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Arizona Set to Open First New Copper Mine in Decade By Giles Lambertson
tured for easier access. A leaching solution is pumped down the hole and dissolves the ore. The resulting solution is pumped to the surface, where the copper is extracted and processed. If all goes as planned, the mine will be brought online in stages with eventual full production of 125 million lbs. of copper cathode per year. The project is appealing to state officials because it is environmentally friendly—nearly all the water pumped into the ground is recovered and reused — and because it will infuse Arizona’s economy with some $3 billion over the life of the mine. This low-profile copper recovery operation is quite different from the common image many people have in their minds when they think of copper mines — vast open pits.
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Mining is part of Arizona’s economic and cultural heritage dating back hundreds of years to when Native Americans plinked for turquoise and coal. Spanish explorers invaded the region in the 1600s looking for silver and gold to carry back across the Atlantic. Today, more than 300 operating mines plumb the Arizona desert landscape, most of them quarrying sand and crushed rock for industrial and commercial use — a $450 million takeaway in 2017. And then there’s copper. The reddish-brown mineral isn’t as ubiquitous as aggregate, but historic and operating copper mines dot a wide swath of the state running from Bisbee near the Mexican border 300 miles northwest to Jerome, which overlooks the Verde Valley in the Black Hills. Current mines are mostly clustered in the southeast quadrant of the state east of Phoenix and Tucson — and a brand-new mine is about to join them.
More than 300 operating mines plumb the Arizona desert landscape, most of them quarrying sand and crushed rock for industrial and commercial use — a $450 million takeaway in 2017.
In-Situ Mine In the fall of 2017, the state issued an operating permit for what will be Arizona’s first new copper mine in more than a decade. Vancouver-based Excelsior Mining was given permission to start developing a 9,500-acre property southeast of Tucson near Benson and Wilcox in Cochise County. As the year ended, all that remained after issuance of the state permit was a federal EPA goahead. Excelsior executives were not available for interviews for this article. Some $47 million in initial con-
struction costs will be invested by Excelsior to set up a mine that is expected to produce copper for a quarter century. But it won’t look like mining to casual observers. The operation eschews traditional mining methods as imagined in popular lore. Hard-hatted miners won’t trudge into a tunnel in the side of a mountain with pickaxes resting on their shoulders. Excelsior’s Gunnison Copper Project will extract copper by employing in-situ leaching. The method involves drilling down into a copper deposit, which may have been explosively frac-
In the fall of 2017, the state issued an operating permit for what will be Arizona’s first new copper mine in more than a decade.
Open Pit Mining Just 90 mi. north of Wilcox is a prime example of such an operation: the Morenci mine. Owned jointly by Freeport-McMoRan and Japan’s Sumitomo Metal Mining, the Morenci operation began nearly 150 years ago as an underground undertaking and has evolved into a whole complex of surface-mining activities. Together, they constitute one of the largest open-pit mining operations in the world. The mine employs some 3,300 people and, in 2017, produced 740 million lbs. of copper. McMoRan executives declined to be interviewed. As is typical of open-pit mining, the Morenci operation has miles of benches circling each gigantic excavation. The benching allows the holes to be stair-stepped into the ground one level at a time. An upward sloping haul road is carved see MINE page 4
Page 2 • May 27, 2018 • www.constructionequipmentguide.com • Arizona State Supplement • Construction Equipment Guide
Phoenix Council OKs $13.5M Investment for ASU Expansion Arizona State University’s partnership with the city of Phoenix on its 12,000-student downtown campus was reaffirmed as the Phoenix City Council approved a $13.5 million investment in a new building for Thunderbird School of Global Management, a 72-year-old international business management school that joined the university in 2014. The move will bring more than 300 graduate students, more than 100 staff and faculty members and hundreds of executive education participants into downtown Phoenix from around the United States and the world. Plans call for construction to begin in 2019 on the new building, on the northwest corner of Polk and Second streets adjacent to the Beus Center for Law and Society. The grand opening is expected to occur by 2021, the school’s 75th anniversary. In the interim, Thunderbird will move to One Arizona Center, as early as this summer for the fall 2018 semester. The Arizona Center is located at 455 N. Third St., adjacent to ASU’s downtown campus. “This is a strategically important move for Thunderbird and the university that we believe will have a very favorable impact on the downtown Phoenix community,” said Michael Crow, ASU president. “We are committed to the downtown campus and to our partnership with the city of Phoenix, so
