Structural Failures Cost Lives and Time

Recent failures of storage bins, silos and other structures highlight the need to increase awareness of hazards associated with these structures. Since 2010, one miner was killed when a storage bin collapsed; another miner was killed when the concrete silo he was standing on collapsed. These deaths and several near misses are alarming. Careful examination and prompt correction of hazards are essential to maintaining these structures. These occurrences can be greatly reduced by utilizing the following best practices.

Examine structures for indications of damaged, weakened or displaced structural elements, bulging or deformed bin sides or tops, gapped joints, cracked or broken concrete, corroded or fatigue-cracked metal, bent or buckling columns, beams or braces, loose or missing connectors, cracked, broken or inadequate welds, etc.

Inspect structural elements for reduced load-carrying capacity, thinned or missing sections of beam and column webs or flanges, corroded rusted or flaked metal surfaces, delaminated plywood or water-weakened wooden structures.

Clean accumulations of material from around the base of structures and flanges of horizontal beams. Carefully inspect for damaged support columns, braces, anchor bolts and eroded foundations.

Report all areas where indications of structural weakness are found. Protect lower level structural elements from collision damage by mobile equipment. Minimize spillage and eliminate the source promptly. New structures should be designed and certified as appropriate by a registered

professional engineer in accordance with local building codes and in conformance with accepted engineering practices. Significant modifications to existing structures should be undertaken only after consultation with an engineer. Structures should be constructed according to plans and specifications by trained workers using good materials and employing generally accepted construction methods.

Report Structural Damage or Deterioration

To Your Supervisor

PowerPoint prepared by Terry Taylor, P.E., Senior Civil Engineer, PSHTC

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Structural Condition Assessments

3

Structural Materials

Steel Concrete (plain, reinforced,

pre-stressed) Timber Other - Masonry, Aluminum, Fiber-

Reinforced Polymer (FRP), etc.

4

Inspecting Structural Steel

Corrosion (holes,delamination & loss of cross section)

Cracking (overload & fatigue)

Overloads (buckling & deflection)

Member Impact Damage

5

Corrosion holes & delamination

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Reinforced Concrete

Concrete is strong in compression but weak in tension. Rebar is introduced so that steel, which is strong in tension, can carry the tensile load while concrete carries the compressive load.

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Inspecting Concrete Structures

Cracking Delamination

(Internal Splitting - Silos)

Spalling Rebar Corrosion Crushing Impact Damage

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Spalling & Corrosion from Exposure to Chemicals

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Inspecting Timber Structures

Cracking Deflection /

Sag Crushing Fungi - molds,

rot, dry rot Wood Boring

Insect Damage

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Inspection Tools

Cleaning chipping hammer, wire brush

Inspection chipping hammer, screw driver or ice-

pick, plumb bob, flashlight, binoculars Measuring tape, calipers,

ultrasound, level Safety & Misc. - safety harness, dust

mask, compass

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MNM Surface - 56.11001 MNM Underground 57.11001 Safe Access

Safe means of access shall be provided and maintained to all working places.

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MNM Surface - 56.14100 MNM Underground 57.14100 Machinery & Equipment Safety Defects

b) Defects on any equipment, machinery, and tools that affect safety shall be corrected in a timely manner to prevent the creation of a hazard to persons.

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MNM Surface -56.14205 MNM Underground -57.14205 Machinery, Equipment, & Tools

Machinery, equipment, and tools shall not be used beyond the design capacity intended by the manufacturer where such use may create a hazard to persons.

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Inspection of Processing Plants

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Beams - Bending & Shear Resistance

Beams and girders are common members used to resist bending moments and shearing forces. Bending is resisted by flanges; shear is resisted by web.

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Bending Moment

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Shear Force

Equal (magnitude) but opposite (direction) forces which tend to slide one section of a member past an adjacent section.

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Corroded web of wide flange beam

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Long corrosion hole at web to flange interface

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This beam was still standing (?)

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Corrosion hole in web of beam (hidden by piping)

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Corrosion holes in web of beam

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Corroded web @ end of beam

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Corrosion hole in web & buckled top flange

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Heavy delamination of bottom flange

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Buckled web

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Buckled webs of corroded channels

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Beam modifications need engineered!

