and grubbing the RWP area at the end of
July 2007. Activities continued with excavating the North
Embankment foundation and a portion of the spillway. Work continued
until wet weather conditions in October prohibited work from
continuing. At the beginning of the 2008 dry season, WBHO resumed
activities with peak construction occurring during the middle of
the year. Phase 1 of the TSF and RWP was substantially complete by
the beginning of the 2008/2009 wet season. The RWP and the portion
of the TSF below elevation 1,367 mamsl were ready for operation by
the end of February of 2009. In addition to drill and blasting
services and quarry management, TFM performed parts of WBHOs work
scope to maintain the project schedule until additional WBHO
equipment could be mobilized to the site. TFMs activities
included:
Topsoil stripping and stockpiling from the west end of the TSF
to the central portion
Constructing the Fwaulu haul road from the rock quarry to the
TSF and RWP
Hauling Zone 1 rockfill from the Fwaulu rock quarry to the
Return Water Dam, North Embankment and West Embankment
Grouting to abandon the storm drain pipe through the Return
Water Dam TFM performed the activities in conjunction with the WBHO
team, working side by side in some areas. Surveying and
construction quality control remained WBHOs responsibility for all
work performed by TFM. The sequence of work is described herein as
two parts. Part 1 is work mainly completed by WBHO between 2007 to
the end of January 2009. Part 2 is the completion of the North
Embankment by TFM after WBHO had demobilized from the project. In
general, the sequence for Part 1 construction activities consisted
of:
1. Procurement and contractor mobilization 2. Site preparation,
clearing and grubbing, and stripping 3. Embankment and dam
construction 4. Basin contouring and subgrade preparation for the
HDPE geomembrane liner 5. Temporary stormwater drain installation
and abandonment 6. Basin and perimeter road construction 7. HDPE
liner installation 8. Spillway excavation
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 10
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
The general sequence for Part 2 construction activities
consisted of:
1. North Embankment temporary storm drain abandonment 2. Zone 1A
and geotextile filter material placement on the North Embankment
from
elevation 1,367 to the crest of the rockfill at approximately
elevation 1,378 mamsl
3. Engineered fill placement in Zone 2 of the North Embankment
from elevation 1,367 mamsl to approximately elevation 1,380
mamsl
4. HDPE geomembrane installation on the North Embankment from
elevation 1,367
mamsl to approximately elevation 1,380 mamsl Since WBHO had
forces already on site for the plant site bulk earthworks,
mobilization for the TSF consisted of adding more earth moving
equipment and personnel to their existing force. TFM purchased the
HDPE geomembrane and manufactured the Zone 1A and Zone 4 gravel for
the project. Geotextile, piping, and other materials required by
the project were furnished by WBHO. Materials delivered to the site
were unloaded and stored in the HDPE liner lay-down area that WBHO
constructed early in the project. Prior to disturbing ground, the
area was surveyed by the TFM social and environmental department to
identify rare species of plants that would require relocation and
appropriation of land in accordance with the TFM social and
environmental policies for the project. After receiving a social
clearance, site preparation for an area would begin with harvesting
timber, clearing and grubbing, and topsoil removal. WBHO first
began site preparation activities at the North Embankment footprint
and spillway excavation area consisting of clearing and grubbing
and stockpiling topsoil. WBHO also cleared and grubbed the RWP area
in 2007, which had to be repeated in 2008 due to the vegetation
re-growth during the wet season. Timber was harvested by TFM labor
crews and used for beneficial use by the communities. Late in 2007,
WBHO demobilized a portion of its force due to the delay by GRD
Minproc and TFM in determining a rock quarry source. In December
2007, TFM selected the Salabwe quarry for the source of Zone 1
rockfill material. WBHO began constructing the 5-km-long Salabwe
haul road shortly thereafter. The haul road construction required
approximately 4 months to complete due to wet weather delays. The
North Embankment and Return Water Dam are the largest of the Phase
1 structures and required the largest quantity of construction
materials. Construction began at the North Embankment, followed by
the Return Water Dam and the West Embankment, which was the last of
the three structures to be completed. The general sequence of
construction for each embankment and the Return Water Dam was:
1. Foundation excavation 2. Embankment drain installation 3.
Zone 1 rockfill placement 4. Zone 1A embankment gravel
placement
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 11
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
5. Zone 1A filter geotextile installation 6. Zone 2 and 2A
engineered fill placement 7. HDPE geomembrane installation
TFM began drill and blasting operations at the Salabwe quarry in
late February 2009. After almost two months of quarry development,
the first load of Zone 1 rockfill was hauled to the North
Embankment prepared foundation on April 26, 2009. Due to the large
volume of unusable Zone 1 rockfill at the Salabwe quarry, TFM
decided to develop the Fwaulu rock quarry as another source of Zone
1 rockfill. The Fwaulu rock quarry proved to be a significantly
better source for Zone 1 rockfill, reducing the initial waste to
usable rock ratio from 3:1 to 0.8:1 by the end of the project. Rock
became available from the Fwaulu rock quarry the last week of July
approximately 4 months after starting development of the Salabwe
rock quarry. TFM crews began hauling Zone 1 rockfill from the
Fwaulu rock quarry during the week of July 28, 2008, to the Return
Water Dam foundation. In October WBHO moved its Salabwe quarry
crews to the Fwaulu quarry along with the TFM crews due to more
efficient production of rockfill and closer haul distance to the
TSF. After the level of the rockfill in the North Embankment and
Return Water Dam reached the required elevation, the drains were
installed, which connected to the underliner drains in the TSF and
RWP basins. Zone 1 rockfill placement continued at the North
Embankment and Return Water Dam concurrently. The Zone 1 rockfill
reached the Phase 1 design crest elevation for the Return Water Dam
in the last week of September, followed two months later with the
West Embankment and, lastly, the North Embankment reaching its
rockfill crest elevation in the middle of December. Zone 1A
embankment backfill gravel, filter geotextile installation, and
Zone 2 engineered fill were constructed concurrently. The Zone 1A
gravel was placed over the Zone 1 rockfill followed by the
geotextile filter fabric, extending 3 to 5 m above the working
elevation of the Zone 2 engineered fill. The Zone 2 engineered fill
was completed at the North Embankment in the first week of October
to an elevation of 1,367 mamsl, followed a month later by
completing the engineered fill at the Return Water Dam engineered
fill to an elevation of 1,386 mamsl and, lastly, at the West
Embankment to a crest elevation of 1,380 mamsl completed in late
December 2008. Zone 2A consisted of hand picking out oversized
materials from the surface and smooth drum rolling and hand raking
the surface in preparation for the HDPE liner installation. The
general sequence of the Part 2 construction activities consisted of
abandoning the temporary storm water drain and completing the
remainder of the North Embankment components from elevation 1,367
mamsl to 1,380 mamsl consisting of:
1. Installing Zone 1A gravel 2. Installing Zone 1A filter
geotextile 3. Placing Zone 2 engineered fill 4. Installing the
geomembrane liner
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 12
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
Table 2.2 summarizes the general sequence of the work by quarter
for each project component.