having made this decision, we want to take action as soon as possible.” Phoenix Mayor Greg Stanton said moving a school focused on international business and management into downtown Phoenix will be an economic development asset to the city of Phoenix in addition to what it does for the ASU campus. “Downtown Phoenix is a growing hub for higher education and innovation, and Thunderbird’s presence offers even more opportunity to attract talent and grow our economy,” Stanton said. Moving Thunderbird from its iconic airbase location in Glendale, home to the school for more than 70 years, will result in a public planning process with the city of Glendale for redevelopment of the nearly 140 acres that encompass the campus and its surrounding area. “Moving is always a leap of faith that brings a sense of renewal and spike of energy,” said Allen Morrison, director-general and CEO of Thunderbird. “It is a wonderful opportunity for a renewal of the school, now better integrated with the university. We appreciate the support from the city of Phoenix, and we couldn’t be more enthusiastic about forging new relationships and new partnerships with the downtown Phoenix community.” Thunderbird began as the American
School of Foreign Trade in 1946 on an air base that was used to train Allied foreign pilots from more than 30 countries for service in World War II. Phoenix business leaders such as Frank Snell, Walter Bimson, Edward O’Malley and Frank Brophy, as well as many others, were founding board members of the new school. Today, Thunderbird has more than 44,000 alumni around the world, with active alumni chapters in more than 140 countries. The school offers specialized master’s degrees in global management and executive education. The school’s bachelor program, which began in 2015 after the merger with ASU, will remain at ASU’s West campus. When complete, Thunderbird’s new building will be 85,000 to 95,000 sq. ft. and will sit adjacent to the Beus Center, which houses the Sandra Day O’Connor College of Law as well as several other organizations. Operational funding will come from the university. Construction of the building will be financed through philanthropy, funds from disposition of the existing Thunderbird site, and the city investment. The university has already begun the public procurement process for hiring an architect and general contractor. “The impact of Arizona State University’s downtown campus has been beyond my expectations,” said Michael Nowakowski,
Phoenix City Councilman, whose district includes the campus. “Thunderbird students, faculty, staff and curriculum will provide an international component for downtown, adding to both the substance and diversity of our community.” In addition to the physical move, Thunderbird will be reshaping its graduate school curriculum and its executive education structure to be more responsive to the demands of a rapidly changing global marketplace. Details on the graduate program modifications are still under review. In addition, Thunderbird will launch a new and more robust model of executive education, with stronger administrative and disciplinary linkages to other ASU units, especially with ASU colleges of law, engineering, journalism, design, health solutions, sustainability and public service and community solutions. “Thunderbird has always been a school based on rigor, excellence and innovation,” said Crow. “With this move, we will be rededicating the school to its core mission to be a force for leadership globally, and we are raising the bar. It is an elite institution. We want students and professional partners whose goal is to stretch, strive and make an impact.” (This story also can be found on Construction Equipment Guide’s website at www.constructionequipmentguide.com.)
ADOT’s $24.4M I-17 Project Rock Removal Begins for Improves Travel to Flagstaff Next Phase of SMF Project An Arizona Department of Transportation project started April 30 to deliver a smoother driving surface along 28 mi. of northbound Interstate 17 leading to Flagstaff, a stretch battered by repeated cycles of freeze and thaw during the winter. In addition to replacing pavement north from the Coconino County line at milepost 312, the $24.4 million project will rebuild 2 mi. of the heavily traveled interstate between mileposts 312 and 314. Crews placed concrete barriers along the interstate between mileposts 312 and 314 in order to start rebuilding the right lane. The highway will first be narrowed to the left lane northbound through the work zone. After the right lane has been reconstructed, crews will rebuild the left lane. This one-lane restriction will stay in place until mid-summer. A 12-ft. vehicle-width restriction will be in place as well as a lowered speed limit throughout the lane restriction. Drivers can expect other restrictions as crews replace pavement along the other 26 mi. of
northbound I-17. Those heading to Flagstaff this summer should budget extra travel time. The project also includes replacing the bridge decks in each direction on the I-17 overpass at Willard Springs Road, near milepost 326. Drivers can expect periodic closures of Willard Springs Road and ramp closures. The majority of the work is expected to be completed later this fall, with additional work happening next spring. ADOT is improving pavement along 182 lane mi. of Interstate 40 and Interstate 17 in the Flagstaff area, addressing deterioration caused by snow and snowplowing, freeze-thaw cycles and heavy use by commercial vehicles. In addition, ADOT is replacing the I-40 bridge decks over I-17 and Beulah Boulevard at the I-40/I-17 interchange in Flagstaff. For more information, visit azdot.gov/projects. (This story also can be found on Construction Equipment Guide’s website at www.constructionequipmentguide.com.)
