a p p e n d i x 1.5 143022-01-ga-001 - area 01 – site...

A P P E N D I X 1.5

143022-01-GA-001 - AREA 01 – SITE LAYOUT

A P P E N D I X 1.6

ARUP - TECHNICAL NOTE TN-P2-CS-002 REV A/JUNE 2014

Technical Note

Subject YPL - Wilton Portal Construction Activities Date 27 August 2014 Job No/Ref

236611 TN-P2-CS-002 Rev 01

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The following is a list of construction activities for the portal construction at the Wilton site. It is intended as a guide for the estimation of environmental impact for the EIA only. The portal geometry is based on a preliminary internal width of 12m and a depth of approx 16m to base slab at the tunnel eye, and a 3.3% limitation on slope. A staircase to the portal depth will be located near the portal eye. Assumptions:

• From the data available from historical SI the site consists of 6-8m of Glacial Till underlain by Redcar Mudstone Formation

• Ground water is approximately 2m below ground level. • As the Wilton area is industrial, there is a risk that the ground and groundwater are contaminated.

Form of construction: The portal walls could be, contiguous pile, secant pile or diaphragm wall construction. For the purpose of this estimate, contiguous piles has been assumed. In order to minimise groundwater ingress during temporary works the contiguous piles may need rock mass grouting between the piles and below the base slab. The walls will require temporary propping until the roof and base slabs are cast and providing permanent propping. Space constraints make external anchoring difficult; therefore the temporary propping will be internal between walls. To expedite the launch of the Tunnel Boring machine it is considered that the TBM launch chamber will be built first. Construction Activities: Activity Estimated Quantity Estimated Duration Place & compact working platform

400m x 25m x 600mm thick 1 month

Contiguous piled wall 800 linear m of contiguous wall comprising a total of 140m of 900mm piles (average length 12m) with 200kg/m3 reinforcement; 520m of 750mm piles (average length 16.2m) with 260kg/m3 reinforcement; 63m of 900mm piles (average length 24m) with 270kg/m3 reinforcement; 43m of 1050mm piles (average length 25.1m) with 230kg/m3 reinforcement; Approximately 1775Tonnes of Reinforcement Rock mass grouting = 1070m3 grout injected (Walls = 800x16.5x0.6x10% void = 800m3, Base = 150x9x2x10% void = 270m3)

6 months

Reduced dig excavation & install temporary propping

Total Dig Approximately 32000 m3 (for ramp: 350m x 9m x 7.5m deep (ave) = 23500m3 for TBM Chamber: 40m x 12m x 17.5m deep (ave) = 8500m3) Temporary Props: Steel H-section walers (2 levels in ramp and 3 levels in TBM Chamber) and 1 approx..

3 months

Subject YPL - Wilton Portal Construction Activities Date 27 August 2014 Job No/Ref

236611 TN-P2-CS-002 Rev 01

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110 x 9m long props in ramp and 30 x 11m long props in the TBM Chamber

Roof & Base slab Construction

Say 11,000m3 of concrete with average 150kg/m3 of reinforcement = 1650Tonnes

4 months

Demolition phase post operation

Infill Tunnel box at depth (230x4.5x7) = 7245m3 Breakdown top 1m of exposed concrete (800m of contiguous piles. Break down stairwell, and top 1m of open channel 350m3 of RC walls to be grubbed down Backfill open channel section = 2500m3.

A P P E N D I X 1.7

K HOME INTERNATIONAL – 143022-R-002 – SURFACE WATER DRAINAGE – DESIGN BASIS REPORT

Materials Handling and General Infrastructure Project Doc No: 143022-R-002 Consultant No: Project No.: 143020 Rev: P1 Document Type - Report Page: 1 of 8 Document name Date: July 2014

J:\143020\civil\Water Management\Surface Water Drainage - Design Basis Report.doc\DMC

YORK POTASH LIMITED

MATERIALS HANDLING FACILITY

WILTON

Surface Water Drainage – Design Basis Report

P1 RAS July 2014 Issued for information

REV BY DATE CHK’D APPROVED REVISIONS

York Potash Project Team



CONTENTS

SECTION TITLE

1.0 INTRODUCTION

2.0 OPERATIONAL SURFACE WATER DRAINAGE CONCEPT DESIGN

3.0 CONSTRUCTION SURFACE WATER DRAINAGE CONCEPT DESIGN

4.0 CONCLUSION



1.0 INTRODUCTION

K Home International has been commissioned by York Potash Limited to develop the concept surface water drainage (SWD) design for the proposed York Potash site at Wilton, Teesside. This concept design is in support of a Planning Application scheduled for summer 2014. The purpose of this report is to set out the design basis for the surface water drainage system proposed both during construction and operation of the Material Handling Facility at Wilton. The SWD concept design has been developed in parallel with the masterplan for the site.

1.1 Design Guidance

The design standards used in the concept design include:

Sewers for Adoption (7th Edition, 2012)

BS EN 752 Drains and sewer systems outside buildings

DEFRA, Rainfall runoff management for developments – Report SC030219

Technical Guidance to NPPF

Design Analysis of Urban Storm Drainage – The Wallingford Procedure

CIRIA Report C697, The SuDS Manual

CIRIA Report C609, Sustainable Drainage Systems

Environment Agency, Pollution Prevention Guidelines, PPG3; Use and designof oil separators in surface water drainage systems.

BRE Digest 365, Soakaway Design

CIRIA Report 156, Infiltration Drainage – Manual of Good practice.



2.0 OPERATIONAL SURFACE WATER DRAINAGE CONCEPT DESIGN

2.1 General Arrangement

Generally the site slopes from the South to the North. It is bounded by the Wilton industrial site to the South and West and the Wilton perimeter road and rail routes to the North and East. The general arrangement drawing in Appendix A shows the concept for the surface water drainage. There is a natural watercourse, Mains Dyke, running to the East of the site that is a tributary of the Tees. Additionally, there is a natural watercourse, the Mill Race, running centrally through the site South to North that connects to Mains Dyke as a tributary. It is understood that the Mill Race provides land drainage for the existing site greenfield runoff. Development of the site will necessitate the removal of Mill Race and the diversion of Mains Dyke where it passes through the site to the site perimeter. However, all greenfield areas of the site will continue to drain to Mains Dyke via a SuDS network. The proposed connection points are to the East and North East of the site.

2.2 Design Principles

The surface water drainage (SWD) will be designed to drain both the proposed developed areas and the proposed landscaped areas so that the development does not increase flood risk to the surrounding area and manages flood risk at the site. Areas of the site that will be at risk of becoming contaminated with hydrocarbons such as car parks, access roads and hard-standing, will be positively drained and will outfall via a hydrocarbon interceptor to an attenuation tank before passing through a wastewater treatment facility for reuse within the process. The landscaped areas will be drained to swales that discharge either to the stormwater wetlands or directly to Mains Dyke. Where possible the use of permeable materials will be used on areas where the pollution risk is low. These will be investigated at later stages of the design. Clean roof water will be stored in the attenuation tank and reused within the process.

2.3 Drainage Features

Refer to the general arrangement drawing and cross sections in Appendix A for the location of the main surface water drainage features. Only a skeletal network is shown for the concept design. More details will be provided at later stages of the design.

2.3.1 Filter Drains

Filter drains will pick up some of the runoff at the toe of the landscaped bunds where there is not enough space for swales. Filter drains or trenches will also intercept runoff across the landscaped areas where appropriate. Filter drains will not be designed to pick up ground water and in places may be designed with an impermeable membrane around the trench to prevent ground water entering the surface water system. The filter drains will have catchpits spaced appropriately.

2.3.2 Swales

The concept is for swales to be placed at the toe of the landscaping bunds to pick up surface water runoff from them. The runoff from the landscaping bunds to the swales is considered to represent a low pollution risk in the final operational phase once vegetation has been established. The swales will discharge either into Stormwater Wetlands or directly into the existing drainage ditch/watercourse. It is proposed that Swales will incorporate check dams to create a terraced ponding effect on steeper sections, thus helping to attenuate the flow. Energy dissipation and erosion protection shall be provided for swales where appropriate and will extend downstream of the check dams across both the base and sides of the swale. Where possible, swales that are not located next to a permanent road, will incorporate a 3.5m wide access route to allow maintenance vehicles to reach these assets.



