Oosthuizen, M – Large Diameter Vertical Raise Drilling and Shaft Boring Techniques as an alternative to Conventional Shaft

Sinking Techniques
SANIRE 2004 – The Miner’s Guide through the Earth’s Crust, South African National Institute of Rock Engineering

Large Diameter Vertical Raise Drilling and Shaft Boring Techniques as

an alternative to Conventional Shaft Sinking Techniques

M Oosthuizen
Murray & Roberts RUC

Raiseboring in South Africa started in 1968 with machines capable of drilling 1,2m diameter
raises up to a length of 90m. Today, raiseboring machines are capable of drilling shafts to a
diameter of 6,1m to depths in excess of a 1000m. That is an immense improvement from its
humble beginnings.

The next step in the evolution of mechanically sinking shafts progressed in 1971 with the use of
the first shaftboring machine designed and manufactured in the Federal Republic of Germany,
boring a 4,88m diameter, 231m deep shaft.

In the quest for shaft drilling technology it is now possible to sink shafts mechanically up to
8,5m in diameter to 2000m in depth. As less personnel are used the safety risk component is
drastically reduced.

The technological improvements in the shaftboring machines (raise boring and V-mole)
progressed at an astronomical rate. With the increase in diameter of raisebored holes
however, comes greater potential for instability of the sidewall and face of the bored hole.

A systematic flowchart developed by Stacey & McCracken, is discussed to quantify the risks
associated with raiseboring and thereby determining the risk attached to any shaft prior to
commencement of the excavation so that the reliability of the bored holes can be evaluated.

The capabilities of these machines and associated risks are explained with reference to specific
drilling projects.

1. Introduction the V-mole shaftboring techniques. To

date, four major shaft projects have been
Murray & Roberts RUC has been involved completed viz.: The Oryx 1B Ventilation
in raiseboring contracting since 1978. Shaft in South Africa, Pasminco’s Brokenhill
Murray & Roberts RUC has become the No. 5 Airway in Australia, Anglogold’s
world’s largest raiseboring contractor and is Western Deep Levels South Mine, sub
considered a leader in the field of large ventilation shaft and the AlpTransit St
diameter raiseboring. The Company Gotthard project in Sedrun, Switzerland.
operates a total of 23 raisedrills, which These projects were done in a joint venture
includes 4 Wirth HG330SP type machines, with Thyssen Schachtbau GmbH of
these being some of the largest raisedrills Germany using a Wirth SBVIII rodless
ever manufactured in the world. shaftboring machine, better known as a V-
mole.
Since 1989 RUC has also gained
operational experience in shaftboring using

SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST 149
 2. Raiseboring of the hole where it is mucked out by a
mechanical loader.
2.1 Modes of Operation It is a safe, efficient and cost-effective
Raiseborers can be used in various modes method of making holes through different
of operation, the modes most often used geological formations with the use of
are: powerful machines, high strength drillstring
 Conventional pilot drilling and reliable heads. The maximum loading
 Conventional up reaming of vertical capacity of the drillstring limits the diameter
and inclined holes as well as the length of the shaft. The
 Down boring with a pre-drilled pilot loading is dynamic and only approximately
hole calculable because tensile, torsional and
bending stresses are overlapping.
 Blind up boring
See figure 1
 Directional pilot and raiseboring
used in conjunction with a
shaftboring machine (V-mole), for
the drilling and supporting of a large
diameter shaft.