Controlled rock blasting for the Loop 202 South Mountain Freeway west of 32nd Lane began April 19, requiring brief closures of a road leading to a residential development currently under construction. Periodic closures of Shaughnessey Road are expected to last approximately 30 minutes, as crews need to secure and clear the area before breaking large rock into smaller, more manageable pieces to create a path for the freeway through two ridges at the southwestern edge of South Mountain Park. All controlled rock blasts will be scheduled during daylight hours through early 2019. Message boards will provide advance notice of any traffic restrictions. There will be no more than one closure per day, and the work will comply with safety standards established by the city of Phoenix and the U.S. Bureau of Mines. South Mountain Freeway construc-
tion in the Center segment, a 3-mi. portion of the freeway between 51st Avenue and 32nd Lane, began in March with work to install right-of-way fencing, salvage trees and cactuses and assess the soil, rock and depth of groundwater along the freeway alignment. The South Mountain Freeway will provide a long-planned direct link between the East Valley and West Valley and a much-needed alternative to I-10 through downtown Phoenix. Approved by Maricopa County voters in 1985 and again in 2004 as part of a comprehensive regional transportation plan, the South Mountain Freeway will complete the Loop 202 and Loop 101 freeway system in the Valley. For more information, visit SouthMountainFreeway.com. (This story also can be found on Construction Equipment Guide’s website at www.constructionequipmentguide.com.)
Construction Equipment Guide • Arizona State Supplement • www.constructionequipmentguide.com • May 27, 2018 • Page 3
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Page 4 • May 27, 2018 • www.constructionequipmentguide.com • Arizona State Supplement • Construction Equipment Guide
Excelsior Invests $47M in Construction Costs Into New Mine Mining Engineer Goes Deep to Study Arizona From Below
The Apaches were concerned about water pollution. They also feared damage to sacred sites such as a cliff area called Apache Leap. MINE from page 1
from the hillside for ore-bearing trucks to carry 400-ton payloads of ore to a processor at ground level. The Morenci mine has reportedly produced as much as 900,000 metric tons of ore in a day. The mine also is the home of the world’s first commercial copper concentrate leaching-electrowinning process, which integrates sulphide treatment with other processing methods. Such a massive open-air operation has environmental implications, of course, beginning with the excavation itself. Some open-pit mines have displaced so much earth that they are plainly identifiable by orbiting astronauts. Restoring such manmade holes in the ground to a more natural and sustainable condition comes at an enormous cost, which is factored into every open-pit operating and reclamation budget. Furthermore, severe ecological impact can result from the disruption of the natural balance of water and ground cover, exacerbated by piles of accumulated waste. Widespread erosion and air and water pollution can result from all this. For example, in 2012, the Morenci operation was fined several million dollars by the U.S. Department of the Interior for air pollution violations. However, the fact of the matter is, no
matter how one goes about it, extracting copper ore from Mother Earth is a dirty job, an earth-shattering job. Nature is natural, a manmade excavation obviously is not. Consequently, every proposed mine anywhere is opposed by naturalists and other communities wanting to leave acreage undisturbed, even if that means leaving valuable minerals in the ground for perpetuity. In Arizona, mining opposition includes Native American populations. Deep Mining Near Superior, Ariz., two of the world’s largest mining companies — Rio Tinto and BHP Billiton — are developing a copper mine that is notable for its depth and for early opposition from Native American communities. Dubbed the Resolution Copper Mine, its shafts dive into the earth for more than a mile and will have laterals running between them under the copper deposit. In essence, the ore is mined from beneath, a method called block cave mining. Why would Indian tribes or any other community find such deep-down activity undesirable? Out of sight, out of mind. Yet the mined ore ultimately is moved to the surface for processing, and tailings from processes will be mounded on site. Furthermore, the
