breakthroughs in tunneling 2019 drill & blast and … · 2019. 9. 25. · sandvik access detection...
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BREAKTHROUGHS IN TUNNELING 2019DRILL & BLAST AND ROADHEADER
RMDS IN DETAIL
Sandvik AB – Sandvik Mining and Rock Technology – Product Division Mechanical Cutting – Uwe Restner
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TABLE OF CONTENTS
2
DRILL & BLAST AND ROADHEADER TUNNELING
• Selection criteria for excavation method• Rock & rock mass cuttability assessment• Facts & developments in drill & blast• Latest & ongoing roadheader developments• Closing movie
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SELECTION CRITERIA FOR EXCAVATION METHOD3
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EXCAVATION METHOD SELECTION CRITERIA
4
ROCK MASS PROJECT ENVIRONMENT
Drill & Blast
Shield Machines
Hardrock TBM
Excavator Attachments
Roadheaders
Rock Compressive Strength
Roc
k M
ass
Con
ditio
ns
Mechanical Excavationwith Breakers / Splitters
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MECHANICAL TUNNEL EXCAVATION
5
Mechanical Tunnel
Excavation
Part face excavation
Soft (loose)
rock
Full face excavation
Hard (stable)
rock
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ROADHEADER TUNNEL EXCAVATION
6
CAI
–C
ERC
HAR
Abr
asivi
ty In
dex
[mm
]
UCS – Uniaxial (Unconfined) Compressive Strength [MPa]50 100 150 2000
0
1
2
3
4
Limestone (867)UCS=85MPa, CAI=1.1
Sandstone (1197)UCS=80MPa, CAI=2.2
Basalt (64)UCS=119MPa, CAI=2.5
Coal (56)UCS=24MPa, CAI
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OVERALL CUTTING PERFORMANCE TOO LOW
7
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CUTTING TOOL CONSUMPTION TOO HIGH
8
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EXCAVATION METHOD SELECTION CRITERIA
• Complex and variable geology• Free access to tunnel face• Ability for partial face excavation• Smooth excavation process• Not sensitive against squeezing rock mass• High cutting performance in weak and medium
strong rock mass
9
CRITERIA FOR ROADHEADER SELECTION
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EXCAVATION METHOD SELECTION CRITERIA
• Flexible system in terms of profile shape and size• Accurate excavation resulting in less over-break
and less concrete installation work• Low primary investment• Fast mobilization
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CRITERIA FOR ROADHEADER SELECTION
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ROCK & ROCK MASS CUTTABILITY ASSESSMENT11
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GEOTECHNICAL CHARACTERIZATION
• Rock:Natural aggregate of components including minerals, rarely glasses, fragments of minerals and rocks, binding agent and X-ray amorphous substances.
• Rock mass:Combination of rock and discontinuities, separating rock into different rock bodies and forming characteristic areas of homogeneity.
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DIFFERENTIATION BETWEEN ROCK AND ROCK MASS
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REPRESENTATIVE ROCK SAMPLING
Select typical rock samples in correct quality and sufficient quantity
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KEY SUCCESS FACTOR FOR ROCK CUTTABILITY ASSESSMENT
Block sample: 20 x 20 x 20 cm
Drill core:50 mm diameter500 mm length
Batchingcard forsampleidentification
Sample
Specimens
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PRECISE LABORATORY ROCK TESTING
Rock test results representing intact rock properties
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LEADING TO REPRESENTATIVE ROCK TEST RESULTS
USM UCS BTS CAI
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INTERPRETATION OF ROCK TEST RESULTS
15
PRINCIPALLY SIMPLE, BUT VERY EFFECTICE EVALUATIONS
Rock toughness&
Fracture energy
Quick characterization of rock fracturing behavior
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SUMMARY OF ROCK TEST RESULTS
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PROVIDING CLEAR OVERVIEW OF ROCK CHARACTERISTICS
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ROCK TESTINGASSESSMENT OF NCR FOR INTACT ROCK
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0
10
20
30
40
50
60
70
80
90
100
110
120
130
140
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
Unia
xial
Com
pres
sive
Str
engt
h [M
Pa]
Net Cutting Rate [solid m³/nch]
Net Cutting Rate for MR/MT/MH620 (300 kW installed cutter head power)equipped with Cutter Head 105-G 57+ and 22 mm TC Diameter Picks
according to Uniaxial Compressive Strength for Intact to Moderately Fractured Rock Massfor Cross Sections > 35 m²
very tough rock normal rock very brittle rock
The volume of cut rock per effective net cutting time (counted in net cutting hours ... nch) defines the netcutting rate. The effective net cutting time is defined by the time the cutter head is in contact with the rockand actually cutting. Thus, supplementary actions of the cutter head like profiling and loading or any idlingtime during cutting operation does not contribute to the effective net cuttingtime.