2.1.1 Conventional Pilot Drilling

A tri-cone pilot bit is normally used varying
from 9 inches (229mm) to 15 inches
(381mm). The 15 inches (381mm) bit is
normally used on long holes with a 12 7/8
inches (327mm) integral drillsteel string with
a 10 1/8-inch DI 42 tool joints. During
drilling a fluid is pumped through the center
of the drillstring to the cutting face, where
the rock cuttings are flushed and raised Figure 1
from the bottom of the hole through the
annulus around the drillstring to the collar of 2.1.3 Down Boring with a Pre-drilled pilot
the hole. The drilling fluid is settled in a hole
closed loop via a series of settling dams so In this case an oversize pilot hole is drilled.
that the drilling water can be re-used. The cutting head is installed at the top of
See figure 1 the pilot hole and drilling takes place in the
downward mode. Rock cuttings are flushed
2.1.2 Conventional Up-reaming of Pilot down the oversize pilot hole to the bottom of
Holes the hole where it is removed. In the case of
On completion of pilot drilling and at such smaller holes, the machine provides cutter
time that the pilot hole breaks through into thrust and in the case of large diameter
the lower excavation, a reaming head is shafts the cutter head is weighted through
fitted to the end of the drillstring. The size the addition of steel collars. The down
of the reaming heads range between 1,2 boring method is not used often as the risk
metres and 6,1 metres in diameter. The of blocking the pilot hole and creating mud
head is rotated by the machine and is pulled rushes at the bottom of the hole is too high.
back against the rock face at the same See figure 2
time. Tungsten Carbide insert cutters are
fitted to the head and these cut grooves in
the rock in a rotary crushing mode. The
‘kerfs’ of rock in between the grooves ‘spall’
out and rock failure occurs in a tensile
mode. The rock cuttings fall to the bottom

150 SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST
 Murray & Roberts RUC currently holds the
following world records:

 Largest diameter shaft raisebored:

7,1m dia, 180m deep at Sasol’s
Bosjespruit Mine. See figure 4

Figure 2

2.1.4 Blind Up Boring

In this case the machine is placed at the Figure 4
bottom elevation and the cutting head drills
upwards. Rock cuttings fall to the bottom of  Longest hole reamed: 1,83m dia,
the hole where it is deflected into muck 1260m deep – HG330 used at the
cars. This method has limited applications. Primsmulde Project, Germany.
See figure 3 See figure 5

Figure 3 Figure 5

2.1.5 Directional Piloting and  Hardest rock raisebored: Lava formation

Raiseboring with an UCS between 600 and 750MPa
Directional piloting and raiseboring is very – Kloof Gold Mine, South Africa.
costly and is therefore only used in See figure 6
applications where a high degree of
accuracy is required. The accuracy of a
vertical pilot hole can be guaranteed to
depths within the capability of the raisebore
machine.
2.2 Breaking New Ground

SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST 151
  Largest diameter V-mole shaft bored in
hard rock: 7,1m dia, 752m deep –
Western Deep Levels Gold Mine, South
Africa

2.3 Risks and the control thereof

2.3.1 Deviation of the pilot hole:

Accuracy in pilot holes has been a concern
for almost since the invention of
mechanized rotary drilling. This problem
became much more apparent as operators
continued for even longer holes with 1100m
not being uncommon anymore.
The deviation of a borehole from its
intended path can be attributed to both
geological and technical factors, which can
be divided into three categories:-

Controllable factors
Figure 6  Set-up accuracy
 Equipment condition
 Longest inclined raisebored hole in the - Machine
world: 3,5m dia, 755m deep – BCL, - Starter pieces
Botswana. - Correct boring tool
See figure 7 (bit)
- Bit sub
- Stabilizer
 Bit contact pressure (force)
 Rotation speed
 Flushing rate
 Starting procedure

Semi-controllable factors
 Build rate
 Stiffness (design) of the
drillstring
 Bit walkrate

Non-controllable factors
 Different rock hardness
levels
 Strata dip
 Ground conditions – jointing,
Figure 7 fractures, partings, etc.
 Geological features – faults,
 Deepest shaft V-mole bored: 6,5m dia, dykes, bedding planes, etc.
972m deep – Oryx Gold Mine, South
Africa The graph (figure 9) shows a typical
deviation with a constant build rate of 0,25
degrees per 100m of drilling. The build rate
represents the increase in inclination of the