removal of ore deep within the earth eventually leads to the sinking of the surface area above it. The Resolution mine depression ultimately could be a mile or so across and as deep as a thousand feet. This eventual deformation of the land, which sits on the edge of Tonto National Forest, was protested by San Carlos Apache leaders, the Sierra Club, and other environmental groups. The Apaches were concerned about water pollution. They also feared damage to sacred sites such as a cliff area called Apache Leap, even though the Resolution mining operations are 20 mi. from the San Carlos Apache Nation boundaries and outside of any areas considered sacred. For their part, environmentalists saw threats to recreational areas. A struggle to win approval of the mine went on for a full decade. Finally, in 2014, Congress approved a federal land swap that allowed the project to begin. To develop the mine on their 2,400 acres, the two international mining companies bought up and exchanged 5,300 acres of prime recreational, conservation and culturally significant land elsewhere in the state. In addition, near Apache Leap — where 75 trapped Apaches warriors are said to see MINE page 6
Kim Huether is into rock. Deep into it. The Rio Tinto mining engineer is responsible for leading technical studies of the Resolution Copper Mine project near Superior, Ariz. Specifically, she is studying southeast Arizona geology more than a mile below the surface of the mine’s entrance where a massive deposit of copper-bearing ore awaits recovery. That sounds like pretty interesting stuff to those of us whose day consists of pushing paper at a desk or sitting in commuter traffic twice a day. Huether said she also finds it interesting, even though she has been at it for 20 years. “It is still exciting. Every mine has its own appeal.” Huether has been on Kim Huether the Resolution Copper Mine site for 14 months, but it isn’t her first deep-mine experience. A graduate of South Dakota School of Mines and Technology, she has studied deep-underground mines — as well as other types of ore-recovery operations — for company properties elsewhere in the United States as well as in Australia, Indonesia and Mongolia. This one in Arizona is a different professional experience because the mine is still being developed. “I actually have quite a passion for this project,” she said. “It is challenging and exciting to be in on it this early. A lot of the other operations in which I was involved were already operating and I was only trying to make them better.” She was asked if the Resolution Copper Mine is technically challenging in any way. “They all seem challenging,” she said. “I think the most challenging thing about it is the depth. We are down 7,000 ft. and with that comes some really significant challenges, geotechnical challenges, like how the rock is going to behave at that depth.” She hopes to stay with the Resolution project for the next couple of stages of development and perhaps longer and watch a mine move almost from inception to production. For now, she is settling in for a few years of data-gathering. Drilling information. Extensive monitoring of underground conditions. Environmental studies. To a commuting paper-pusher, that all sounds a trifle boring. Not to an engineer, however. “It is quite interesting, actually,” Huether said. For a woman to be in this critical management position on a project of this scope is somewhat notable, but Huether said she is not breaking a glass ceiling or anything. “There are quite a few of us [women] out there in these positions and have been for quite a while. We are very lucky.”