2.3.3 Attenuation Ponds

There is an existing pond to the West of the site that will be maintained and utilised to accept flows from the swales and hardstanding areas within the western quadrant of the site. The pond will discharge via a culvert or swale to the next downstream pond. Additional ponds will be created in other areas of the site to capture drainage from both hardstanding and landscape areas. Initial “quick-storage” estimate calculations suggest that the required overall pond volume during operation is approximately 4,500m

3 to accept all of the predicted flow and stored volume

from a 1 in 100 rainfall event plus climate change. It is proposed that the flow from the ponds will terminate at a final pond in the North East quadrant of the site prior to discharging to a pumping chamber which will pump the water to the water treatment plant for utilisation within the process. The pump will be sized to accommodate the attenuated flow from the ponds for the 1 in 100 rainfall event plus climate change. Any higher rainfall event over and above this will discharge via an emergency spillway to Mains Dyke. The attenuation ponds will have a freeboard of 300mm and a maximum side slope gradient of 1 in 3.

The concept design will be based on a discharge rate restricted to the Qbar rate for all return periods up to the 1 in 100 year plus climate change event. The greenfield runoff rate (Qbar) should be calculated using the IH124 method, subject to agreement with the Environment Agency.

2.3.4 Stormwater Wetland

Stormwater wetlands will be provided where possible downstream of the swales as the last stage of SuDS treatment before discharge to Mains Dyke. The catchments that drain the permeable areas do not need to discharge into a wetland, however, due to the layout of the site, there is potential to incorporate additional wetland or ecological areas to improve biodiversity. As the design progresses and becomes fixed, areas to utilise as wetland will be identified. However, an area to the North East of the site will be utilised as a wetland area for the collection of runoff prior to discharge to Mains Dyke. These additional wetland areas will have a degree of attenuation and treatment associated with them which will provide some additional benefit to the site drainage. These areas will be designed to protect and enhance the biodiversity value of the area before the runoff is discharged to the nearby Mains Dyke. The volume requirement of the stormwater wetland will calculated using the initial sizing of treatment storage volume calculation within the DEFRA guidance document: “Rainfall runoff management for developments”.

2.3.5 Hydrocarbon Interceptors

Hydrocarbon interceptors shall be provided on all surface water drainage systems installed to serve all hard standing areas and shall be installed in advance of the attenuation tank thus minimising future maintenance requirements and reducing the load on the wastewater treatment plant. The interceptors will be designed in accordance with the Pollution Prevention Guidelines PPG3.

2.3.6 Wastewater Treatment A wastewater treatment plant will be installed on the site. This will accept flow streams from the attenuation ponds, tunnel wastewater returned from Doves Nest and foul water from the welfare facilities on site. The facility will treat the incoming flows to a standard suitable for use in the granulation process. Since the process has such a high water demand there is expected to be little to no wastewater remaining.



However, solids in the form of sludge will require disposal from the wastewater treatment process by tanker or by skip.

2.3.7 Outfalls

The position and number of outfalls will depend on the final topography, site constraints, the network configuration and agreement with relevant stakeholders. All outfalls will discharge to the upstream tributaries of Mains Dyke. The outfalls will be designed with a free discharge. Erosion control proposals will be developed at these outfalls to prevent scour and minimise siltation of the watercourse.

2.4 Groundwater

It is assumed that there will be no permanent ground water discharges to the proposed surface water drainage network or attenuation features. Where drainage features need to be below normal ground water level, the design will ensure that the storage is provided above natural ground water levels or else liners will be used to exclude ground water from the surface water drainage system. The strategy for infiltrating and the use of soakaways will be assessed further using completed soakaway test results.

3.0 CONSTRUCTION SURFACE WATER DRAINAGE CONCEPT DESIGN

3.1 Design Principles

The phasing for the surface water drainage will follow the earthworks phasing strategy. The earthworks have been split into 6 phases but from a drainage point of view some of the phases can be combined as they are very similar. Phase 6 is equivalent to the finished operational phase. Refer to Appendix B for the earthworks phasing arrangement. Attenuation ponds along with the wastewater treatment facility will be one of the first features to be constructed on site and will be used for attenuation of the construction surface water runoff. The runoff from all developed and disturbed areas needs to be directed (either by gravity or in some cases using temporary pumps) to the attenuation facilities. When vegetation is established and the permanent swales constructed, the runoff from bunds no longer needs to pass through the attenuation facilities. Only surface water runoff is to be directed to the attenuation facilities during construction. Other sources of water have not been designed to discharge to the attenuation ponds.

3.2 Drainage Features

Drainage plans for each phase will be developed showing a skeletal drainage network around the perimeter of the drained areas, including filter drains, swales and carrier pipes. In some instances temporary drainage is needed to collect and convey runoff to the attenuation facilities prior to the permanent drainage being installed. Phasing plans will be developed as the design progresses.

3.2.1 Sediment Control

In addition to filter drains and swales with check dams, there will be further sediment control techniques and features such as silt fences at the toe of the bare landscaped bunds. These features will be maintained throughout the construction period to ensure the silt runoff is managed appropriately. Details of these features will be developed further during later stages of the design.



3.2.2 Temporary Pumping

As runoff from all the landscaped areas needs to pass through the attenuation ponds until they have vegetation established, some temporary pumping will be required. The temporary pumps would be sized for the appropriate flow rate and it is envisaged that the pipes would be laid on the ground surface and discharge into the attenuation facilites. However, there may be other alternatives to temporary pumping which could be considered at a later stage in the design.

3.2.3 Attenuation Ponds

Like the operational phase, during construction the ponds will act predominantly as an attenuation control limiting the discharge to the allowable rate. However, in the construction phase, it is envisaged that some sediment will pass forward through the silt fences, swales and filter drains into the ponds. The ponds will assist in settlement of sediments for the larger rainfall events and as such will also need to be maintained and dredged at appropriate intervals.

3.2.4 Flow control

As the effective contributing catchment areas increase and decrease throughout the construction period, the allowable discharge rates from the tank/ponds also change. It is envisaged that simple orifice controls would be implemented which would be easy to modify as and when required to maintain the design standards.

3.2.5 Stormwater Wetlands

The stormwater wetlands would be constructed at the same time as the attenuation facilities at the start of the construction period. During construction it is envisaged that the stormwater wetlands would predominantly be acting as a final settlement feature prior to discharge to Mains Dyke. The wetlands have the advantage of being able to settle out sediment from all rainfall events, as they are designed to hold a minimum volume of water at all times. The wetlands should be monitored during construction and silt removed if there is a build up.

3.3 Construction to Operation Transformation

When the vegetation has been established on the landscaped bunds the discharge from these soft areas can be diverted away from the attenuation facilities and into the tributaries of Mains Dyke. At this point, the attenuation facilities should be cleaned out and the orifice flow control converted to a suitable vortex flow control device. The wetlands should also be cleared of excess silt and any additional planting requirements provided.



4.0 Conclusions

The concept design demonstrates how the final operational layout of the surface water drainage successfully drains the site. The arrangements will ensure that the site is not at risk of flooding and does not impact on flood risk elsewhere. The construction phase SWD concept design demonstrates how the construction phase strategy will both control the runoff rate from the construction site and prevent silt from entering the watercourse for each phase.

Materials Handling and General Infrastructure Project Doc No: 143022-R-002 Consultant No: Project No.: 143020 Rev: P1 Document Type - Report Page: Appendix A Document name Date: July 2014


APPENDIX A

Drainage General Arrangement

Materials Handling and General Infrastructure Project Doc No: 143022-R-002 Consultant No: Project No.: 143020 Rev: P1 Document Type - Report Page: Appendix B Document name Date: July 2014


APPENDIX B

Earthworks Phasing Arrangement

A P P E N D I X 1.8

K HOME INTERNATIONAL – 143022-R-001 – WATER AND WASTEWATER MANAGEMENT STRATEGY REPORT


J:\143020\civil\Water Management\Wilton Water Management.doc\DMC

YORK POTASH LIMITED


WILTON

Water and Wastewater Management Strategy

P1 RAS July 2014 Issued for information





CONTENTS

SECTION TITLE

1.0 INTRODUCTION

2.0 SITE ACTIVITIES

3.0 WATER DEMAND

4.0 WASTEWATER TREATMENT

APPENDIX

A WATER BALANCE SCHEMATICS



1.0 INTRODUCTION

The purpose of this report is to document the philosophy which will govern the management of water and wastewater at the Materials Handling Facility (MHF) at the Wilton site. It considers the construction and operational phases of the project. This report should be read in conjunction with the Integrated Water and Wastewater Management

Strategy1 for the project as a whole.

2.0 SITE ACTIVITIES

The following table documents the activities which require water and/or generate wastewater which impact on the Wilton site:

Activity Source Demand? Generate Wastewater?

Potential Reuse?