152 SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST
hole and is measured from the vertical axis. processed by computer at the collar of the
It can be seen that due to the compounding hole and the operator can monitor the motor
effect the deviation becomes exponential toolface, as well as the hole direction, on
and increases drastically with depth. the drillers display unit. A high viscosity
In order to minimize deviation any increase mud is then pumped through the drillstring,
in the inclination of the hole should be which causes the mud-motor to rotate at a
avoided. speed of roughly 120rpm. The drillstring is
Highly sophisticated survey tools are used now moved downward to provide sufficient
to monitor the inclination and direction of thrust to the bit, no rotation of the drillstring
the hole. The instruments are capable of takes place during the correction-run,
detecting movement off the vertical through rotation is provided through the mud-motor
angles as low as 0,05 degrees in inclination directly to the bit.
and 0,5 degrees in Azimuth. On completion of the correction-run the
directional drilling gear is removed from the
hole and conventional pilot drilling is
resumed.
The biggest disadvantage of the Navi-Drill
system is that it is used re-actively. To
rectify the hole deflection the drillrods must
be removed from the hole, the Navi-Drill
attached and lowered to the bottom of the
hole, which is a very tedious process. The
Navi-Drill must be removed when the hole
direction has been rectified. To remove the
Navi-Drill, the drillrods must be removed.
The drillbit must be attached and lowered
before piloting can commence. To
overcome this problem the self-steering
drilling system was developed.
See figure 10

Figure 9

There are two ways in which the direction of

the pilot hole can be steered:-

 Using navigational drilling equipment Figure 10

The downhole motor such as the Navi-Drill
is used re-actively, i.e. when the hole  Using the Rotary Vertical Drilling
deviates it is rectified. The Navi-Drill is System (RVDS)
fitted with an adjustable bent-sub. The The ZBE3000 (DMT GmbH) self-steering
motor angle is set to a suitable angle and is directional drilling is in use since the mid
lowered down the hole. The motor is then 1980’s. High maintenance costs and
orientated, 180 degrees opposite to the occasional problems necessitated the
direction of deviation, using the steering further development of this type of
tool. The steering tool is fitted with a series equipment. New models have been
of magnetometers and accelerometers that brought out, namely the Well Director, The
relay information via the wireline conductor ZBE4000 and the ZBE5000.
to the surface equipment. All data is

SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST 153
Micon’s rotary vertical drilling system has A fully digital electronic unit located in the
been available since the mid 1990’s. This Steering Sub supplies the two
equipment is particularly suitable for accelerometers with the required voltage.
directional drilling in conjunction with Inclination data is then compared to
raiseboring. This system uses a pair of predetermined data and, if necessary,
incline sensors to measure the borehole transformed into steering signals.
inclination and transmit the data to an Subsequently, one or two of the four control
electronics unit. If the pre-programmed valves are being supplied with current. The
directional limits are exceeded, the steering valves control the cylinder oil pressure,
function is initiated by the hydraulic steering which in tern generates the compensating
system, which extends or retracts the four forces necessary to achieve vertical drilling.
external, independently operated control The directional data signals are also
ribs. transformed into a pulse pattern by the
The extendable stabilizer ribs generate digital electronics and they are transmitted
radial forces and work against the angle to the surface.
build-up. The system for large holes between 15 -
The RVDS is supplied to the rig as a 17½’” has been jointly developed by Murray
complete system consisting of the downhole and Roberts RUC and Micon. The
tool and an independent PC-based surface improvements are reflected in the new
system. The downhole tool can be divided design (See figure 12). Various holes have
into two parts, each of approximately 1,5m been drilled with better accuracies than
length – the pulser sub & the steering sub. 0,15% using RVDS. Hoisting shafts can
In order to monitor the self-steering drilling now be raisebored by using the Rotary
process, data signals are transmitted to the Vertical Drilling System (RVDS).
surface via positive water pulses and are
received decoded and visualized by a
surface unit. See figure 12
The upper part of the RVDS, called the
Tank-Sub, rotates with the drillstring. The
outer steerable stabilizer is a part of the
lower Steering-Sub. It is non-rotating and
running in bearings on the drive shaft. The
drive shaft transmits the torque of the
drillstring to the bit.
The non-rotating lower part contains the
sensors, the data processing electronics
and steering unit. This sub is fitted with
radically extendable ribs. The required
steering force is generated hydraulically by
an oil pump inside the Pulser-Sub and is
transmitted to the borehole wall by pistons
and steerable ribs.
The directional data signals are also
transmitted to the mud pulser for further
communication to the surface. Both the
water pulser for data transmission and
alternator for the electrical power supply as
well as the pump for hydraulic power supply
are housed within the Pulser/Generator
Sub. A water turbine drives the alternator Figure 11
and pump.