For calculating machine productivity or excavation performance, please consider that the ratio of machineoperating hours to net cutting hours is usually about 2:1 (ranging from 1.5:1 to 2.5:1). This difference in thetimes is caused by a number of delays and standstills (non-productive times) during cutting operation,when the machine is operated at the face.
Uniaxial Compressive Strength measured onH:D=1:1 specimen with 50 mm diameter @ 10
NCRtheor=24 solid m³/nch @UCS=100 MPa &UCS:BTS=8-15 => normal rock
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ROCK TESTINGOPERATING LIMITS DEFINED BY NCR
18
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Specific Pick Consumption (SPC) for Low Speed Cuttingwith Transverse Cutterhead and 22 mm TC Diameter Picks of High Quality
0,001
0,010
0,100
1,000
10,000
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180Uniaxial Compressive Strength [MPa]
Spec
ific
Pick
Con
sum
ptio
n [p
icks
/sol
id m
³]
CAI=0,5CAI=1,0CAI=1,3CAI=1,8CAI=2,3CAI=3,0CAI=4,5
Effective minimum specific pick consumption: 0,005 picks/solid m³
Uniaxial Compressive Strength measured on H:D=1:1 specimen with 50 mm diameter @ 10 kN/s
CAI ..... CERCHAR Abrasivity Index measured on rocksurface of natural roughness (e.g. surface of brokenBrazilian Tensile Strength test specimen) usingoriginal CERCHAR testing apparatus and test pickswith HRC=54-56
SPC=0.1 picks/solid m³ @UCS=100 MPa & CAI=1.0
ROCK TESTINGASSESSMENT OF SPC
19
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ROCK TESTINGOPERATING LIMITS DEFINED BY SPC
20
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EVALUATION OF ROCK MASS CUTTABILITY
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USING GEOTECHNICAL REPORTS OR DOING JOB SITE INVESTIGATIONS
Mapping and recording of all relevant rock types and rock mass features/discontinuities like bedding planes, fractues, etc.
The picture can't be displayed.
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EFFECT OF ROCK MASS ON CUTTING
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PRINCIPLES OF ROCK MASS INFLUENCE ON ROADHEADER CUTTING
I
II
III
Excavation predominantly byactivation of parting planes:„RIPPING ZONE“Activation of existing parting planesand generation of new fracture planes:„INTERMEDIATE ZONE“
Excavation predominantly bygeneration of new fractureplanes: „CUTTING ZONE“
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ROCK MASS CUTTABILITY RATING
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SYSTEMATIC APPROACH FOR ROCK MASS EVALUATION
Block size [m3] Rating> 0,6 20
0,3 - 0,6 160,1 - 0,3 10
0,06 - 0,1 80,03 - 0,06 50,01 - 0,03 3
< 0,01 1
Surface Aperture Wall/Fill Rating Influence on cuttability
Rating
rough closed hard, dry 30 very favorable -12slightly rough
< 1 mm hard, dry 20 favorable -10
slightly rough
< 1 mm soft, dry 10 fair (and if block size 5 mm soft, damp to wet
0 very unfavorable 0
Rating of joint conditions Rating of orientation of joint set
100 - 200 2> 200 1
25 - 50 750 - 100 4
1 - 5 155 - 25 12
Rating of block size
UCS [MPa] Rating
Rating of uniaxial compressive strength Block Si
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ROCK MASS CUTTABILITY RATING