Phase

Concreting Mains Yes Yes Yes C Cooling water for machinery

Mains (top-up closed cooling water circuit)

Yes No No C/O

Drilling for blasting Mains/reused Yes Yes Yes C Drilling for grouting Mains/reused Yes Yes Yes C Dust suppression Mains/reused Yes No Yes C/O Fire fighting Ringmain Yes Yes No C/O Grouting Mains Yes Yes Yes C Shotcreting Mains/reused Yes Yes Yes C Site irrigation Mains/reused Yes No No C/O Surface Water Drainage

N/A No Yes Yes C/O

Shallow Ground Water Drainage

N/A No Yes Yes C/O

Welfare (above ground)

Mains/reused Yes Yes No C/O

Wheel washing Mains/reused Yes Yes Yes C/O Granulation Mains/reused Yes No No O

In addition, Ref 1 identifies that wastewater from Doves Nest and the MTS Tunnel (arising from operations and in-leakage) will be pumped to the MHF for treatment. This wastewater flow occurs during phase 4 (operation).

1 ‘Integrated Water and Wastewater Management Strategy’, REP-P2-WSD-003 Rev 0, 17 June 2014

(Arup)



3.0 WATER DEMAND

3.1 Construction Phase

Water for welfare/amenities during this phase will be provided from a tie-in to Wilton potable water supply. Typical water usage rate is 90l per person per day. The peak number of construction workers at the MHF site is 600. Therefore: Design volume per day 54 m

3/d

Assuming that the majority of this demand occurs at shift changes, a buffer tank will be required. Buffer tank capacity 20 m

3

Required fill rate 10m3/h

Required Pressure 3 barg The concrete batching operation is estimated to require up to 38.3 m

3/d of water (assumed to be during a

12 hour working shift). This will be obtained from new pipework tied into Sembcorp’s process water distribution system. Demands from drilling/grouting have been estimated to be 32.4 m

3/d and shotcreting

operations are estimated to require 9 m3/d. It is further assumed that demand is relatively constant

during the 12 hour working shift. An arbitrary 25% design margin will be applied: Design Flowrate 10 m

3/h

Required Pressure 3 barg (assumed) Minor users during construction include site irrigation, dust suppression, wheel washing and machine cooling. These users will be fed from the tie-in to Semcorp’s water distribution. Wheel washing and dust suppression present significant demand. Temporary firefighting provision will have to be in place for the initial phase of construction, until the tie-in to Sembcorp’s firewater ringmain and installation of required monitors etc is made. This will be provided by the Wilton site fire response service. Wheel washing will be provided by a low pressure spray system, using recirculated water. A typical consumption is 5m

3 per HGV. The forecast peak HGV movements are approx 1400 HGVs per month

during construction. Therefore: Monthly water usage 1400 x 5 = 5600 m

3

Average daily usage 5600 / 30 = 187 m3

Hourly usage 187 / 12 = 15.6 m3/h (assume during 12 hour working shift)

In order to limit the amount of fresh water required a treatment and reuse system will be utilised. This will be required to remove sand, silt, oil/diesel and road debris. Assume 75% water recovery: Fresh water required 3.9 m

3/h

Assuming a 6000l bowser is in operation on site to suppress dust during a 12 hr shift with one fill every hour: Fresh water required 6 m

3/h



3.2 Operations Phase

Water for welfare/amenities will be provided from the tie-in to Wilton potable water supply. During operation maximum personnel numbers will reach approximately 110. This is far less than will be required during construction, therefore the provision made for the construction phase will be adequate. The major demand for water during operations is the input required into the granulation process. The current basis is to increase the water content of the product from 2% w/w to 4% w/w. Therefore: Product flowrate 2400 tph (basis: as received, scaled to account for 20hr/d working)

Initial water content 2%

Final water content 4%

Water addition 2400 x (1/0.96 – 1/0.98) = 51 m3/h

Rainwater runoff is not a sufficiently available resource to reliably offset the water import requirement for the process. Additionally, the granulation process is not currently sufficiently defined to be confident that 4% final water content is adequate. The impact of change is significant. For example, if the initial water content was 1% and the final required water content 6% then the water addition requirement increases to 130 m

3/h. The actual figures may not be available until material is extracted from the mine, therefore a

cautious but arbitrary design flowrate of 110 m3/h will be selected for design. This value should be

reassessed as the process development continues. Therefore: Design Flowrate 110 m

3/h

Required Pressure HOLD Firewater will be provided from a tie-in to Sembcorp’s firewater ringmain. Design flowrate and pressure will be developed during detailed design. Minor users during operation include site irrigation, dust suppression, wheel washing and machinery cooling. These users will also be fed from the tie-in to Semcorp’s water distribution and, with the exception of wheel washing, the demand is assumed to be accounted for within the above overall flowrate. It is estimated that there will be approximately 10000 HGV movements from the MHF per year during operations. Utilising the same consumption per wash as above (5 m

3/h per HGV):

HGV movements per month 10000 / 12 = 834 HGV movements per day 834 / 30 = 28 HGV movements per hour 28 / 12 = 2.4 (assume movements occur in 12 hour period) Water consumption per hour 12 m

3/h

In order to limit the amount of fresh water required a treatment and reuse system will be utilised. This will be required to remove sand, silt, salt, oil/diesel and road debris. Assume 75% water recovery: Fresh water required 3 m

3/h



4.0 WASTEWATER TREATMENT

4.1 Construction Phase Wastewater generated during construction of the mine and MTS will be tankered away from the construction sites for treatment at a licensed waste disposal site. Wastewater loading at Wilton is anticipated from the concrete batching, drilling, grouting and shotcreting operations. Any waste water arising from these operations will be managed on site and discharged to the Semcorp ‘W’ drain. The main source of wastewater at the Wilton site will be surface water drainage as the impermeable floors, roofs etc are constructed. Wheel wash consumption as above (15.6 m

3/h) with 75% water recovery:

Fresh water required 3.9 m

3/h

Waste to drain 3.9 m3/h

Surface water drainage during the construction phase will be managed on site utilising interim water treatment methods with discharges to both Sembcorp ‘W’ drain and the existing watercourse until such time as the permanent surface water drainage network has been commissioned. Enabling works will be required to divert the existing watercourses and install shallow ground water drainage in order to create suitable water routes across the site and to maintain a dry working site. 4.2 Operations Phase No significant wastewater generation is anticipated from the process itself. The water added for granulation will remain bound in the product granules, as will the small amount sprayed elsewhere for dust suppression. Any machine cooling requirements will be served by closed loop cooling water systems, which will not generate a waste stream. There will be three major contributors to wastewater generation; rainwater runoff, arisings from the mine and tunnel, and wheel washing. 4.2.1 Rainwater Runoff Approximately 13 hectares of impermeable surface will be constructed at the Wilton site. The runoff from rain and storm events from this surface will be collected within a piped surface water drainage network and directed to an underground storage tank. The surface water will pass through an initial filtration system to remove silts and hydrocarbons before entering the storage tank. This water will be utilised in the granulation stage of the process. A water treatment plant will be required to remove remaining solid and dissolved contaminants from the water en route to the process.



Based on historical met office data for Whitby, the expected rainfall (averaged over a month) landing on 13 hectares is:

Average per month 9.41 7.95 7.00 7.60 7.87 9.04 8.57 9.78 8.98 9.16 11.16 10.92 m3/h

Maximum 22.08 19.49 15.84 25.05 20.92 31.74 19.13 24.85 24.33 21.08 34.91 19.52 m3/h

Minimum 1.91 0.57 0.72 0.50 1.81 0.91 1.39 0.61 2.00 1.36 1.75 1.59 m3/h The rainwater storage tank will be designed to cope with a 1:100 year storm event plus a 10% allowance for climate change. Therefore, under normal conditions all of the rainwater will be collected for treatment and reuse. There will be approximately 15ha of land utilised for spoil heaps at the Wilton site. It is anticipated that the spoil will be encapsulated to prevent ground water from percolating through it and that any greenfield run off from the spoil heaps will discharge to the local watercourse. Where this cannot be achieved the water will be treated and utilised within the process. 4.2.2 Arisings from the Mine and Tunnel Ref. 1 states that up to 959 m

3/d of wastewater (approx 40 m

3/h) from the MTS will be pumped to Wilton

for treatment. It is proposed that a water treatment plant capable of treating the maximum arisings from the MTS and the maximum average monthly rainfall (11.16 m

3/h) be installed. An arbitrary design margin of 25% will

be added:

Wastewater treatment rate 64 m3/h

If insufficient rainwater is available for the process then water from the Sembcorp distribution network will be utilised. In the unlikely event that the rainwater storage tank is full and filling faster than the treatment plant or process can reuse it, then it will overflow to Wilton ‘W’ drain and eventually to the Tees. 4.2.3 Wheel Washing Wheel wash consumption as above (12 m

3/h) with 75% water recovery:

Fresh water required 3 m

3/h

Waste to drain 3 m3/h

Refer to Appendix A for a diagrammatic representation of water demand and treatment during both the construction and operational phases.