TABLE 2.2 SEQUENCE OF WORK SUMMARY
Project
Component Construction Activity1 Performed By
Year 2007 2nd Quarter2
Procurement and mobilization
Purchase HDPE geomembrane for the Phase 1 TSF and RWP from
Aquatan Tanks (Pty) Ltd. and ship to the site
GRD Minproc
Construction capital cost estimating using feasibility study
design
GRD Minproc, Golder, and WBHO
Begin mobilizing equipment and personnel for TSF and RWP
construction
WBHO
Prepare HDPE liner laydown area WBHO Year 2007 3rd Quarter2
Spillway Begin excavation WBHO North Embankment
Begin foundation excavation WBHO
RWP Clearing and grubbing Return Water Pond WBHO Year 2007 4th
Quarter2 (Wet Season)
Spillway Continue excavation WBHO Year 2008 1st Quarter2 (Wet
Season)
Salabwe rock quarry haul road
Begin Salabwe haul road construction WBHO
Year 2008 2nd Quarter North Embankment
Continue foundation excavation WBHO Begin to haul and place Zone
1 rockfill from the Salabwe quarry
WBHO
Return Water Dam
Begin foundation excavation WBHO Return Water Dam foundation
excavation WBHO
Underliner drain Begin to produce Zone 4 gravel for underliner
drain TFM Perimeter road Begin the RWP perimeter road construction
WBHO HDPE liner Begin installing the liner in the RWP WBHO
Year 2008 3rd Quarter North Embankment
Continue the foundation excavation WBHO Continue hauling and
placing Zone 1 rockfill from the Salabwe quarry and begin hauling
Zone 2 rockfill from the Fwaulu quarry
WBHO and TFM
Install the temporary stormwater drain WBHO Begin construction
of the Zone 2 engineered fill WBHO
Return Water Dam
Continue excavating the foundation WBHO Begin hauling and
placing Zone 1 rockfill from the Fwaulu quarry
WBHO and TFM
Install the temporary stormwater drain WBHO Underliner drain
Begin installing the underliner drain at the RWP and TSF WBHO
Perimeter road Continue the RWP perimeter road construction and
start the
TSF perimeter road construction WBHO
HDPE liner Continue installing liner in the RWP and begin
installation in the TSF
WBHO
Spillway Resumed excavation activities WBHO Year 2008 4th
Quarter
North Embankment
Complete placing Zone 1 rockfill from the Fwaulu quarry WBHO and
TFM
Complete the temporary storm drain WBHO Complete the
construction of the Zone 2 engineered fill and geomembrane to
elevation 1,367 m
WBHO
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
Construction Report x 13
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
Project Component Construction Activity1
Performed By
Return Water Dam
Complete hauling and placing Zone 1 rockfill from the Fwaulu
quarry
WBHO and TFM
Complete the Zone 2 engineered fill WBHO Underliner drain
Complete the underliner drain WBHO Perimeter road Complete the RWP
and TSF perimeter roads WBHO HDPE liner Complete the deployment of
the liner for the RWP and TSF WBHO
Year 2009 1st Quarter Demobilization WBHO demobilizes from the
TSF project WBHO North Embankment
Abandon the temporary storm drain TFM
HDPE Liner Complete the liner detail work WBHO Spillway Complete
excavation of the spillway TFM RWP Abandon temporary storm water
drain WBHO TSF and RWP Abandon wells WBHO
Year 2009 2nd Quarter TSF and RWP Commissioning TFM North
Embankment
Complete engineered fill and geomembrane from elevation 1367
mamsl to 1380 mamsl
TFM
Notes: 1. Only key construction activities are listed 2.
Calendar quarters
WBHO had provided TFM with construction pricing in April of 2007
based on a conceptual design prepared for the TSF Feasibility
Study. Later in 2008, WBHO re-priced the project based on the
detailed design and construction specification packages and
re-pricing package prepared by MWH listed in Section 1.3 Project
Documents. The majority of the construction was performed under the
re-pricing agreement. The small portion of work performed in 2007
and the Salabwe haul road construction in 2008 was performed under
the 2007 agreement for plant site earthworks administered by GRD
Minproc. 2.5 PART 1: CONTRACTING APPROACH ORGANIZATION This section
describes the project roles and responsibilities by the owner,
EPCM, designer, and contractor for the Part 1 work using a
contracting approach for work completed between 2007 to the end of
January 2009. Changes in the roles and responsibilities of the
parties occurred two times during the project. The first change
occurred when MWH assumed the role of construction manager at the
beginning of 2008. The second change occurred when TFM terminated
their contract with WBHO because of TFMs decision to defer Phase 2
of the TSF and RWP construction. During this time, TFM also made
the decision to self-perform the bulk earthworks to complete Phase
1 construction of the project and take on the responsibility to
manage the remainder of the Phase 1 construction. MWH provided only
QA services for the final month of Phase 1 construction in 2009.
Table 2.3 summarizes the project roles and responsibilities by the
owner, EPCM, designer, and contractor during the construction phase
of the project.
