TM

Innovation on a Roll
CANAL LINING
Project Info

JUN

2 02 / 06 / 22

CCX-MATTM (CCX-MTM)
Bulk Rolls

# 32,000m2

Transverse layers

Kolwezi, Democratic
Republic of Congo (DRC)

Contractor: KCS
Client: Kamoa Copper
S.A
CCX-M™ was installed to
i canalise pumped water
from settling ponds to a
river outlet.

Arial shot of completed canal lining works

In June 2022, CCX-MAT™ (CCX-M™) was installed to canalise pumped water from settling ponds to a river outlet in
Kolwezi, Democratic Republic of Congo. Mining operations at Kamoa Kakula Mine are mainly carried out underground.
Due to the high water table and prevalence of subsurface water, continuous pumping is required to ensure safe and
favourable working conditions. This underground water is pumped into settling ponds which allow sediments to settle
prior to canalising to the local river outlet - with the settling ponds to the river outlet being approximately 4km long.

To ensure that no water permeated back into the mine as well as protect the substrate from erosion, a lining solution was
required. In addition to the pumped water, the canal needed to have the capacity to drain stormwater collected from the
catchment above ground. As the subgrade running the length of the canal are lateritic the flow rates in which the canal
would be operating under would have caused the soil to erode but also allow the water to permeate back into the mine.

A number of lining solutions were considered including a geomembrane underlay with poured concrete, shotcrete or
riprap protection. However, due to the scale of the canal and proximity to the rainy season, a fast and effective solution
was needed. Due to the canal being used to divert pumped water as well as storm water, the lining solution needed to
withstand and sustain flow rates of up to 6m/s as well as abrasion caused by sediment accumulated by storm water
runoff.

*Geosynthetic Cementitious Composite Mat

+44 (0) 345 680 1908 [email protected] www www.concretecanvas.com

This document is provided subject to our General Disclaimer a copy of which can be found at https://linksto.cc/tlgd. All warranties, representations and other terms, express or implied, that may apply to this document or any information within
it including warranties of merchantability, fitness for any particular purpose, and non-infringement of third party patents are excluded, and we accept no liability with respect to or arising from use of information or any product discussed in it.
© Concrete Canvas Ltd. 2023 Patent and Trade Mark information can be found here: https://www.concretecanvas.com/patent-trademark-info/
 TM

Innovation on a Roll
CANAL LINING

Canal profile and anchor trenches excavated prior to installation CCX-M™ laid transversely across the canal

CCX-M™ overlapped by 100mm and secured using stainless steel screws New day to previous day overlap with double row of screws

CCX-M™ secured within a transverse anchor trench using pegs & poured concrete Anchor trenches backfilled with non-erodible fill

+44 (0) 345 680 1908 [email protected] www www.concretecanvas.com

This document is provided subject to our General Disclaimer a copy of which can be found at https://linksto.cc/tlgd. All warranties, representations and other terms, express or implied, that may apply to this document or any information within
it including warranties of merchantability, fitness for any particular purpose, and non-infringement of third party patents are excluded, and we accept no liability with respect to or arising from use of information or any product discussed in it.
© Concrete Canvas Ltd. 2023 Patent and Trade Mark information can be found here: https://www.concretecanvas.com/patent-trademark-info/
 TM

Innovation on a Roll
CANAL LINING

CCX-M™ hydrated using a hose and water bowser

CCX-M™ was chosen as the prefered lining solution due to it being rapid to install - with very little need for a large
workforce and plant. CCX-M™ was also chosen for the project due to the material being able to withstand significant
flow rates, protect the canal from any erosion and mitigate any water from permeating the soil.

Prior to CCX-M™ being installed, the canal had to be first dug to specifiction. The canal profile with an invert width of
2m, top width of approximately 7m, depth of 1.5m and side slopes of 1:1.5 was excavated to the requisite falls and
compacted to between 90 and 95% MOD AASHTO. All vegetation and protruding objects were removed, and voids
filled to achieve a uniform profile. Anchor trenches at least 150mm deep were excavated parallel to the canal profile,
offset at 300mm from the profile crest.

Once the canal was excavated, Bulk Rolls of CCX-M™ were brought onto site and and lifted into place using an excavator
with a spreader beam attachement. Using the excavator boom arm, the CCX-M™ was laid transversely across the width
of the canal. The material was cut to length using basic hand tools to ensure a minimum run-out of 100mm within the
anchor trenches. Each layer of CCX-M™ was overlapped by 100mm in the directional flow of water. Prior to jointing the
overlapping layers, intermediate flat round head pegs were installed through the underlap of each joint at the transition
from side slope to invert. This served a dual function, counteracting hydration shrinkage whilst the CCX-M™ material
cured as well as resisting hydraulic shear under the anticipated flow conditions.

The overlapping layers of CCX-M™ were then thermally bonded with a handheld hot air welder to achieve a low
permeability joint. Stainless steel screws at 100mm spacings, 50mm from the overlap edge were used to further secure
the overlapping layers. The CCX-M™ material was pegged within anchor trenches and the backfilled with non-erodable
fill. Transverse anchor trenches were installed at the upstream and downstream ends of the canal as well as transitions
at all structures crossing the canal. These transverse anchor trenches were excavated to a minimum width and depth of
300mm. CCX-M™ was terminated within these trenches and then filled with poured concrete.

+44 (0) 345 680 1908 [email protected] www www.concretecanvas.com

This document is provided subject to our General Disclaimer a copy of which can be found at https://linksto.cc/tlgd. All warranties, representations and other terms, express or implied, that may apply to this document or any information within
it including warranties of merchantability, fitness for any particular purpose, and non-infringement of third party patents are excluded, and we accept no liability with respect to or arising from use of information or any product discussed in it.
© Concrete Canvas Ltd. 2023 Patent and Trade Mark information can be found here: https://www.concretecanvas.com/patent-trademark-info/
 TM

Innovation on a Roll
CANAL LINING

Completed installation

The weather conditions during the day were hot, dry and windy. To ensure the CCX-M™ did not cure prematurely
the material was hydrated a minimum of 3 times to ensure adequate hydration. These hydrations were carried out at
30-minute intervals with no trafficking of the CCX-M™ surface permitted. All material was hydrated on the day it was
installed.

Due to the speed and ease of application, CCX-M™ was installed at an average rate of 10 rolls (950m2) per day with a
team of 10 installers. The installation team was spilt into teams each designated by task which involved laying, jointing,
fixing and hydrating.

The project has been deemed a significant success by both the client and the EPCM contractor, DRA. This has resulted in
the specification of CCX-M™ for significant additional scope on the mine as well as consideration for other applications.

“CCX-M™ was easy to work with as the installers could learn and apply the installation techniques easily and quickly.
The quick and efficient technical assistance received from Concrete Canvas Ltd also aided in the success of this part
of the project.”
Ettienne Breytenbach @ DRA Global

+44 (0) 345 680 1908 [email protected] www www.concretecanvas.com

This document is provided subject to our General Disclaimer a copy of which can be found at https://linksto.cc/tlgd. All warranties, representations and other terms, express or implied, that may apply to this document or any information within
it including warranties of merchantability, fitness for any particular purpose, and non-infringement of third party patents are excluded, and we accept no liability with respect to or arising from use of information or any product discussed in it.
© Concrete Canvas Ltd. 2023 Patent and Trade Mark information can be found here: https://www.concretecanvas.com/patent-trademark-info/