Materials Handling and General Infrastructure Project Doc No: 143020-R-003 Consultant No: Project No.: 143020 Rev: P1 Document Type - Report Page: Appendix A Document name Date: July 2014


APPENDIX A

WATER BALANCE SCHEMATICS

Source Demands m3/d

PW Concrete 38

PW Grout 19

PW Shotcrete 9

PW Cooling

GWDrilling for

Grouting14

PWDust

Suppression72

PW Site Irrigation 35

PW Welfare 54

PW Wheel Wash 47

Sembcorp Mains Connection (?? m3/d)

Rainwater Harvesting

(0 m3/d)

Total Water Resources Available

Grey Water (72 m3/d)

MTS Wastewater (0 m3/d)

Groundwater Ingress

(225 m3/d)

Non-domestic Wastewater

(61 m3/d)

Non-domestic Wastewater Treatment (286 m3/d)

Tankering off site (214 m3/d)

Domestic Wastewater

(54 m3/d)

Tankering off site

(54m3/d)

Lost to ground

(107 m3/d)

Embedded in the works (66 m3/d)

Water Balance at Wilton during Construction

Source Demands m3/d

PWProduction

process1020

PW Site Irrigation 35

PW/GW Welfare 10

PW Wheel Wash 36

Sembcorp Mains Connection (?? m3/d)

Surface Water Drainage

(267 m3/d)

Total Water Resources Available

(1262 m3/d)

Grey Water (0 m3/d)

Non-domestic Wastewater Treatment (995 m3/d)

Wilton 'W' Drain (0 m3/d)

Domestic Wastewater Treatment (10 m3/d)

Sludge disposal (?m3/d)

Lost to ground

(35 m3/d)

Water Balance at Wilton during Operation

MTS Tunnel Wastewater (959 m3/d)

Rainwater Harvest (0 m3/d)

Storage (4500 m3)

A P P E N D I X 1.9

K HOME INTERNATIONAL – 143022-R-003 REV P1 - MATERIALS HANDLING FACILITY – WILTON – BASIS OF DESIGN REPORT

Materials Handling and General Infrastructure Project Doc No: 143022-R-003 Consultant No: Project No.: 143020 Rev: P1 Document Type - Report Page: 1 of 10 Wilton MHF – Basis of Design Date: August 2014

H:\E drive\2014\PROJECTS\1433Port - York Potash\Outgoing\Reports\1433PortOR05Rev3 HRA\Appendices\Appendix 1\1.9 1433PortIR20.docx\DMC

YORK POTASH LIMITED


WILTON

Basis of Design Report

P1 RAS Aug 2014 Issued for information





CONTENTS

SECTION TITLE

1.0 INTRODUCTION

2.0 DEVELOPMENT DETAILS

3.0 EARTHWORKS STRATEGY

4.0 FOUNDATIONS STRATEGY

5.0 DRAINAGE STRATEGY



1.0 INTRODUCTION

K Home International has been commissioned by York Potash Limited to develop the concept

design for the proposed York Potash site at Wilton, Teesside. This concept design is in support

of a Planning Application scheduled for summer 2014. The purpose of this report is to set out

the design basis for the groundwork elements of the proposed Material Handling Facility at

Wilton.

The concept design has been developed in parallel with the masterplan for the site.



2.0 DEVELOPMENT DETAILS 2.1 General Arrangement Generally the site slopes from the South to the North. It is bounded by the Wilton industrial site

to the South and West and the Wilton perimeter road and rail routes to the North and East. The

general arrangement drawing in Appendix A shows the concept scheme layout.

2.2 Construction Programme Construction work is anticipated to commence on the Wilton site during 2015 and continue for a

period of approximately two years. An outline construction programme is shown in Appendix B.



3.0 EARTHWORKS STRATEGY 3.1 Method Statement This method statement provides an indication of how the earthworks can be carried out at the

Wilton site. It is not a definitive method of how the works are to be constructed, this will depend

on the individual Contractor and the type and nature of the plant he decides to use to execute

the works.

3.1.1 Month 1 – 3 The Contractor will take possession of the site and fence and secure the perimeter.

The Contractor will set up his own compound of accommodation/ stores etc and make secure

with a perimeter fence a centrally allocated area set aside for the second phase Granulation

Building. This area is to be accessed using the existing site entrance off Boundary Road East.

The Contractor will need to stone up the site access roads as the prescribed drawings to

access all areas of this site and enable the transportation of material to its necessary

destination.

All existing services are to be located, positions recorded and tested. All services are to be

made safe or diverted prior to any further excavation works are started. All existing building

structures are to be demolished and carted away.

The whole site will be stripped of top soil and placed in a central heap, located in the area

which will eventually be occupied by the first phase Granulation Building. This area is

approximately 150 x 120m rectangle adjacent to the Contractors compound. The whole site is

to have an average of 300mm of top soil removed, as the thickness varies in different locations,

to sub soil level.

A total topsoil capacity of 113,385m3 is therefore to be accommodated from the strip and will

be stored here for later use.

There are five attenuation ponds to be excavated site wide. The excavated material is from the

drift deposits layers and not taken too deep into the mudstone strata, some 1,000m3 each, will

be placed within adjacent mounding. Three ponds are located on the west side of the site

towards the rear of the proposed Storage Building , a further pond is located in front of the

Office Block and a fifth between the Granulation and Finished Product Screening Buildings.



3.1.2 Month 3 – 6 Within this site is an existing large flat topped mound, ‘L’ shaped in plan and located on the

north west boundary, which has to be removed first to make the site ‘flat’ for construction in that

area. This mound of previously excavated material consists of 52,850m3 of spoil and will be

moved to form more naturally shaped mounding along the staggered western boundary. The

spoil will also be used to infill the existing large pond and reeded area and also the existing

ditch of a previously culverted pipe carried out some years ago.

There will be three mounds ‘ backed’ into a peninsular of land that projects along the west

boundary, one 12,000m3, one 62,500m3 and a third 125,000m3. It is the intention to start

earthworks in the North West corner of the site first, and then work in a southerly direction down

the western boundary as access to these ‘landlocked’ areas will be difficult, as building work

proceeds. It is therefore essential that these mounds are formed early in the excavation

logistics.

The material of the existing flat topped mound, to be moved, must be kept separate from that of

the waste spoil of the tunnel excavation as it is not classed as mining waste. An impermeable

geosynthetic membrane is to be used to isolate the two spoils. This mounding will have a

general level of 6m high rising to 8 to 9 metres high locally. The mounds will be constructed in

as natural formation as the volume of material will allow.

As the spoil from the Tunnel portal and boring comes online, some 247,758 m3 of waste from a

6m diameter tunnel, the rest of these mounds can be added to particularly at the most southern

end and also within a long finger of land projecting westward adjacent to the road Northway

North.

It is acknowledged that the clay subsoil layer found below the topsoil on this site can be used

as an isolation layer when placing Tunnel spoil on top in lieu of a geotextile sheet membrane as

a separating membrane.

3.1.3 Month 6 – 9 The largest pond outside the Office block can now be excavated and the spoil tipped within the

‘bulge’ on the southern boundary and mounded to suit a natural feature being highly visible

from the road on the front side of the site.



As tunnel waste is being excavated, at the rate of 600m3 per day the next area to

accommodate the spoil is a central position in front of the northern half of the Storage Building.

In tandem, the topsoiling of the mounds along the western boundary can commence from the

central heap of 113,385m3, adjacent to the Contractors Compound, working from north to south

in direction.

As the centrally located mounding near the Storage Building becomes completely filled with

tunnel spoil further mounding can be started along the eastern boundary. A narrow strip of land

exists along the full length of the eastern site boundary part of which is occupied by a water

course, The Mill Race.

The proposal is to culvert the complete water course along its full length then mound along the

complete eastern boundary stopping just short of the Truck and Car Entrances at the southern

extremity. This will allow at least 56,840m3 of spoil to be mounded in three long separate linear

mounds some 26m wide and at least 6m high.

There is an attenuation pond in front of the Granulation Building which will generate

approximately 1,000m3 of dug material which also must be added to the spoil mounds as the

excavation takes place.

3.1.4 Month 9 – 12 Once the linear mounds along the eastern boundary are complete the last remaining area in

which the tunnel waste can be dispersed is around the site of the Administration Block. This

area can absorb in the region of 18,000m3 of material suitably placed in rolling mounds to

enhance the setting of the main vehicle approach to the site, along within the large pond in front

of the Office Block.

As mounding in this area proceeds topsoiling can begin along the eastern boundary starting

with the mound at the north end of the site and proceeding in a southerly direction following

Boundary Road East

Topsoiling will complete the earthworks when all mounds have been covered.

3.2 Earthworks Phasing Refer to Appendix C for a graphical representation of the anticipated earthworks phasing.



4.0 FOUNDATION STRATEGY 4.1 Finished Product Store

• Piled foundations to the main portal structure. Anticipated 750mm diameter. • Piled foundations to mechanical reclaimer rail support structure. • Engineered stone / improved ground over membrane instead of concrete ground slab.

