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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St r uc t ur al Condi t i on Assessment s
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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

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Cor r osi on hol es & del ami nat i on
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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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Cor r oded web of w i de f l ange beam
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Long corrosion hole at web to flange interface
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Thi s beam was st i l l st andi ng (?)
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Cor r osi on hol e i n web of beam (hi dden by pi pi ng)
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Cor r osi on hol es i n web of beam
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Cor r oded web @end of beam
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Cor r osi on hol e i n web & buck l ed t op f l ange
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Heavy del ami nat i on of bot t om f l ange
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Buck l ed web
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Buc k l ed webs of c or r oded c hannel s
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Beam modifications need engineered!
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Columns
Buc k l ed c ol umn f l anges @web c or r osi on hol e
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Cor r osi on hol e i n web of c ol umn
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Buc k l ed f l anges at bot t om of c ol umn @c or r osi on
hol e
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Repai r ed c ol umn base (appear s 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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Rot t ed t i mber c ol umn
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An equi pment mi shap t hese t ypes of
r epai r s c an be eval uat ed by an engi neer
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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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I nspec t t he c ol umn f oundat i ons
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Dont take the bracings out!
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Cor r oded di agonal br ac e
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Cor r oded di agonal and gusset pl at e
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Cor r oded di agonal
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Cor r oded c hannel s/gi r t s suppor t i ng t he
si di ng
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Check equipment supports! Corrosion hole in channel post
for a magnetic separator
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Cor r oded c hannel
post suppor t f or a
magnet i c
separ at or
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Cr ac k i n a suppor t beam f or a shaker sc r een
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Fr ac t ur ed spr i ng suppor t f or
vi br at i ng equi pment
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Det er i or at ed c onc r et e f l oor i ng
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Fl oor sl ab c r ack s - a pot ent i al sour c e of
r ebar c or r osi on
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Look at f l oor gr at i ng - c or r osi on @suppor t s
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Corrosion at support edge of grating
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Cor r oded st ai r c hannel s
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Corroded angle supporting stair tread
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Dont f or get t o c heck t he handr ai l s!
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Cor r osi on hol es i n handr ai l suppor t post
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Heavy Roof
Loadi ng
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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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Cor r osi on of bot t om f l ange of r oof suppor t c hannel
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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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I nspec t c onnec t i ons! Cor r oded bol t 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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Fr ac t ur ed wel d @c onnec t i on
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Vi br at i ng equi pment - f r ac t ur e & poor
qual i t y wel d
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Irregular weld surface w/porosity
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Ex posed r ebar on t he si de of a c onc r et e
set t l i ng t ank
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Collapsed floor Avoid this!
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Pl ant c ol l apses c an be c ost l y.
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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