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MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
TABLE 2.3 PROJECT ROLES AND RESPONSIBILITIES FOR
TSF AND RWP PROJECT
Part
Time Period
Party Role Responsibility
Part 1 C
onstruction Com
pletion
July 2007 through January 2009
TFM Owner Define responsibilities of the other parties
Final approval of contractors Supply owner-furnished materials
and
supplies Site-wide health and safety Site-wide environmental
monitoring Social and environmental surveys of
work areas Tree harvesting Payment to other parties
GRD Minproc
EPCM Detailed design and CM of tailing distribution and water
reclaim system
Project planning Procurement Contract administration Project
health and safety Schedule and cost control Construction quality
assurance Logistics
MWH and Golder
Designer Detailed design of TSF and RWP (civil and
earthworks)
Construction drawings and specifications for the TSF and RWP
(civil and earthworks )
WBHO Contractor Work execution Surveying Construction quality
control Managing subcontractors
March 2008 through January 2009
TFM Owner Same as above including: TSF project specific on-site
owners
representative during construction Quarry management Allocation
of contractors resources
between the TSF and other projects Supplementing contractor for
topsoil
removal and Zone 1 rockfill hauling GRD Minproc
EPCM Detailed design and CM of tailing distribution and water
reclaim system
Procurement Project health and safety Logistics
MWH and Golder
Designer Same as above
MWH CM and CQA
Project planning Contract administration Schedule and cost
control Construction quality assurance
WBHO Contractor Earthworks and liner installation Surveying
Construction quality control Managing subcontractors
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MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
Part
Time Period
Party Role Responsibility
Part 2 C
onstruction Com
pletion
February 2009 through June 2009
TFM Owner Same as above, plus: Project planning Self perform
earthworks and North
Embankment temporary storm drain abandonment
Contract administration Schedule and cost control Construction
quality control for
earthworks and liner Surveying
GRD Minproc
EPCM Detailed design and CM of tailing distribution and water
reclaim system
Procurement Project health and safety Logistics
MWH and Golder
Designer Same as above
MWH CQA Construction quality assurance Aquatan Contractor Liner
installation (under contract to
TFM) Liner construction quality control
(under contract to TFM) Notes:
1. WBHOs work performed in March 2008 was based on the plant
site earthworks contract unit rates and was a transition month from
GRD Minproc to MWH for providing CM and CQA services.
2. WBHOs work performed in April 2008 was based on the plant
site earthworks schedule of values and the work scope in the 2008
re-pricing agreement.
3. WBHOs work in May 2008 was based on the schedule of values
and scope of work in 2008 re-pricing agreement.
4. WBHOs payment certificate 13 for work performed in April 2008
was prepared using the plant site agreement unit rates. The
previous payment was set to $0.00 to avoid duplication of payment
for items in both the old and new agreements.
2.5.1 Owner In 2008, the owner assigned Mr. David Barraza to
oversee all work on the TSF as a representative of the owner. Mr.
Barraza became involved with the project in April 2008 and had a
full-time presence on the project site thereafter. He monitored the
work in the field on a daily basis and acted as a liaison between
the contractor and the owner. Mr. Barraza worked closely with MWH
on CM topics and with MWHs QA personnel to review daily QA reports
and observe construction in the field. Mr. Barraza prepared monthly
presentations, reviewed pay requests from WBHO and MWH, and
conveyed instructions and directives from TFM to the project team.
He also conducted progress meetings with the contractor and QA
personnel weekly or as needed. The owner also had several other
representatives on site who supported the project. Table 2.4
provides a list of the Owners team and their role:
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
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MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
TABLE 2.4 OWNERS PERSONNEL AND ROLES
Name Role
Tamara Johndrow FMI Manager Tailings and Water Resources
Chris Schmitz TFM Mine Manager and TSF Project Sponsor
Dave Ogonowski FMI Construction Project Director Bill Cravens
FMI Senior Construction Manager Lello Galassi Senior Project
Manager David Barazza FMI TSF Superintendent Lee Passmore FMI
Quarry & Construction Superintendent Tom Weiskoph TFM
Environmental Manager Wolfram Shuh TFM Manager of Geological
Services Luis Beaza FMI Project Health and Safety Manager Mike
Brewer TFM Procurement and Logistics Manager
The owner was responsible for managing the quarries, including
drilling and blasting to develop the quarries. The owner also had
representatives that oversaw site vehicles, fuel supplies, water
supplies, safety, security, equipment commissioning, labor
relations, and overall construction of the facility. As
construction of the TSF and the main processing plant were
underway, the owner was developing the mine, stockpiling raw
materials, and developing a permanent village for full-time,
long-term operations personnel. Beginning in 2008, TFM would
convene a meeting each day to summarize overall progress on the
project and to discuss any quality or safety issues that needed to
be addressed. MWH QA personnel attended the meeting each day and
reported progress made on construction of the TSF. Any instructions
or directives from the owner were communicated to the MWH project
team and the contractor on a daily basis. The progress meeting was
convened six days a week. MWH also attended special training and
safety classes as needed to comply with the owners requirements.
