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CASE HISTORY ZAF - CH - 030: Eng - Rev. 08, June 2014 VAN RYSSEN DAM PHALABORWA, LIMPOPO PROVINCE HYDRAULIC & EROSION CONTROL / DAMS & RESERVOIRS Product: Terramesh® System Problem In order to comply with the National Water Act (Act 36 of 1998), Foskor Mine wants to collect and contain polluted surface runoff from its tailing dams in the Van Ryssen Dam for re-use in the mines processing plant. The Water Management Project incorporating this recycling will result in reduced raw water requirements, which are currently sourced from this water scare area at a barrage in the Olifants River. The dam will be sealed with an impermeable Bentonite layer and designed to cater for the 1:50 year flood, further benefiting the environment by preventing contamination of the downstream water resource. Starting Terramesh® Installation Date: Oct 2003 Packing the front face Date: Oct 2003 Backfilling Date: Oct 2003 Solution As with all earth embankments, the higher the structure the more fill material is required. The initial design solution comprised a 22m high rockfill dam with an upstream earthfill facing only. However, through a simple adjustment involving reducing the height of the rockfill structure to 19m and making up the last 2,4m in height with a vertical Terramesh® wall on the upstream side, the amount of required rock was reduced significantly. Lack of suitable dam-building material e.g. clay, meant that recycling of the waste rock dumps to create a rockfill dam was the most obvious solution. Client name: FOSKOR MINE Main contractor name: GRINAKER LTA CIVIL ENGINEERING Consultant: KNIGHT PIESOLD Product used: TERRAMESH® SYSTEM Construction info: Construction date: SEPTEMBER 2003 Completion date: MARCH 2004 Page 1 of 2 As part of the ISO 9001 Management Systems, guided research and development programmes, information contained herein is continuously updated. Please confirm with Maccaferri SA (Pty) Ltd the latest version of the Product’s Specification available. Benefits The greatest benefit lay in the reduced earth fill quantities and project costs as tabled below: Earthfill (m³) Cost (R million) Original 290 000 32 Saving 100 000 8 % Saving 30 25 Maccaferri’s MacStars 2000™ software program was used to design the structure. The program performs a series of stability checks of the reinforced structure and provides a detailed calculation report, cross sections and safety factors for the final design. Seismic loading together with the RMF flood had to be accounted for during the design of the wall. Compaction of material in front of wall Typical Section Page 2 of 2 Date: March 2004