Construction Equipment Guide • Arizona State Supplement • www.constructionequipmentguide.com • May 27, 2018 • Page 5
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Page 6 • May 27, 2018 • www.constructionequipmentguide.com • Arizona State Supplement • Construction Equipment Guide
Arizona Expects to See $1B in Benefits From New Copper Mine in 10 Years MINE from page 4
have leapt to their deaths rather than surrender to U.S. Cavalry soldiers — 142 acres were donated by Resolution Copper Mine to the U.S. Forest Service as a part of an 839-acre special management area in which mining will be barred. In the four years since the agreement finally was reached, Resolution Copper company officials have continued to meet with area residents in Superior, where the company is headquartered. The “community working group” meets in the Superior Chamber of Commerce office and includes leaders from towns situated across the local area and San Carlos Apache representatives. Topics range from social and environmental impact issues to air quality, health standards and recreational changes. “We’ve been working with the community and Native Americans for many years now, collaborating, having dialogue, listening and providing input,” said Kyle Bennett, principal advisor of communications at Rio Tinto Kennecott in Utah. Kennecott is a subsidiary of Rio Tinto. “In January, the U.S. Forest Service finalized a plan after a consultation process with 12 tribes and, in addition, the Town of Superior. We are starting to see all the stakeholders coming together in a cooperative way to help shape the project.” According to Resolution Copper spokesman Jonathan Ward, an Arizona State University survey shows some lingering opposition to the project, but 85 percent of the local community now approves of it. Maintaining such support is important because the mine is still a decade away from beginning production. Currently, the mine’s engineers are both digging and data collecting. The digging is happening in No. 9 shaft, a vertical excavation that drops 4,800 ft. A concrete tube, 21 ft. in diameter, is being constructed inside it. The shaft was created in 1971 for a previous mining operation on the site and now is being rehabilitated and deepened to 6,800 ft., a process that will take two more years. At the bottom of the shaft, a lateral tunnel will be excavated that will connect to shaft No. 10. That shaft — which required removal of 475,000
Since work began in February 2017, crews have completed all piers and abutments that will support the 2,700-ft.-long Salt River Bridges. Meanwhile, work is progressing on the bridges’ girders, decks and railings.
Salt River Bridges Reach New Heights The mine is expected to produce about $1 billion in economic benefits for Arizona every year, or more than $60 billion by the time the huge copper deposit a mile down is depleted.
tons of rock — is an all-new penetration of the site. Its tube is 28 ft. in diameter and bottoms out almost 7,000 ft. below the surface. The two shafts skirt the edge of what is expected to become North America’s biggest copper mine, with some two billion metric tons of copper-bearing ore awaiting recovery. Over the 40-year life of the mine, additional shafts will be sunk alongside the deposit. Because air pressure and geothermal factors raise temperatures so far underground — to well above 120 degrees Fahrenheit in some cases — fans and refrigerator units are being installed at various depths to pump cooling air into the tunnels as well as into deep-underground computer work stations and offices adjacent to the shaft. (The heat is, of course, not a local phenomenon. Some South African mines are almost 2.5 mi. deep and have bottom temperatures in the range of 140 degrees Fahrenheit.) Topside, ongoing work at Resolution includes reclamation activity stemming from the site’s old Magma Mine. This year, some 125 Resolution employees are working above and below ground. At full production, after the shafts are functioning and the processing and transportation facilities are built, the mine will have a workforce of 1,400 people. Pre-production investments for deep mining are as massive as the operation itself. Some $600 million is being expended just to sink and prepare the two shafts. In all, $7 billion is expected to be spent by the partnering companies
before the first copper ore is raised to the surface. Analysts for London-based Rio Tinto, which owns 55 percent of the project, are betting the price of the commodity will stay high enough over the long haul to recoup all that expense and then some. During the last decade, the price of a pound of copper has ranged from $2 up to $4. As of mid-April, it stood at $3.13. What must the price average in the years ahead for the mine to be profitable? Bennett, the Rio Tinto Kennecott spokesman from Utah, would only say it all depends. “You have to measure that on a caseby-case basis. A lot of factors come into play, including development costs and production,” he said. “I would say in general we invest in long-life, low-cost assets. We feel that geologically this is going to be one of the greatest copper assets in the world once we have a chance to actually mine it.” Which is good news for Arizona. As Bennett puts it, Resolution Copper Mine will provide “a significant financial contribution to the state of Arizona and local economies. The economic piece of the operation is very strong.” Specifically, the mine is expected to produce about $1 billion in economic benefits for Arizona every year, or more than $60 billion by the time the huge copper deposit a mile down is depleted. (This story also can be found on Construction Equipment Guide’s website at www.constructionequipmentguide.com.) CEG