2.5.2 EPCM GRD Minproc was the EPCM for the Tenke Fungurume Mine
project. They were responsible for managing the logistics on the
project, including safety, health care, lodging, meals, and
security for all workers. The EPCM procured materials and equipment
used for construction at the site, managed the subcontractors and
day to day work products, and transportation and QA for the
constructed work in the main plant area. The EPCM also managed WBHO
at the beginning of the TSF and RWP project (i.e., through February
2008) and was responsible for procuring the HDPE geomembrane and
manufacturing the gravels needed for construction the TSF and RWP
facilities.
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
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MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
2.5.3 Designer The design of the TSF and RWP project was
completed jointly by Golder and by MWH. The design was completed in
multiple design packages to allow the contractor to begin work at
the site in 2007 prior to the rainy season, to work through the
2007/2008 rainy season, and then continue as weather improved
during the dry season. The TSF design was submitted on time with
construction specifications in English, and the specifications
followed the United States Construction Standards Institute (CSI)
format. The design incorporated standards from United States and
worldwide organizations, including the American Society for Testing
and Materials (ASTM International), South African National
Standards (SANS), and The US Army Corps of Engineers Concrete
Research Division (CRD). The Golder/MWH design included field work
to find source areas for the rockfill used in the embankments. The
quarry locations and mine plans for the Salabwe and Fwaulu quarries
were developed by Golder and MWH, respectively. MWH prepared the
construction level drawings and specifications. MWH performed
on-site design oversight services during the initial part of the
TSF and RWP construction with an expanded role to provide
construction management and CQA beginning in early 2008. A summary
of the design team, as well as a brief description of the role of
each project position, is shown in Table 2.5:
TABLE 2.5 DESIGNERS PERSONNEL AND ROLES
Firm. Name Role
MW
H
James Obermeyer Client Service Manager and Engineer of
Record
Tatyana Alexieva Design Manager
Keith Johnson Lead Designer
Josh Rogers Project Engineer
Staff Discipline Staff Engineers
Golder
Dave Walker Principal
Staff Discipline Staff Engineers
2.5.4 Construction Manager MWH provided construction management
and CQA services beginning in March 2008 through January 2009
utilizing a defined project team approach under the direction of a
client service manager and principal-in-charge. Prior to March, MWH
provided a design representative in the field. The EPCM provided
construction management and quality assurance services. The
construction manager was the on-site senior representative for MWH
and was primarily responsible for all field engineering activities
and for verifying that the construction activities were performed
in accordance with the design intent and contract documents. The
construction managers responsibilities included:
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MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
Oversight of construction activities Overall management of MWH
field personnel Review and reply to contractor submittals and
technical queries Attendance at construction meetings Participation
in final inspection and acceptance of the work Promotion of safety
awareness and daily direction so that MWHs personnel could
conduct work according to safety standards. MWHs home office
located in Denver, Colorado, USA, provided engineering support to
the field team in answering technical RFIs and provided guidance
and input on the design intent and design clarifications. A summary
of the MWH project team, as well as a brief description of the role
of each project position, is shown in Table 2.6:
TABLE 2.6 CONSTRUCTION MANAGERS PERSONNEL AND ROLES
Base Name Role
Office
James Obermeyer Client Service Manager and
Principal-in-Charge
Tatyana Alexieva Design Manager Phillip Crouse Construction
Project Manager Keith Johnson Contract Administrator Rick
Shassetz
Director of Environmental Health and Safety
Field
Pedro Rodriques Construction Manager Robert Pocano QA Manager
Eric Lundborg/Will Hatrick QA Supervisor Atanas Atanasov QA
Supervisor Patrick Beya Dibwe QA Inspector Fernando Torres QA
Inspector Herve Kitambo QA Inspector Fred Kabin Dampande QA
Inspector Philamon Onyango Liner QA Supervisor Stephen Onyango
Liner QA Inspector David Ogada Liner QA Inspector Louvin Baruani
Liner QA Inspector Solange Matuga Field Administrator
The construction project manager spent over half of his time at
the site especially at the beginning of MWHs role as the
construction manager. The engineer of record visited the site
frequently to review the work. Both the construction project
manager and construction manager were intimately involved with
day-to-day operations and all field changes for the work up to the
end of 2008.