24
FINAL RMCR SYSTEM FOR ROADHEADERS
RMRrev Influence on cuttability by roadheaders
40 - 60 no to little influence25 - 40 moderate influence15 - 25 considerable influence10 - 15 high influence
< 10 dominating influence
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Block size [m3] Rating> 0,6 20
0,3 - 0,6 160,1 - 0,3 10
0,06 - 0,1 80,03 - 0,06 50,01 - 0,03 3
< 0,01 1
Surface Aperture Wall/Fill Rating Influence on cuttability
Rating
rough closed hard, dry 30 very favorable -12slightly rough
< 1 mm hard, dry 20 favorable -10
slightly rough
< 1 mm soft, dry 10 fair (and if block size 5 mm soft, damp to wet
0 very unfavorable 0
Rating of joint conditions Rating of orientation of joint set
100 - 200 2> 200 1
25 - 50 750 - 100 4
1 - 5 155 - 25 12
Rating of block size
UCS [MPa] Rating
Rating of uniaxial compressive strength
ROCK MASS CUTTABILITY RATING
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EVALUATION OF RMCR VALUE AND ITS INFLUENCE ON NET CUTTING RATE
Evaluation of Rock Mass Influence on NCR(Low cutting speed - 1.4 m/s)
NCReff/NCRtheor = 45,553RMCR-0,9821
R2 = 0,9332
0123456789
10
0 10 20 30 40 50 60
RMCRN
CR
eff /
NC
Rth
eor
Erzberg Stillwater PozzanoPremadio Athens BilecaFresnillo Montreal
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EXCAVATION STRENGTHEVALUATED AND DEFINED BY RMCR
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Rock Mass Cuttability Rating (RMCR)Reduction of Rock Mass Strength (UCSRM) related to Rock Strength (UCSR)
for SANDVIK Roadheaders using Low Cutting Speed (~1.4 m/s)
0
50
100
150
200
250
300
0 50 100 150 200 250 300
UCSR [MPa]
UC
S RM [M
Pa]
RMCR=10RMCR=15RMCR=20RMCR=25RMCR=30RMCR=35RMCR=40RMCR=45RMCR=50
RMCR = 30
UCSR~200MPa
UCSRM~120MPa
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ROCK TESTINGOPERATING LIMITS DEFINED BY RMCR
27
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FACTS & DEVELOPMENTS IN DRILL & BLAST28
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DRILL & BLAST CYCLE
• Hole size and round length slightly increasing• Rock supporting tasks with jumbo are becoming more important (e.g. short & long
bolt holes, self-drilling anchors, injection hole drilling & grouting, casing, installation of steel arches, rod handling)
• Multifunctional use of drilling jumbo increasing (e.g. installation works, charging, ground monitoring, profile measurement, scaling, water leakage testing)
• Faster round cycle times• Quality and cost awareness increasing• Stricter safety and environmental requirements
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CURRENT TRENDS
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DRILLING PERFORMANCENET PENETRATION RATES (M/MIN)
• Rock drillability• Percussion power level (and feed
force)• Bit diameter, type and rotation speed• Flushing• Rock drill (and impact frequency)
GROSS PENETRATION RATES (DRM/H)
• Boom moving and collaring time• Fast feed and possible anti-jamming time• Set-up time (cables, hoses and jacks)• Navigation time (Data & TCAD jumbos)• Marking of tunnel face• Cleaning tunnel floor for bottom hole
charging• Idle of booms (bit changes, repairs, etc.)