4.2 Combined Granulation, Drying, Screening & Coating

• Piled foundations to the main braced steel frame structure. Anticipated 600mm diameter. • Piled foundations to plant plinths (isolated from ground slab) • 200mm thick reinforced concrete ground slab – formation level = 7.700m AOD

4.3 Loco Shed

• Pad foundations with light reinforcement – formation level = 4.900m AOD • 200mm thick reinforced concrete ground slab – formation level = 5.930m AOD

4.4 HPGR


4.5 Classification

• Pad foundations with light reinforcement – formation level (rock) = 4.350m AOD • 200mm thick reinforced concrete ground slab – formation level = 6.700m AOD

4.6 Secondary Crushing & Ore Storage


4.7 Finished Product Screening


4.8 Emergency ROM Store




4.9 Water Treatment Plant

• Piled foundations to the tank bases. Anticipated 600mm diameter. • 200mm thick reinforced concrete ground slab – formation level = 10.250m AOD

4.10 Workshop & Control Room


4.11 Offices & Administration


4.12 Substation A

• Pad foundations with light reinforcement – formation level = 9.750m AOD • Precast concrete floor slab, raised 2m above finished ground level

4.13 Substation B


4.14 Substation C




5.0 DRAINAGE 5.1 Surface Water Drainage Strategy The surface water drainage philosophy for the Wilton site has been dealt with in a separate

document: ‘Material Handling Facility Surface Water Drainage – Design Basis Report’

document number 143022-R-002.

Further information regarding drainage strategies for the construction and operational phases

can be found in: ‘Water and Wastewater Management Strategy’ document number 143022-R-

001.

Materials Handling and General Infrastructure Project Doc No: 143022-R-002 Consultant No: Project No.: 143020 Rev: P1 Document Type - Report Page: Appendix A Document name Date: August 2014


APPENDIX A

General Arrangement Plan

Materials Handling and General Infrastructure Project Doc No: 143022-R-002 Consultant No: Project No.: 143020 Rev: P1 Document Type - Report Page: Appendix B Document name Date: August 2014


APPENDIX B

Wilton Construction Programme

Materials Handling and General Infrastructure Project Doc No: 143022-R-002 Consultant No: Project No.: 143020 Rev: P1 Document Type - Report Page: Appendix C Document name Date: August 2014


APPENDIX C

Earthworks Phasing Plans

Materials Handling and General Infrastructure Project Doc No: 143022-R-002 Consultant No: Project No.: 143020 Rev: P1 Document Type - Report Page: Appendix D Document name Date: August 2014


APPENDIX D

Proposed Site Levels Plans

A P P E N D I X 1.10

YORK POTASH – 3000-APP-ENV-REP-001 – DECOMMISSIONING PLAN FOR THE MINEHEAD AND MTS


K HOME INTERNATIONAL – 143020-SCH-001 REV B – YORK POTASH MATERIALS HANDLING FACILITY PRELIMINARY CONSTRUCTION

PROGRAM

Activity ID Activity Name Original Duration

York Potash Materials Handling FacilityYork Potash Materials Handling Facility 585

Milestones & Key DatesMilestones & Key Dates 585

A1100 Contract Award - Materials Handling Facility 0

A3900 Material Handling Facility Commissioned 0

ConstructionConstruction 585

Site EstablishmentSite Establishment 70

A1000 Erect Temporary Fencing 10

A1200 Erect Temporary Site Offices 50

A1300 Erect Welfare Facilities 50

A4000 Set Up Batching Plant 60

Enabling WorksEnabling Works 70

A1400 Site Stripping, Back Fill, Remediation, Etc 60

A4400 Form Temporary Access Roads & Storage Area 60

TunnelTunnel 380

A2100 Excavation of Tunnel 370

A2200 Removal of Excavated Material from the Tunnel Ramp & Tunnel 380

A2600 Install Pre Cast Concrete Invert Units to Form Base of Tunnel 370

A4600 Install Light Rail Track 370

A2500 Construct Tunnel Drainage Network 280

A2400 Install Rock Anchors & Gunite Lining to Excavated Tunnel (where required) 330

EarthworksEarthworks 380

A2700 Compaction of Excavated Material Over Site 380

A2800 Formation of Screen Bunds With Excavated Material 250

BuildingsBuildings 410

A2900 Install Piles for New Build Structures 160

A4300 Erect Construction Facilities (Grout Plant, TBM Store, Segment Yard, etc) 60

A3200 Construct Raw Materials Storage Facility 210

A4200 Construct Process Buildings 310

A3100 Construct Rail Maintenance & Storage Shed 150

A3000 Construct Permanent Site Offices 150

InfrastructureInfrastructure 500

A3300 Construct Surface Water Culvert for Existing Watercourse Diversions 40

A3500 Construct Foul Water Drainage Network & Install Klargester 50

A3400 Construct Drainage Network from Tunnel Drain 50

A4100 Install Site Storm Drainage & Storage Ponds 200

A4500 Other Services 240

A3700 Construct Site Access Roads & Above Ground Rail Track 70

A3800 Landscaping & Finishes Inc Footpaths, Etc 80

A3600 Construct Plant Car Park 40

ProcessProcess 545

A4700 Procurement 320

A4800 Mechanical Installation 135

A4900 Commissioning 90

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Month

York Potash Materials Handling Facility

Preliminary Construction Programme

Remaining Work

Critical Remaining Work

Actual Work

Baseline Milestone

Milestone

Critical Milestone Page 1 of 1

Layout Name: York Potash Without Tunnel or Portal_1

Doc No - 143020-SCH-001 Rev B

Date Revision Checked Approved

25-Mar-14 Incorporated Civils Comments AC AH

26-Mar-14 Additional Sections added for Process AC AH

12-Aug-14 Incorporated Revised Civils Comments PH AH


ARUP – 25900-MTS-C00-2250-22101 TO 259000-MTS-C00-2250-22103 - WILTON PORTAL GENERAL ARRANGEMENT – SHEET 1 TO 3

℄MJ

CH 120.000

40

00

300

0

Bre

akline

Plan (rail level)

Scale 1:250

℄MJ ℄MJ ℄MJ ℄MJ

℄Tunnel

Chainage

0m

CH 140.000m

Tunnel

℄

CH 25.000 CH 50.000 CH 75.000 CH 100.000

Pile RC = 200kg/m

3

Pile RC = 150kg/m

3

Indicative zone of rock

mass grouting between

piles if required to manage

groundwater ingress




groundwater ingress

Pressure relief

wells required

Cross Section A1-A1

Scale 1:100

7000

70

0

Va

rie

s - 0

to

19

00

℄Tunnel

700700

Pile

le

ng

th

10

0 B

lin

din

g

PGL

20

0

CJ CJ

8400 min. See note 2

Top of Redcar Mudstone (indicative)