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Columns

Buckled column flanges @ web corrosion hole

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Corrosion hole in web of column

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Buckled flanges at bottom of column @ corrosion hole

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Repaired column base (appears good)

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Bad Repair At Column Base

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Another Bad Column Repair (base)

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a few feet up from base

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Rotted timber column

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An equipment mishap these types of repairs can be evaluated by an engineer

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Crooked Column (creation of moment)

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Severe equipment damage

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Replacement time!

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Inspect the column foundations

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Dont take the bracings out!

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Corroded diagonal brace

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Corroded diagonal and gusset plate

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Corroded diagonal

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Corroded channels/girts supporting the siding

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Check equipment supports! Corrosion hole in channel post for a magnetic separator

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Corroded channel post support for a magnetic separator

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Crack in a support beam for a shaker screen

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Fractured spring support for vibrating equipment

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Deteriorated concrete flooring

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Floor slab cracks - a potential source of rebar corrosion

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Look at floor grating - corrosion @ supports

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Corrosion at support edge of grating

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Corroded stair channels

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Corroded angle supporting stair tread

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Dont forget to check the handrails!

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Corrosion holes in handrail support post

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Heavy Roof Loading

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Roof Collapse Due to Clinker Buildup and Snow Load

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Inside of Failed Structure

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Collapsing Roof Support Purlins

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Corrosion of bottom flange of roof support channel

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Buckled Vertical Roof Truss Member

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Check tightness Look for missing bolts sheared bolts elongated bolts excessive

corrosion

Bolted Connections

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Inspect connections! Corroded bolt heads

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cracked welds poor quality - irregular

surface corrosion in connected

parts Always use qualified

welders

Welded Connections

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Fractured weld @ connection

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Vibrating equipment - fracture & poor quality weld

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Irregular weld surface w/porosity

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Exposed rebar on the side of a concrete settling tank

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Collapsed floor Avoid this!

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Plant collapses can be costly.

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Recap - Inspection of Processing Plants

Check the beams, columns, diagonal braces

Examine members for buckling, corrosion, damage, excessive sag, holes, local buckling, and cracking.

Examine connections for corrosion, missing or cracked elements

Examine floors, roofs, walls, & foundation

Examine equipment supports, stairways, & handrails

StructuralFailuresAlertAttach.pdfStructural Inspection of Processing Plants Slide Number 2Structural MaterialsInspecting Structural Steel Slide Number 5Reinforced Concrete Inspecting Concrete StructuresSlide Number 8Inspecting Timber StructuresInspection ToolsMNM Surface - 56.11001 MNM Underground 57.11001 Safe AccessMNM Surface - 56.14100 MNM Underground 57.14100Machinery & Equipment Safety Defects MNM Surface -56.14205MNM Underground -57.14205 Machinery, Equipment, & ToolsInspection of Processing PlantsBeams - Bending & Shear ResistanceBending MomentShear ForceSlide Number 18Slide Number 19Slide Number 20Slide Number 21Slide Number 22Slide Number 23Slide Number 24Slide Number 25Slide Number 26Slide Number 27Beam modifications need engineered! Slide Number 29Slide Number 30Slide Number 31Slide Number 32Bad Repair At Column BaseAnother Bad Column Repair (base) a few feet up from baseSlide Number 36Slide Number 37Crooked Column (creation of moment)Severe equipment damageReplacement time!Slide Number 41Slide Number 42Slide Number 43Slide Number 44Slide Number 45Slide Number 46Slide Number 47Slide Number 48Slide Number 49Slide Number 50Slide Number 51Slide Number 52Slide Number 53Corrosion at support edge of grating Slide Number 55Slide Number 56Corroded angle supporting stair treadSlide Number 58Slide Number 59Slide Number 60Roof Collapse Due to Clinker Buildup and Snow LoadInside of Failed StructureSlide Number 63Slide Number 64Slide Number 65Slide Number 66Slide Number 67Slide Number 68Slide Number 69Slide Number 70Slide Number 71Slide Number 72Collapsed floor Avoid this!Slide Number 74Recap - Inspection of Processing Plants