154 SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST
 variability on the probable quality and the
required minimum rock quality for
compatibility with the proposed raise-bored
shaft specifications. The important aspect
is to assess the rock conditions with respect
to the required minimum quality for stability.
A flow chart that sets out the activities to be
followed for a systematic assessment of the
risk related to the geotechnical aspects of
any raise-boring project is presented in
Figure 13.
Figure 13

Figure 12

2.3.2 Geotechnical risks for large

diameter raisebored shafts:
The two primary geotechnical risks are
boreability and stability. Boreability is  Initial risk assessment
determined by the hardness and abrasivity The preliminary geotechnical assessment
of the rock material and by the structure of should be aimed at determining average
the rock mass, that is, its jointedness and and lower bound conditions in terms of
by machine factors. ‘raisability’ and stability. The range and
Stability is determined by the rock mass distribution of the raise-bore rock quality QR
structure, which defines the potential and the important parameters RQD/Jn and
freedom of movement of the rock blocks Jr/Ja must be compared with the required
and by the stresses acting, which provide minima for stability at the proposed shaft
confinement to the rock mass, but may also diameter.
be of such a magnitude as to induce failure The Q value for the rockmass is obtained
in the rock material and rock mass. from the relation
A detailed geotechnical evaluation or
‘raisebore rock quality assessment’ based Q = RQD x Jr x Jw
on the Stacey and McCracken method is Jn Ja SRF
recommended in the case of deep and/or
large diameter shafts, which will be outlined where RQD is rock quality designation
in this paper. Jn is joint set number
Jr is joint roughness number
The risk attached to any raisebore project Ja is joint alternation number
will depend on the confidence with which Jw is joint water reduction factor,
the rock mass conditions are known. The and
level of confidence in, or reliability of, SRF is stress reduction factor
information depends on the amount of
information that is available, the variation of RQD/Jn gives an estimate of rock block
individual parameters, the impact of this size, Jr/Ja provides an indication of
discontinuity shear strength and Jw/SRF

SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST 155
indicates the conditions of active stress A method of quantifying the geotechnical
surrounding the excavation. risk to a raise-bored shaft has been
To obtain the raisebore quality index, QR presented above, based on shaft diameter
from Q, the following adjustment factors, and a raise-bore rock quality index, QR.
which are cumulative, must be applied. The approach that has been outlined
 Wall adjustment provide an indication of overall geotechnical
 Discontinuity orientation adjustment feasibility. All excavations must, however,
factor be considered individually and the potential
 Weathering adjustment problems should be addressed on merit.
The chart presented in Figure 14 does not
At the preliminary evaluation stage the risk replace classical analysis as a means of
should only be deemed ‘acceptable’ if the evaluating the incidence and stability of
quality consistently exceeds the required potential failure wedges, but it does allow
throughout its length. This pre-supposes the probability of failure to be predicted in a
the availability of sufficient information for simple manner. Comparison of the
this conclusion to be drawn. probability so obtained with the required
reliability permits assessment of the overall
 Final risk assessment feasibility and the risk to a proposed raise.
The assessment of risk will depend In many cases adverse ground conditions
ultimately on the acceptability of failures can be treated by cement grouting prior to
within the raise-bored shaft and on the raiseboring, alternatively advanced planning
incidence and volume of failures that can be can be done to carry out support works
tolerated. In general, an acceptable directly after raiseboring.
probability of failure of a raise-bored shaft,
given its function, is considered to be
0,05%, i.e. 5%. This is commensurate with 3. Shaftboring (V-mole method)
an RSR value of 1,3. Given a proposed
raise-bore diameter and a rock mass of a 3.1 Background
certain range of QR values, the range of In the late sixties, following the successful
probability of failure can be obtained. If the application of tunnel boring machines in
length of the raise is known, the likely gullies and tunnels, thought was given to
length of raise liable to be affected by use this new excavation technique to
failures can be calculated and the volumes underground coal mines with a view to fully
of failure determined from stability analyses. mechanise tunnel and shaft sinking.
A chart showing the probabilities of failure, In 1971 the first shaftboring machine was
P(f), or alternatively the reliability, R, of a put into service in the coal mines in
shaft (where R = 1 – P(f) x 100%), for the Germany by a consortium of specialist
range of raise-bore diameters and rock mining contractors – Deilman-Haniel GmbH
mass qualities is presented as Figure 14. (Dortmund) and Thyssen Schachtbau
Figure 14 GmbH (Mulheim). The shaftboring machine

Suggested levels of reliability, R, and Excavation Service Reliability Probability

probabilities of failure P(f), that are Life, R(%) of Failure
considered acceptable for the raise-wall (Years) P(f)
stability of different types of excavations are Unlined >15 99 0,01
presented in Table 1. These provide hoisting
guidelines for other raise-bored shafts. Shaft
Ventilation 10 95 0,05
Table 1 : Suggested acceptability of risk for Shaft
various raise-bored shafts Ore Pass >2 85 0,15
Ore Pass 1 75 0,25
 Conclusion used was a Wirth GSB-V-450/500 capable

156 SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST
of reaming shafts with a diameter of up to
5m on a pilot hole.
Numerous improvements were made on the
machine since 1971, which is reflected in
the three machine generations, with the
latest model in use being the Wirth SBVII.

3.2 Mode of Operation

The rodless shaftboring machines (V-mole)
can be applied to sink deep shafts with a
diameter of more than 5m. The
requirements for this method are competent
rock and a pilot hole between shaft head
and shaft bottom of approx. 1,8 to 2,4m
diameter with sufficient verticality.
During the boring operation the pilot hole is
used to drop the cuttings and is also used
for ventilation purposes.
The shaftboring machine, mainly
constructed like a tunnelboring machine,
widens the pilot hole to the final shaft
diameter. Reaming, muck disposal and
temporary or final lining of the shaft can be
performed continuously and concurrently.
The steering system of the machine
guarantees the verticality of the bored shaft
with the aid of a laser beam through the
centerline of the shaft. The boring diameter Figure 15
can be varied within the range of 5,0 to
8,5m. The depth to be bored is not 2. Construction of the pre-sinked shaft
restricted by the machine parameters. The (foreshaft) and the installation of the
shaft depth is unlimited as long as a pilot hoisting facilities
hole is available. On completion of the reaming of the center
core hole the foreshaft is sliped and lined to
A V-mole shaft construction is carried out in a depth of ± 15metres for the assembly of
three (3) stages:- the V-mole. The foreshaft can be sunk
 The raiseboring of the pilot shaft before the pilot hole is drilled with the
 The construction of the pre sinked raiseborer. The installation of the hoisting
shaft (foreshaft) and the installation facilities is done concurrently with the pre-
of the hoisting facilities sink. The hoisting facilities are required to
 V-mole boring and the installation of transport the men and material to the shaft
the permanent rock support. borer (V-mole). See figure 16

1. The raiseboring of the pilot shaft

The pilot shaft is raisebored using a Wirth
HG330 raisedrill. The verticality is ensured
by using directional drilling tools, i.e. the
Navi-Drill or the RVDS (preferred).
See figure 15

SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST 157
 electrical motors with 132kW each were
installed. The penetration rates achieved at
this project were satisfactory. Hard rock
formations (e.g. Quartzite) with a
compressive strength ranging from 220 to
280MPa were penetrated.
On completion of the Oryx project the joint
venture could start a second project namely
the ventilation shaft No. 5 in the south field
of Pasminco Mining in Broken hill, Australia.
During the course of sinking of the 810m
deep, 6,5m diameter shaft, the steep
Figure 16
formations of amphibolite with a
compressive strength of 350MPa and
3. V-mole boring and the installation of
gneiss with approx. 150MPa had to be
the permanent rock support penetrated. After these two remarkable
The shaft borer (V-mole) then reams the projects the following conclusions could be
pilot hole to the required size with the rock made:
chips being loaded at the bottom. The shaft
 Both shafts could be completed on
can be concrete lined or shotcreted by
schedule
means of a robotic arm mounted on the
stage. The ‘drilling’ and ‘lining’ is co-  Performances of up to 18m/day
ordinated in an innovative construction unit. (Oryx project) and 12m/day
The SBVII shaftboring machine is mainly (Pasminco) concrete lined shaft
built with a stable frame (outer Kelly), which could be achieved, the average
is hydraulically clamped against the shaft performance was 7,6m/day.
wall by means of twelve gripper pads,  The concurrent operations, drilling
arranged symmetrically at two levels of six and concrete lining, could be
pads. The rotating inner Kelly includes the conducted undisturbed
main drive shaft, bearings and gears. The  In the course of shaftboring
upper non-rotating end is square shaped necessary injections could be
and accommodated in an articulated frame performed to seal off the fissure
of the outer Kelly. The lower end is carrying waterinflows
the rotating cutterhead, which is powered by  A number of intermediate stations
six electrical motors of 110kW each. were excavated during the sinking
process
3.3 Track record
Some fifty-five shafts around the world have V-moling at depth, the ultimate challenge
been completed successfully with the V- Anglogold awarded the 752m, 7,1m
mole. The last four shafts were done by the diameter Sub Vent Shaft construction
Joint Venture between Thyssen Schachtbau project to the joint partners Murray &
GmbH and RUC. The Wirth SBVII Roberts RUC and Thyssen Schachtbau
shaftborer (V-mole) is jointly owned by the GmbH. The design brief read as follows:
two companies. The new SSV (Sub Shaft Ventilation) is to
The joint venture started its first project in be sunk from 84 level to 109 level (3312
1989 in South Africa. The 972m deep metres below datum). The SSV shaft must
ventilation shaft 1B for the Oryx Gold Mine have a 7,0m diameter, (752m deep). The
with a diameter of 6,5m was sunk with the shaft will be used as a return air ventilation
shaftboring machine SB VII. Prior to this shaft and will pass through the mined out
operation in South Africa the machine was reef horizontal between 84 and 109 level.
thoroughly overhauled and prepared for the The exposed sidewall is to be supported by
application in hard rock formations, six means of ‘splitset’ anchors, providing the