A3

A3

140000 to start of Portal roof

392200 total structure length

25000 2000025000 25000 25000 20000

A1

A1

A2

A2

FGL & EGL

Indicative barrier, may take the

form of a closed canopy

30000 Open cut. Max. excavation depth = 2000

10000 10000 10000

Piles

900 dia @ 1050crs

Length = 9250

10000 10000 1000010000 10000 10000 10000 10000

Piles

900 dia @ 1050crs

Length = 9575

Piles

900 dia @ 1050crs

Length = 11750

Piles

900 dia @ 1050crs

Length = 12100

Piles

900 dia @ 1050crs

Length = 12450

Piles

900 dia @ 1050crs

Length = 12750

Piles

900 dia @ 1050crs

Length = 12800

Piles

750 dia @ 900crs

Length = 12150

Piles

750 dia @ 900crs

Length = 12500

Piles

750 dia @ 900crs

Length = 12800

Piles

750 dia @ 900crs

Length = 13200

Longitudinal Section

Scale 1:250

3% Fall

CJ

CJ

CJ

CJ

CJ

CJ

Buried joint

EGL & PGL

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

Ramp opening

E 457947.229

N 523010.297

IL 7.862mAOD

Cross Section A2-A2

Scale 1:100

11

00

Va

rie

s-1

90

0 to

3

60

0

℄Tunnel

11001100

Pile

le

ng

th

10

0 B

lin

din

g

7000

20

0

PGL

CJ CJ


Cross Section A3-A3

Scale 1:100

7000

12

00

Va

rie

s - 3

60

0 to

5

00

0

℄Tunnel

12001200

Pile

le

ng

th

10

0 B

lin

din

g

60

00

Indicative zone of rock mass

grouting between piles if required

to manage groundwater ingress

PGL

CJ CJ

20

0


℄MJ

Any temporary works

obstructing permanent

works cut down

12100

13200



25000 2000025000 25000 25000 20000

Ø1050 Pile

1500

1400


10000 10000 10000

Piles

900 dia @ 1050crs

Length = 9250

10000 10000 1000010000 10000 10000 1000010000 10000

Piles

900 dia @ 1050crs

Length = 9575

Piles

900 dia @ 1050crs

Length = 11750

Piles

900 dia @ 1050crs

Length = 12100

Piles

900 dia @ 1050crs

Length = 12450

Piles

900 dia @ 1050crs

Length = 12750

Piles

900 dia @ 1050crs

Length = 12800

Piles

750 dia @ 900crs

Length = 12150

Piles

750 dia @ 900crs

Length = 12500

Piles

750 dia @ 900crs

Length = 12800

Piles

750 dia @ 900crs

Length = 13200

8500 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 1000010000

Piles

750 dia @ 900crs

Length = 12600

Piles

750 dia @ 900crs

Length = 13000

Piles

750 dia @ 900crs

Length = 13500

Piles

750 dia @ 900crs

Length = 13900

Piles

750 dia @ 900crs

Length = 14350

Piles

750 dia @ 900crs

Length = 14800

Piles

750 dia @ 900crs

Length = 15250

Piles

750 dia @ 900crs

Length = 15700

Piles

750 dia @ 900crs

Length = 16100

Piles

750 dia @ 900crs

Length = 16500

Piles

750 dia @ 900crs

Length = 16900

Piles

750 dia @ 900crs

Length = 17300

Piles

750 dia @ 900crs

Length = 17700

Piles

750 dia @ 900crs

Length = 18150

Piles

750 dia @ 900crs

Length = 18550

Piles

750 dia @ 900crs

Length = 18950

Piles

750 dia @ 900crs

Length = 19350

Piles

750 dia @ 900crs

Length = 19750

Piles

750 dia @ 900crs

Length = 20200

Piles

750 dia @ 900crs

Length = 20600

Piles

750 dia @ 900crs

Length = 20900

Piles

900 dia @ 1050crs

Length = 23850

Piles

1050 dia @ 1200crs

Length = 25100


℄MJ

20000

℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ

940020000 20000 20000 20000 20000 20000 20000 20000 20000

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

℄MJ ℄MJ

1200 1200

2140021400

1400

(to match wall)

Indicative zone of rock mass grouting

between piles if required to manage

groundwater ingress

CH 370.800

Pile RC = 200kg/m

3

Pile RC = 150kg/m

3

Pile RC = 260kg/m

3

Pile RC = 260kg/m

3

Pile RC = 270kg/m

3

Pile RC = 230kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 130kg/m

3

RC = 130kg/m

3

RC = 130kg/m

3 RC = 160kg/m

3

RC = 160kg/m

3

RC = 190kg/m

3

RC = 190kg/m

3

RC = 190kg/m

3

RC = 200kg/m

3

RC = 200kg/m

3

RC = 200kg/m

3

RC = 170kg/m

3

1200

CJ

CJ




groundwater ingress

CJ

CJ




groundwater ingress

Pressure relief

wells required




groundwater ingress




groundwater ingress


mass grouting if

required to manage

groundwater ingress


mass grouting if

required to manage

groundwater ingress







groundwater ingress

YORK POTASH LIMITED

PROJECT

DRAWING No.

CONSULTANT

DRAWING No.

DRG SIZE: SCALE:

CLIENT

APPR

REVISION:

ISSUE STATUS DESCRIPTION

DOCUMENT REVIEW

CODE 1: WORK CAN PROCEED

CODE 2: REVISE TO ADDRESS COMMENTS

CODE 3: REJECTED, WORK NOT TO PROCEED

CODE 4: DOCUMENT FOR INFORMATION

SIGNED: DATE:

A1

THIS DRAWING IS A PRIVATE AND CONFIDENTIAL COMMUNICATION

AND THE PROPERTY OF YORK POTASH LIMITED AND MUST NOT

BE COPIED OR LOANED WITHOUT THE PRIOR WRITTEN CONSENT

OF YORK POTASH LIMITED

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

A

B

C

D

E

F

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DRAWING TITLE:

REVPREP CHECKDATE PEM

13 Fitzroy Street

London W1T 4BQ

Tel +44(0)20 7636 1531 Fax +44(0)20 7580 3924

www.arup.com

25900-MTS-C00-2250-22101

WILTON PORTAL

GENERAL ARRANGEMENT SHEET 1 OF 3

CONCRETE OUTLINE

1:250 & 1:100

B

JH JAIssued for billing

DP RDRock mass grouting details amended

A

B

19/08/2014

28/08/2014

MS

MS

Notes

1. For general notes refer to drawing 25900-MTS-C00-2250-32100

2. Due allowance should be made for additional infill mass concrete required for variation in pile vertically

and positioning based on construction methodology. Section sizes shown are minimum values to be

achieved. Piles are drawn vertically with zero horizontal error.

3. For pricing of rock mass grouting between piles 1No probe drilled between each pile & injected with

grout.

4. Temporary pressure relief wells may be required during excavation where less than 2.5m thick of fill

overlays bedrock. Assume one 5m deep open hole bore into rock every 10m drilled from 4m above

rock

5. Design & installation of grouting to be undertaken by specialist sub-contractor

Key Plan

Created using CADplot http://www.oasys-software.com/cadplot/

Cross Section B1-B1

Scale 1:100

Headwall upstand

(indicative)

7000

12

00

50

00

℄Tunnel

20

0

Pile

le

ng

th

10

0 B

lin

din

g


grouting between piles if required to

manage groundwater ingress

PGL

CJ CJ


CJ CJ

Va

rie

s - 5

00

to

8

35

0

Cross Section B2-B2

Scale 1:100

45

00

7000

12

00

10

00

℄Tunnel

900

900

10

0 B

lin

din

g

Pile

le

ng

th

PGL

CJ CJ


grouting if required to manage

groundwater ingress

Backfill

CJ CJ



grouting between piles if required to

manage groundwater ingress

B2

B2

B1

B1


210800 to Chamber

750 dia @ 900crs

8500 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 1000010000

Piles

750 dia @ 900crs

Length = 12600

Piles

750 dia @ 900crs

Length = 13000

Piles

750 dia @ 900crs

Length = 13500

Piles

750 dia @ 900crs

Length = 13900

Piles

750 dia @ 900crs

Length = 14350

Piles

750 dia @ 900crs

Length = 14800

Piles

750 dia @ 900crs

Length = 15250

Piles

750 dia @ 900crs

Length = 15700

Piles

750 dia @ 900crs

Length = 16100

Piles

750 dia @ 900crs

Length = 16500

Piles

750 dia @ 900crs

Length = 16900

Piles

750 dia @ 900crs

Length = 17300

Piles

750 dia @ 900crs

Length = 17700

Piles

750 dia @ 900crs

Length = 18150

750 dia @ 900crs

Length = 18550


Scale 1:250

20000

3% Fall

20000 20000 20000 20000 20000 20000

CJ

CJ

CJ

CJ

CJ

CJ

CJ

Locally landscaped to

cover tunnel

Bre

aklin

e

FGL & PGL

RC = 130kg/m

3

RC = 130kg/m

3

RC = 130kg/m

3

RC = 160kg/m

3

RC = 160kg/m

3

RC = 190kg/m

3

RC = 190kg/m

3

CJ

CJ


mass grouting if

required to manage

groundwater ingress

Bre

akline

Plan (rail level)

Scale 1:250

℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ

CH 140.000m

Brea

klin

e

Tunnel

℄

CH 160.000 CH 180.000 CH 200.000 CH 220.000 CH 240.000

CH 260.000

CH 280.000

Pile RC = 260kg/m

3




groundwater ingress




groundwater ingress

YORK POTASH LIMITED

PROJECT

DRAWING No.

CONSULTANT

DRAWING No.

DRG SIZE: SCALE:

CLIENT

APPR

REVISION:


DOCUMENT REVIEW





SIGNED: DATE:

A1





1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

DRAWING TITLE:


13 Fitzroy Street

London W1T 4BQ

Tel +44(0)20 7636 1531 Fax +44(0)20 7580 3924

www.arup.com

25900-MTS-C00-2250-22102

WILTON PORTAL

GENERAL ARRANGEMENT - SHEET 2 OF 3

CONCRETE OUTLINE

1:250 & 1:100

B


DP RDRock mass grouting details amended

A

B

19/08/2014

28/08/2014

MS

MS

Key Plan

Notes






grout.



rock

5. For pricing of rock mass grouting beneath base assume excavation to 4m above formation then drill

and inject on a 5m grid to treat a zone 2 - 3m thick beneath final excavation level (7m total depth).