The longest bridges on the Loop 202 South Mountain Freeway, two half-mile-long spans over the Salt River, are quickly emerging in Laveen, Ariz. Construction is now twothirds complete on these bridges, which will serve growing areas of the southwest Valley when the freeway opens by late 2019. Travelers in this area currently have access to just one allweather crossing of the Salt River between 35th Avenue and Avondale Boulevard: the city of Phoenix’s 51st Avenue bridge. When the Salt River flows, significant traffic congestion occurs, particularly along 51st Avenue. Since work began in February 2017, crews have completed all piers and abutments that will support the 2,700-ft.-long bridges. Meanwhile, work is progressing on the bridges’ girders, decks and railings. The concrete girders, which are manufactured locally, are the longest precast girders ever installed by the Arizona Department of Transportation. Each weighs 169,000 lbs. and is 170 ft. long. Once the girders are transported to the construction site, two large cranes work in tandem to hoist and methodically place them, with some girders needing to be lifted more than 50 ft. above the riverbank. To date, 238 of 292 girders have been set. By fall 2018, after all the girders are in place and the bridge deck’s surface is finished, construction equipment will be able to travel across the bridges for the first time, aiding earthwork needed to build the freeway mainline. Connect 202 Partners, the developer of the South Mountain Freeway, will then haul more than 700,000 cu. yds. of dirt material across the bridge to locations north of the Salt River. The South Mountain Freeway will provide a long-planned direct link between the East Valley and West Valley and a much-needed alternative to Interstate 10 through downtown Phoenix. Approved by Maricopa County voters in 1985 and again in 2004 as part of a comprehensive regional transportation plan, the South Mountain Freeway will complete the Loop 202 and Loop 101 freeway system in the Valley. For information on the project, visit SouthMountainFreeway.com. (This story also can be found on Construction Equipment Guide’s website at www.constructionequipmentguide.com.)
Construction Equipment Guide • Arizona State Supplement • www.constructionequipmentguide.com • May 27, 2018 • Page 7
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ADOT Tests Pavement Treatment on San Joaquin Road A 4.3-mi. section of San Joaquin Road between Old Ajo Highway and Milky Way Drive has been selected as a testing ground for several pavement treatments. Twelve different treatments will be tested for various factors to ascertain life-cycle return on investment leading to more costeffective selection of pavement treatments for use in Pima County. The treatments will be laid in multiple 1,000-ft. test sections covering both directions of traffic. Pima County will group the treatments by color and texture to minimize the visual patchwork. The balance of the roadway will be repaved by removing 2 in. of existing asphalt and replacing it with 2 in. of traditional asphalt. The result will be the complete repair of a 4.3mi. section of roadway that has fallen into poor condition. The Department will evaluate the wear to test segments every six months, and forecast performance each treatment over time. The County also will study the road over several years to determine the
The treatments will be laid in multiple 1,000-ft. test sections covering both directions of traffic.
best, most cost-effective and longterm treatment options. Construction is scheduled for this summer with treatments to include: • 1 in. green asphalt over existing • 1 ¼ in. overlay of existing with PAG 3 Terminal Blend • 2 in. overlay of existing (PAG 2 mix)
• 2 in. overlay of existing (PAG 2 mix with fiber) • 2 in. overlay of existing (PAG 2 mix terminal blend) • pulverize 5 in. and compact with cape seal (chip seal plus slurry seal) • pulverize 5 in. and compact with chip seal
• pulverize 5 in. and compact with cement (300 psi) and chip seal • pulverize 5 in. and compact with cement (500 psi) and chip seal • 6 in. roller compacted concrete • double chip seal over existing • rubberized chip seal over existing • 2 in. mill and fill (PAG 2 mix)
Evaluation of the test treatments are scheduled to occur six months post construction and at annual intervals thereafter. Observations will include: cracking, rutting, oxidation, surface wear and roughness, supplemented by the regional Pima Association of Governments/city of Tucson Automated Road Analyzer van and additional laboratory tests as needed. Treatment-specific curves will be developed based on data from each evaluation interval to rank treatment benefit-cost projection based on standardized return on investment criteria. These curves will be correlated against longerterm national research data for that treatment type, to infer longer term performance from shorter observation periods. The treatment curves will be controlled to account for minor localized variations in soil or drainage conditions. (This story also can be found on Construction Equipment Guide’s website at www.constructionequipmentguide.com.)
Page 8 • May 27, 2018 • www.constructionequipmentguide.com • Arizona State Supplement • Construction Equipment Guide
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