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TUNNEL ADVANCE RATES
For one equipment set in 3-shift continuous operation
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SINGLE OR MULTIPLE FACE OPERATION
Conditions Average advance rate (m/month)
Single heading Multiple headings
Easy - Competent rock - Minimum rock support (some
bolts)
200 - 300
300 – 450
Average - Varying rock conditions - Regular support (bolts, some
shotcrete)
150 – 250
200 – 350
Difficult - Soft & fractured rock - Heavy rock support (bolts,
shotcrete, mesh / steel arches)
< 150
100 – 200
Conditions
Average advance rate
(m/month)
Single heading
Multiple headings
Easy
· Competent rock
· Minimum rock support (some bolts)
200 - 300
300 – 450
Average
· Varying rock conditions
· Regular support (bolts, some shotcrete)
150 – 250
200 – 350
Difficult
· Soft & fractured rock
· Heavy rock support (bolts, shotcrete, mesh / steel arches)
< 150
100 – 200
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ROCK BOLTING
Selection criteria referring to lifespan and cost
32
BOLT TYPES
BOLT TYPE LIFESPAN RELATIVE COST
GENERAL COMMENTS
Cement grouted rebar Permanent 1 Low cost, good availability, no immediate support
Resin grouted rebar Permanent (if fully grouted)
2 Reasonable cost, availability of resin may be problem, immediate support
Expansion shell (grouted)
Temporary / permanent (if fully grouted)
1.5 Fairly low cost, fast installation, immediate support
Cement grouted wedge-type
Temporary / permanent (if fully grouted)
1.25 Fairly low cost, fast installation, immediate support
Swellex Temporary (longer than split-set)
3 Expensive, fast installation, immediate support
Split-set (or copy) Temporary
1
Low cost, fast installation, immediate support
CT-bolt Permanent
4…5
Expensive, immediate support, good bolt properties
BOLT TYPE
LIFESPAN
RELATIVE
COST
GENERAL COMMENTS
Cement grouted rebar
Permanent
1
Low cost, good availability,
no immediate support
Resin grouted rebar
Permanent (if fully grouted)
2
Reasonable cost, availability of resin may be problem, immediate support
Expansion shell (grouted)
Temporary / permanent (if fully grouted)
1.5
Fairly low cost, fast installation, immediate support
Cement grouted wedge-type
Temporary / permanent (if fully grouted)
1.25
Fairly low cost, fast installation, immediate support
Swellex
Temporary (longer than split-set)
3
Expensive, fast installation, immediate support
Split-set (or copy)
Temporary
1
Low cost, fast installation, immediate support
CT-bolt
Permanent
4…5
Expensive, immediate support, good bolt properties
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AUTOMATION FEATURES
• Possibility to drill the whole face automatically• System handles boom movements and hole drilling automatically• Hole sequences can be imported from drill plan and/or created onboard• Well-functioning hole sequences & roll-overs can be retrieved from previous
rounds (Sandvik patented feature)• Operator supervises the drilling process• Booms have self-collision avoidance
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FULL-AUTOMATIC FACE DRILLING
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SANDVIK ACCESS DETECTION SYSTEM
34
INCREASED SAFETY
Access ProtectorIf the Sandvik Access Protector system recognizes aperson in the detection field, boom and drilling movementswill automatically be stopped. In other words, the Sandvikaccess protector prevents anyone from entering theworking area of the booms while they are in operation inautomatic mode. If boom operation is automaticallystopped, the system must be reset by pressing theacknowledgement button, after ensuring that no-one is inthe hazard zone.
It’s possible to use the Access Protector as Detector –version while automatic drilling cycle is not used.
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LATEST & ONGOING ROAD-HEADER DEVELOPMENTS35
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EXCAVATIONCONTROLPROFILE CONTROL
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• Profile and tunnel planning with office tool and transfer of plans to machine
• Solution fully integrated into machine control system
• Profile control
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EXCAVATIONCONTROLPROFILE CONTROL
3737
• Cutter head is kept within profile limits
• Visualization of cutting process for machine operator
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AUTOMATED EXCAVATIONCUTTING AUTOMATION
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• Planning of cutting path referring to tunnel profile
• Fully automated cutting of one round length / sump distance
• Automated profiling in fast speed
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TELE-REMOTE OPERATION
39
AUTONOMOUS MACHINE WITH VISUALLY SUPPORTED TELE-OPERATION
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40
Thank you for your attention!!!
Breakthroughs in tunneling 2019TABLE OF CONTENTSSelection criteria for excavation methodexcavation method Selection criteriaMechanical Tunnel ExcavationRoadheader Tunnel ExcavationOverall Cutting performance too lowCutting Tool consumption too highexcavation method Selection criteriaexcavation method Selection criteriarock & rock mass cuttability assessmentGeotechnical characterizationRepresentative rock samplingPrecise laboratory rock testingInterpretation of rock test resultsSummary of rock test resultsRock testingRock testingRock testingRock testingEvaluation of rock mass cuttabilityEffect of rock mass on cuttingRock mass cuttability ratingRock mass cuttability ratingRock mass cuttability ratingexcavation strengthRock testingFacts & developments in drill & blastDrill & Blast cycleDrilling performanceTunnel advance ratesRock boltingAUTOMATION featuresSANDVIK ACCESS DETECTion SYSTEMLatest & ongoing road- header developmentsExcavation�controlExcavation�controlAutomated excavationTele-remote operationSlide Number 40
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