Plan (rail level)

Scale 1:250

930

0

Fire escape staircase

(12m long x 2.5m wide)

12

10

0

6600

13

20

0


℄MJ ℄MJ

CH 349.400m CH 390.800m

12001200

Bre

akline

Tunnel

℄

465

04

650

Tunnel

℄

CH 280.000 CH 300.000 CH 320.000

CH 370.800

CH 340.000

Pile RC = 260kg/m

3

Pile RC = 270kg/m

3

Pile RC = 230kg/m

3

12

00

Linear drain

Tunnel

Eye







groundwater ingress

Cross Section C1-C1

(Assembly Area for TBM)

Scale 1:100

Va

rie

s 5

92

6 m

in

14

00

15

00

Cross Section C2-C2

(Starter Tunnel Launch)

Scale 1:100

GFRP Soft Eye, to allow

Excavation Method to break

wall. See Drg 22104 for

details.

9300

Portal Side of Head Wall,

lobby area for emergency

egress staircase.

Construction pit initially 2.5m

deep for TBM assembly

cradle and then 1.426m deep

for TBM transit before being

reinstated to 0m deep for

permanent case. Therefore,

Ladder access from starter

tunnel pit or equivalent

15

00


1400 1400 2500 1200

16

74

@

tu

nn

el

eye

78

24

m

in

@

tu

nn

el e

ye

14

00

PGL

1400

9300

1400

Va

rie

s

Va

rie

s

Va

rie

s

10

0 B

lin

din

g

PGL

60

00

Backfill

Backfill

Va

rie

s 4

50

0 m

in

Mass concrete infill

See Note 2

Mass

concrete

infill

See Note 2

25

00

CJ CJ

Pile

L

en

gth

Pile

L

en

gth

CJ

CJ CJCJ

Install steel staircase before

constructing cover building

SSL Tunnel

Va

rie

s




CJ CJ

Ø6700

℄Tunnel

Emergency escape

headhouse - details TBC

CJCJ

CJ CJ


14

26


grouting between piles if

required to manage

groundwater ingress


grouting if required to manage

groundwater ingress


mass grouting if required

to manage groundwater

ingress

157

60


Scale 1:250

41400

Backfilled TBM Launch Ramp

Emergency escape staircase

Emergency escape

headhouse - details TBC

C1

C1

C2

C2

Any temporary works


works cut down

Refer to tunnel drawings for interface

movement joint and sealant details to

tunnel.

Indicative covered sump

Backfill

3% Fall



210800 to start of Portal roof

Ø1050 Pile

14

26

1500

1400

10000

1000010000 10000 10000 10000 10000 10000

Piles

750 dia @ 900crs

Length = 18550

Piles

750 dia @ 900crs

Length = 18950

Piles

750 dia @ 900crs

Length = 19350

Piles

750 dia @ 900crs

Length = 19750

Piles

750 dia @ 900crs

Length = 20200

Piles

750 dia @ 900crs

Length = 20600

Piles

750 dia @ 900crs

Length = 20900

Piles

900 dia @ 1050crs

Length = 23850

Piles

1050 dia @ 1200crs

Length = 25100


940020000 20000 20000

CJ

CJ

CJ

Bre

aklin

e

2140021400

1400

(to match wall)

TunnelRecess for

TBM cradle

Indicative zone of rock mass grouting

between piles if required to manage

groundwater ingress

PGL & EGL

RC = 190kg/m

3

RC = 200kg/m

3

RC = 200kg/m

3

RC = 200kg/m

3

RC = 170kg/m

3

Tunnel Eye

E 458154.321

N 522678.880

IL -5.165mAOD

CJ

CJ

250

0

14

26

1200 min

Pit for TBM assembly

Indicative zone of rock Indicative zone of rock

mass grouting if

required to manage

groundwater ingress

YORK POTASH LIMITED

PROJECT

DRAWING No.

CONSULTANT

DRAWING No.

DRG SIZE: SCALE:

CLIENT

APPR

REVISION:


DOCUMENT REVIEW





SIGNED: DATE:

A1





1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

DRAWING TITLE:


13 Fitzroy Street

London W1T 4BQ

Tel +44(0)20 7636 1531 Fax +44(0)20 7580 3924

www.arup.com

25900-MTS-C00-2250-22103

WILTON PORTAL

GENERAL ARRANGEMENT - SHEET 3 OF 3

CONCRETE OUTLINE

1:250 & 1:100

B


DP RDMass rock grouting details amended

A

B

19/08/2014

28/08/2014

MS

MS

Notes


2. Mass concrete infill to be reinforced on the top surface

3. Refer to spaceproofing drawings for TBM launch chamber





grout.



rock

7. For pricing of rock mass grouting beneath base assume excavation to 4m above formation then drill

and inject on a 5m grid to treat a zone 2 - 3m thick beneath final excavation level (7m total depth).


Key Plan



ARUP – 25900-MTS-C00-2250-22112, 2590-MTS-C00-2250-22113 – WILTON PORTAL – CONSTRUCTION SEQUENCE – SHEET 2 TO 3

65

00

65

00

60

00

500

500

Va

ries

25

00

ma

x

Varie

s

145

00

m

ax

Varie

s

850

0 m

ax

Install piles and

rock mass

grouting from

ground level

Excavate and

install prop

Excavate Install 2nd prop

Inject rock mass

grouting beneath base

from within excavation

Step 1 Step 2 Step 3 Step 4

60

00

50

0

Va

rie

s

60

00

m

ax

Va

rie

s

25

00

to

4

50

0

Starter bars

Remove prop after

cast base slab gains

full strength

Cast end wall at

tunnel eye and

last wall panel

on both sides.

Va

rie

s

20

50

0 m

ax

Blinding

Contractor

designed

drainage details

not shown

Cast base slab

Starter bars

10

00

Excavate to

formation level


Remove prop after

cast roof slab gains

full strength

Remove prop after backfilling

Cast roof slab

Cast remaining

walls

Pour mass

concrete infill

Backfill

Finish and landscapeCut down piles to

1m below FGL

TBM

assembled

50

0

Va

rie

s 2

50

0 m

ax


YORK POTASH LIMITED

PROJECT

DRAWING No.

CONSULTANT

DRAWING No.

DRG SIZE: SCALE:

CLIENT

APPR

REVISION:


DOCUMENT REVIEW





SIGNED: DATE:

A1





1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

DRAWING TITLE:


13 Fitzroy Street

London W1T 4BQ

Tel +44(0)20 7636 1531 Fax +44(0)20 7580 3924

www.arup.com

25900-MTS-C00-2250-22112

WILTON PORTAL

CONSTRUCTION SEQUENCE - SHEET 2 OF 3

SEQUENCING OF TBM LAUNCH CHAMBER

1:200

B


DP RDGrouting details amended

A

B

19/08/2014

29/08/2014

MS

MS

Notes


2. Construction sequence indicative only.

Key Plan

B


℄MJ

Any temporary works


works cut down



25000 2000025000 25000 25000 20000

Ø1050 Pile

1500

1400


10000 10000 10000

Piles

900 dia @ 1050crs

Length = 9250

10000 10000 1000010000 10000 10000 1000010000 10000

Piles

900 dia @ 1050crs

Length = 9575

Piles

900 dia @ 1050crs

Length = 11750

Piles

900 dia @ 1050crs

Length = 12100

Piles

900 dia @ 1050crs

Length = 12450

Piles

900 dia @ 1050crs

Length = 12750

Piles

900 dia @ 1050crs

Length = 12800

Piles

750 dia @ 900crs

Length = 12150

Piles

750 dia @ 900crs

Length = 12500

Piles

750 dia @ 900crs

Length = 12800

Piles

750 dia @ 900crs

Length = 13200

8500 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 10000 1000010000

Piles

750 dia @ 900crs

Length = 12600

Piles

750 dia @ 900crs

Length = 13000

Piles

750 dia @ 900crs

Length = 13500

Piles

750 dia @ 900crs

Length = 13900

Piles

750 dia @ 900crs

Length = 14350

Piles

750 dia @ 900crs

Length = 14800

Piles

750 dia @ 900crs

Length = 15250

Piles

750 dia @ 900crs

Length = 15700

Piles

750 dia @ 900crs

Length = 16100

Piles

750 dia @ 900crs

Length = 16500

Piles

750 dia @ 900crs

Length = 16900

Piles

750 dia @ 900crs

Length = 17300

Piles

750 dia @ 900crs

Length = 17700

Piles

750 dia @ 900crs

Length = 18150

Piles

750 dia @ 900crs

Length = 18550

Piles

750 dia @ 900crs

Length = 18950

Piles

750 dia @ 900crs

Length = 19350

Piles

750 dia @ 900crs

Length = 19750

Piles

750 dia @ 900crs

Length = 20200

Piles

750 dia @ 900crs

Length = 20600

Piles

750 dia @ 900crs

Length = 20900

Piles

900 dia @ 1050crs

Length = 23850

Piles

1050 dia @ 1200crs

Length = 25100


℄MJ

20000

℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ ℄MJ

940020000 20000 20000 20000 20000 20000 20000 20000 20000

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

CJ

℄MJ ℄MJ

1200 1200

2140021400

1400

(to match wall)