2.5.5 Contractor
WBHO was the prime contractor that performed the Part 1
construction activities as described as in this report between 2007
to the end of January 2009. TFM used a self-perform approach to
complete the Part 2 activities.
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Construction Report x 19
MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
WBHO constructed roads, embankments, grading, and the majority
of the bulk earthworks associated with the TSF and RWP. WBHO also
procured and installed the geotextile, underdrain piping and
installed the HDPE geomembrane with its own crews. Construction QC
and surveying was also performed by WBHO. WBHOs staff included
on-site managers, laboratory technicians, QC personnel, surveying
team, equipment operator trainer, and key heavy equipment
operators. Laborers were hired mainly from the surrounding
communities. The on-site management team included a full-time
project manager, site agents, production manager, quality control
manager, surveying manager, health and safety manager, equipment
manager, and quantity surveyor. Each site agent was responsible for
a specific area such as processing plant site bulk earthworks,
processing plant concrete, and TSF/RWP area. The production manager
was responsible for tracking construction progress and acted as the
crew leader. Other than the site agents, the management team
members spread their time between all the project areas. The
off-site team included division managers and corporate managers for
quality and safety and an off-site scheduler. The off-site team
also included a corporate equipment manager and other construction
support staff as needed. The QC department included a team of
supervisors that oversaw geomembrane quality control testing,
on-site laboratory testing, and earthwork quality control testing.
A copy of WBHOs project organization is presented in Appendix
B.3.1. Table 2.7 provides the contractors key personnel and
roles.
TABLE 2.7PART 1: CONTRACTORS SUPERVISORY PERSONNEL AND ROLES
Base Name Role
Office
Mike Sprott Commercial Director
Mike Adams Contract Director
Arno Boshoff Group Quality Manager
Nick Steenkamp Quantity Surveyor
Field
Dave Birnie Project Manager
Bundu Sparks Production Manager
Givemore Simende TSF Site Agent
Dragan Bibic Survey Manager
Herath Gunawardena Quality Manager
Christian Martey Liner Quality Supervisor
Tinase Manyiwa Laboratory Manager
Tshepo Toho Site Administration
The commercial director, contract director, and the quality
surveyor visited the site approximately once a month. The quality
manager and other corporate management staff visited the site
periodically. The quality surveyor was responsible for preparing
the invoice certificate using the monthly survey measurements of
the pay item quantities. WBHOs management team interacted closely
with the construction management team and owner representative.
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August 2009 Tenke Fungurume Mine TSF and RWP Phase 1
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MWH * 1801 California Street, Suite 2900 * Denver, Colorado
80202 * (303) 291-2222
2.6 PART 2: SELF-PERFORM APPROACH ORGANIZATION 2.6.1 Owner,
Construction Manager, and Contractor TFM self-performed the Part 2
construction activities as described in this report from February
2009 to the end of June 2009. Their role and responsibilities
included that of an owner, construction manager, and contractor.
The TFM mine operations department took the responsibility to
provide construction management and to self perform the bulk
earthworks including installation of the Zone 1A embankment
backfill gravel, and embankment filter for completing the remainder
of the North Embankment. TFM retained specialty contractors for the
geomembrane installation and construction quality control services.
For the self-perform approach, the TFM personnel involved in the
project remained the same as during the Part 1 activities. However,
key individuals from the owners team took a more active role in
managing the day-to-day construction. Table