158 SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST
primary support followed by steel fibre
reinforced shotcrete (SFRS) using the
shotcrete method in place of the
conventional concrete lining. The support
of the sidewalls must occur concurrent with
the sinking operation of the shaft.
On various levels, throughout the depth of
the shaft, return air way (RAW) holings
must be provided into the ventilation shaft.
Competitive tenders were submitted for the
above consisting of conventional blind sink,
slipe and line operations and the V-mole
option.
The decision was made in favour of the Figure 17
shaft drilling technique after considering the
cost and time advantages of the V-mole
method.
The SSV ventilation shaft was the third
boreshaft for the joint venture TS & Murray
& Roberts RUC, which had to be drilled
partly in extremely hard rock formations.
The geological profile shows, that approx.
40% of the formations have a uniaxial
compressive strength of more than
300MPa. In the Alberton Lavas the
compressive strength was as high as
550MPa. The achieved drilling rates of
0,4m/h are of high importance and very
satisfactory. Figure 18
The experience gained from the two
proceedings ‘Oryx’ and ‘Pasminco’ and the The new cutterhead of 7,1m diameter can
knowledge of the geological profile caused be equipped with disc-cutters as well as
the joint venture to design a new cutterhead with tungsten carbide cutters.
for the project (Figure 17). This cutterhead The shaft sinking activities commenced in
has a closed shape in order to achieve a May 1995 with the drilling of the pilot hole.
better stabilization and to provide the head This was carried out with Murray & Roberts
with back loaded cutters (Figure 18). The RUC’s Wirth HG330 raiseborer. The
old system with flatly arranged lower part is assembly of the shaftboring machine took
replaced by a steep new one. All other approximately 6 weeks. The 752m deep
functions remained unchanged. ventilation shaft was completed under
extremely difficult geological conditions.
The highest performance attained under
these conditions was a monthly advance
rate of 137m in the Alberton Lava formation.
After drilling through the lava formations
scaling occurred in the quartzite formations
at 104 level, which necessitated increased
temporary support.
The pilot hole ‘dog-eared’ and had to be
filled (see Figure 19). A platform was
erected underneath the head. A unique site
specific design shutter was installed

SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST 159
underneath the head (see Figure 20). The The bolting with a rock bolt density of 1 bolt
‘dog-eared’ hole was filled with concrete. per m2 respectively was done fully
The shutter was stripped and the last 105m automatically and concurrently with drilling
of V-moling commenced successfully. The using two Atlas Copco drill rigs mounted on
first-time used cutter change device for the the rotating and telescoping topdeck of the
back-loaded shaft cutters operated shaftboring machine (See figure 21).
satisfactorily after minor changes. The time
for cutter change could be remarkably
reduced with safety benefits.

Figure 21

The application of the steelfibre-microsilica-

wetshotcrete with 50MPa strength was also
fully automatic by means of a robotic
nozzle, which was situated on an
independent operating sinking stage with
three decks above the shaftboring machine.
Figure 19 (See figure 22)

Figure 20 Figure 22

The SSV-Ventilation shaft of the Western

New technologies were introduced for the Deep Levels Mine is the world’s biggest,
shaft lining. The splitset pattern bolting, largest and deepest bored shaft.
(SS39) combined with steel fibre shotcrete It is remarkable for its successful
was applied as the final lining with a fully penetration of one of the hardest rock
mechanized system:

160 SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST
formations with compressive strengths of up conventionally and equipped with a high
to 550MPa. performance hoisting system. Thirty metres
alongside Shaft I is the locality of Shaft II,
The St Gotthard Base Tunnel – Sedrun which is designed for ventilation purposes.
Vent Shaft The shaft was originally planned as a
The latest venture between the joint venture raisebore shaft of 4,5m diameter. A
partners Murray & Roberts RUC and proposal by the JV Thyssen-RUC-Oestu,
Thyssen Schachtbau is a 785m, 7,1m which envisaged to sink the shaft using the
diameter vent shaft in Sedrun, Switzerland. rodless-shaft-boring method with 7,1m
The Sedrun vent shaft is part of the diameter was preferred by the client, JV
AlpTransit Gotthard project, which could Transco. The most important advantage for
well be the construction project of the new the client is that it provides another major
century. The 57km long base tunnel under access to the tunnel construction site with
the St Gotthard massif is the core project of four headings and a second hoisting facility
a new railway link through the Alps, with for the big assembly parts of the large
future passenger trains traveling at speeds tunnel construction machines. The
of up to 250km/h through the longest proposal of the shaft boring JV also
railway tunnel in the world. includes the installation of a heavy duty
The 57km tunnel stretches from Erstfeld in hoisting system in the shaft, which during
the north to Bodio in the south. the shaft sinking period serves as a kibble
See figure 23 & 24 winder.
The shaft construction works commenced
mid May 2002. The raisebore machine
(Wirth HG330SP) was installed at the shaft
collar for both directional pilot drilling at
381mm diameter and the subsequent
reaming of the hole to 1,83m diameter. The
vertical drilling system RVDS of Micon was
applied for the directional drilling. Despite
the unfavorable geology, with numerous
vertical joints, the deviation from vertical
was only 28cm(0,036% accuracy). The
reaming of the pilot hole from 381mm to
1,83m diameter was conducted without
problems and completed by mid November
2002.
After the completion of the pilot shaft the
installation of the shaft sinking equipment
and the shaftboring machine commenced.
Figure 23 The V-mole, type Wirth BSV VI with a 7m
borehead, dressed with a combination of
disc and tungsten carbide cutters were
utilized. The drilling operation started in
February 2003 and was completed end
June 2003 with an average drilling
performance of approximately 7m/day. The
continuous drilling and shotcrete lining
Figure 24 system which was perfected at Western
Deep Levels Gold Mine was used.
At 1,340m above sea-level a horizontal See figure 25
tunnel of 1km reaches the top of the first
785m deep subshaft, which was sunk

SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST 161
  The pilot hole can be reduced to
1,83m (optional) by using the RVDS.
The pilot hole can be drilled
accurately therefore no blasting is
required of the pilot hole whilst V-
moling

4. Conclusion
The mining industry’s requirement for safe,
rapid and economical mine development is
met by the mechanical shaftboring methods
described. The technique has provided an
economically sound solution for a large
variety of different requirements, especially
in those projects executed in recent years
involving deep, large diameter holes.
Raiseboring to a depth exceeding 1,000m
and at diameters of up to 6m is no longer
uncommon. The method continues to be
developed to cover an increasingly wide
Figure 25 range of circumstances. The improvements
made in directional drilling now enables
3.4 Risks and the control thereof hoisting shafts to be raise bored, either in
The biggest risk in using the V-mole method one pass or in combination with the V-mole.
is the scaling ‘dog earning’ of the pilot hole. By using the systematic risk assessment
As ground stresses are increasing with developed by A McCraken and TR Stacey,
depth it was experienced that at deep levels a quantitative assessment of the risk
spalling occurs in any kind of vertical attached to any shaft prior to
opening, e.g. boreholes or shafts. The so commencement can be done.
called ‘dog-earing’ starts as soon as the The capabilities and effectiveness of the
shaft wall is exposed and it becomes visible raiseboring and V-mole techniques have
at the shaft wall as spalling and rock been proven in the execution of more than
bursting. (See figure 19) 50 projects throughout the world, with an
Depending on the stress intensity and accumulated depth of 21,000m and in a
excavation diameter the depth of the wide variety of rock types.
disintegration of rock can vary and may be ‘Using alternative scenarios, the future
very different. literally becomes a matter of choice, not
For future applications of shaftboring change’. (Wolfgang Grukke)
machines the following conclusions and
recommendations are deprived from 5. References
experiences made in the past in relation Geotechnical risk assessment for large
with the abovementioned occurrences: diameter raisebored shafts –
 Determination of the individual pilot TR Stacey, A McCracken
hole diameter by assessing the
obtainable geological-geotechnical Rock mechanics considerations in
date of the rock formation to be raiseboring – TR Stacey, Steffen,
drilled through Robertson and Kirsten
 There is a correlation between the
hole diameter and the scaling ‘dog- Fully mechanized sinking of deep shafts –
earing’ Dr Ing. B. Schmucker and Dr Ing. C
Cetindis, THYSSEN SCHACHTBAU,
Germany, GmbH

162 SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST
Directional drilling in the mining industry –
E Berger, THYSSEN SCHACHTBAU,
GmbH

SANIRE 2004 – THE MINER’S GUIDE THROUGH THE EARTH’S CRUST 163