CH 370.800

Pile RC = 200kg/m

3

Pile RC = 150kg/m

3

Pile RC = 260kg/m

3

Pile RC = 260kg/m

3

Pile RC = 270kg/m

3

Pile RC = 230kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 120kg/m

3

RC = 130kg/m

3

RC = 130kg/m

3

RC = 130kg/m

3

RC = 160kg/m

3

RC = 160kg/m

3

RC = 190kg/m

3

RC = 190kg/m

3

RC = 190kg/m

3

RC = 200kg/m

3

RC = 200kg/m

3

RC = 200kg/m

3

CJ

CJ



groundwater ingress

CJ

CJ




groundwater ingress

Pressure relief

wells required




groundwater ingress




groundwater ingress


mass grouting if

required to manage

groundwater ingress


mass grouting if

required to manage

groundwater ingress







groundwater ingress

Install piles and rock mass

grouting and excavate to

formation level

Cast slab

and walls

Install piles and rock mass grouting,

excavate and instal prop.

Cast slab

Excavate to formation level

Remove prop when base slab gains full strength and cast walls


grouting, excavate and install prop

When slab gains full strength, remove 2nd

level prop, partially cast walls and install

prestressed internal prop

Excavate and install

2nd level prop

Remove top prop and complete

casting of walls and roof

Remove internal prop,

cut down piles to 1m

below FGL and backfill


grouting, excavate and install

prop

Excavate to formation

level and cast base

Excavate and install 2nd prop When slab gains full strength remove

2nd prop and cast walls and roof

Remove top prop, cut

down piles to 1m below

FGL and backfill


grouting, excavate and install

prop

Remove lower prop

and backfill

Remove top prop, cut

down piles to 1m below

FGL and backfill


level and cast base, walls

and roof

EGL FGL

EGL FGL

Cut down piles

to 1m below

FGL and backfill

Va

ries

470

0 m

ax.

Va

ries

61

85

m

ax.

500

180

0

Va

ries

48

85 m

ax

Cut down piles to 1m below FGL and backfill


level and cast base

slab

50

0

18

00

50

0

Va

rie

s

30

00

m

ax

Va

rie

s

47

00

m

ax

Va

rie

s

90

00

m

ax

FGLEGL

EGL

EGL

FGL

FGL

50

0

18

00

50

0

18

00

50

0

Va

rie

s

46

00

m

ax

Va

rie

s

42

00

m

ax

Va

rie

s

95

00

m

ax

50

0

Va

rie

s

83

25

m

ax

50

0

Va

rie

s

15

12

5 m

ax

Excavate and install 2nd prop

50

0

Inject rock mass

grouting beneath base

from within excavation

Step 1

Step 1

Step 1

Step 1

Step 1

Step 2

Step 2 Step 3 Step 4




Chainage

30 to 100

Chainage

100 to 140

Chainage

140 to 200

Chainage

200 to 240

Chainage

240 to 348

Step 6

YORK POTASH LIMITED

PROJECT

DRAWING No.

CONSULTANT

DRAWING No.

DRG SIZE: SCALE:

CLIENT

APPR

REVISION:


DOCUMENT REVIEW





SIGNED: DATE:

A1





1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

A

B

C

D

E

F

G

H

J

K

L

M

N

O

P

DRAWING TITLE:


13 Fitzroy Street

London W1T 4BQ

Tel +44(0)20 7636 1531 Fax +44(0)20 7580 3924

www.arup.com

D

R

A

F

T

25900-MTS-C00-2250-22113

WILTON PORTAL

CONSTRUCTION SEQUENCE - SHEET 3 OF 3

SEQUENCING OF TYPICAL TROUGH AND TUNNEL SECTIONS

1:200

B


DP RDGrouting details amended

A

B

19/08/2014

29/08/2014

MS

MS

Notes

1. For general notes refer to drawing 25900-MTS-C00-2250-22100.

2. Construction sequence indicative only.

Key Plan


A P P E N D I X 2

ASSESSMENT OF LIKELIHOOD AND MAGNITUDE, AND ELEVATION OF IMPACT ASSESSMENT MATRIX

CONSTRUCTION PHASE

Receptor

Made Ground

"aquifer"

Superficial

Deposits

Redcar Mudstone

Formation Mill Race

Construction

Workers

Construction

Materials

Key Characteristics

Physical Impacts

Connectivity between Activityand Receptor Very High Very High Very High Low

Receptor Proximity to Activity Very High Very High Very High Low

Likelihood Very High Very High Very High Low

Magnitude of Effect at Source Low Low Low Low

Magnitude of Effect Low Low Low Very Low

Sensitivity (Value of Resource) Very Low Very Low Very Low Very Low

Significance of Impact Negligible Negligible Negligible Negligible

Connectivity between Activityand Receptor Very High Very High Very High Very Low

Receptor Proximity to Activity Very High Very High Very High Low

Likelihood Very High Very High Very High Low

Magnitude of Effect at Source Very Low Very Low Very Low Very Low

Magnitude of Effect Very Low Very Low Very Low Very Low



Connectivity between Activity, Aquifer and

Receptor Very High Very Low Very Low Very Low

Receptor Proximity to Activity Very High High Moderate Very High

Likelihood Very High Moderate Low Moderate





Chemical Impacts


Receptor Very High

Receptor Proximity to Activity Very High

Likelihood Very High

Magnitude of Effect at Source Moderate

Magnitude of Effect Moderate

Sensitivity (Value of Resource) High

Significance of Impact Moderate


Receptor Very High


Likelihood Very High

Magnitude of Effect at Source Moderate


Sensitivity (Value of Resource) Very High

Significance of Impact Moderate


Receptor Very Low


Likelihood Moderate

Magnitude of Effect at Source High


Sensitivity (Value of Resource) Very Low

Significance of Impact Negligible


Receptor Very Low Very Low Very Low Very Low

Receptor Proximity to Activity Very High High Moderate Very High

Likelihood Moderate Moderate Low Moderate






Receptor Very Low Very Low Very High Very Low

Receptor Proximity to Activity Moderate High Very High Very Low

Likelihood Low Moderate Very High Very Low





Impact of contaiminated

water on construction

materials

Wilton

Construction Activity

Alteration of Groundwater

levels due to dewatering

associated with Tunnel

Portal


levels/flowpaths due

contiguous boreed piles

with pregrouting


levels due to reduced

infiltration in areas of

Permanent Waste

Management Facilities

Impact of contaminated

groundwater on

construction workers

Pollution to surface waters

from discharges of perched

groundwater in the Made

ground

Pollution from Permanent

Waste Management Facility

Pollution from pre‐grouting

to control groundwater

ingress to tunnel poratal

September 2014 1433PortOR05Rev4 ‐ Assessment of Risk

OPERATIONAL PHASE

Receptor

Made Ground

"aquifer"

Superficial

Deposits

Redcar Mudstone

Formation Attenuation Pond

Key Characteristics

Physical Impacts

Connectivity between Activityand

Receptor Very High Very High Very High

Receptor Proximity to Activity Very High Very High Very High

Likelihood Very High Very High Very High

Degree of Change Very Low Very Low Very Low

Magnitude of Effect Very Low Very Low Very Low

Sensitivity (Value of Resource) Very Low Very Low Very Low

Significance of Impact Negligible Negligible Negligible


Receptor Very High Very Low Very Low

Receptor Proximity to Activity Very High High Moderate

Likelihood Very High Moderate Low





Chemical Impacts

Connectivity between Activity,

Aquifer and Receptor Very Low


Likelihood Moderate

Degree of Change Very High


Sensitivity (Value of Resource) Very Low

Significance of Impact Negligible


Aquifer and Receptor Very Low Very Low Very Low


Likelihood Moderate Moderate Low





Wilton





levels/flowpaths due to

Tunnel Portal




Permanent Waste


Pollution to surface waters

from discharges of perched

groundwater in the Made

ground


DECOMMISSIONING PHASE

Receptor

Made Ground

"aquifer"

Superficial

Deposits

Redcar Mudstone

Formation

Key Characteristics

Physical Impacts


Receptor Very High Very High Very High


Likelihood Very High Very High Very High






Aquifer and Receptor Very High Very Low Very Low


Likelihood Very High Moderate Moderate





Chemical Impacts


Aquifer and Receptor Very Low Very Low Very Low


Likelihood Moderate Moderate Low





Wilton





levels/flowpaths due infilled

Tunnel Portal




Permanent Waste



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