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Gypsum Stack Extension Home : Photos of a Typical Gypsum Stack Construction
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Mike Fedunec, Environment, Health and Safety Superintendent
Agrium Bag 20
Redwater, AB   T0A 2W0
Phone: (780) 998 - 6312
Fax: (780) 998 - 6143
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Photos of a Typical Gypsum Stack Construction

Photo 1:

 

Site Preparation - Prior to construction, gas and power utilities in the extension area will be relocated.

The first step in the construction process is removal of topsoil. After the topsoil has been removed, the surface is graded and prepared for installation of the synthetic liner above the natural clay till liner.

   
Photo 2:

Site Preparation - This photograph shows the clay perimeter dyke in the background.  During the process of preparing the base for the synthetic liner, we remove some of the clay and use it to construct the perimeter clay dyke which is keyed into the underlying clay till layer.

   
Photo 3:

High Density Polyethylene Liner (60 mil smooth liner) - Following site preparation and construction of the clay perimeter dyke, the synthetic liner is installed. This picture shows a roll of high density polyethylene liner material.  It comes in 23 foot width, in lengths of up to 1,000 feet.

   
Photo 4:

Liner Welding Equipment - The rolls of high density polyethylene material are joined together using a process similar to welding.  This photograph shows a set up of a typical extrusion welding machine in the process of welding a patch.  On the reel is high density polyethylene material used to join the sections of liner together, similar  to a wire feed welding machine.

   
Photo 5:

Liner Welding Equipment - Here you can see a closer view of the equipment used to join  the high density polyethylene liner together using an extrusion welding machine.

 
Photo 6:

Vacuum Testing Liner - After the liner sections are joined together by welding, the joints are tested. There are several different method for testing. This picture shows a welded joint being tested by the “vacuum box method”. The vacuum box is made of clear plastic with a shop vacuum motor setup creating a vegetative pressure inside the box.  There is a soft rubber ring around the outside of the box that seals against the liner.  The test area is soaped down, the vacuum box is applied to the liner section and the fan is turned on.  The area inside the vacuum box is checked by looking for soap bubbles through the plexiglass box.  If there is a leak you will draw air from under the liner into the vacuum box and soap bubbles will appear at the leak site.  Not unlike checking for a leak in a tire or a tube.

   
Photo 7:

High Density Polyethylene Liner - Shown here is the synthetic liner as it nears completion.  The two individuals on the right of the photograph are actually welding the liner together.

   
Photo 8:

High Density Polyethylene Liner - This is another view of the synthetic high density polyethylene liner as it nears completion.  It shows the joints after they have been fused together.

   
Photo 9:

Gypsum Over Synthetic Liner - After completing the synthetic liner and all the necessary design testing to ensure there are no faulty joints or leaks in the liner has been completed, it is covered with a protective gypsum layer.

   
Photo 10:

Slotted Pipe for Under-Drain System - After the synthetic liner has been completed and it has been covered with gypsum, the perimeter under drain system is installed. The purpose of the under drain system is to increase the overall stability of the dyke. This slide shows the slotted piping used for the under drains.  This is very similar to weeping tiles in your home.

   
Photo 11:

Under-Drain System - To install the under-drain a trench is dug into the gypsum that was placed over the liner.  A geo-textile fabric is then placed into the trench.  The fabric is then covered with non-reactive aggregate.  The slotted pipe, shown in the previous photograph is laid on top of  the aggregate.  Then more aggregate is added to cover the pipe.  The fabric is then folded over and sewn together.  The area is then covered with gypsum.

   
Photo 12:

Under-Drain Discharge - This picture shows the perimeter collection ditch.  The under-drains discharge into this area through a series of pipes.  You can see the pipes sticking out in rows on this photo.   The water is collected from the lined gypsum pond through these pipes into this perimeter ditch and returned for reuse. Directly below the truck shows the installation of A Fabriform.  Fabriform is installed for erosion protection.  It is two layers of textile with concrete injected between the layers which will ensure no erosion takes place.

   
Photo 13:

Completed Under-Drain System - Pictured here is  the completed under drain system covered with gypsum.  You can see three completed under-drain systems in this photo.

   
Photo 14:

Gypsum Perimeter Dyke Construction - Here you can see the use of trucks for constructing the gypsum perimeter dyke.

This is the final step prior to beginning operation of the new storage area.