Metec 2009

Benefits of computerized drilling

in drill and blast tunneling

Sandvik Mining and Construction

Drill and
Blast cycle

NAVIGATION & DRILLING, PROBING,

SURVEYING GROUTING

ROCK SUPPORTING CHARGING

SCALING BLASTING & VENTILATION

HAULING LOADING

Sandvik Mining and Construction

GENERAL FEATURES

„ TDATA is an automatic control

system for all drilling functions and
boom positioning
„ Available with 2-, 3- and 4-boom
Sandvik DT jumbos
„ Automatic drilling of a round with
operator supervising the drilling
„ TLOG data logging included
„ VISUAL TUNNELING software for
drill plan and curve design and
reporting

Sandvik Mining and Construction

MAIN COMPONENTS

Multiprocessor control system for

boom and drilling controls

Full graphic control panel

Boom control servo valves

Boom sensors
Software for
designing and
reporting

Sandvik Mining and Construction

SETUP AND NAVIGATION 1/2

„ Drill plan and curve table are selected from system memory
− capacity for 50 drill plans and 20 curve tables
„ Two targets are fixed to a feed rail and boom is driven to the reference line
e.g. tunnel laser

Round length
Imaginary navigation
plane
„ Hole depth is calculated from navigation plane
→ straight round end
Round length can be easily adjusted according to
rock conditions before drilling starts
Laser
Sandvik Mining and Construction
SETUP AND NAVIGATION 2/2

„ Navigation eliminates the effects of carrier position and orientation

− Any boom can be used for navigation
− Navigation ties together the drill pattern and the rig in tunnel co-ordinate

Sandvik Mining and Construction

Drilling
accuracy

Sandvik Mining and Construction

Drilling
accuracy

„ SOURCES OF DRILLING
ERRORS
− Hole collaring position (incl. front stinger)
− Hole direction (angles)
− Hole length and hole deviation
− Drilling pattern position and direction
− Lost holes
„ MEDICINES
− Robust booms
− Precise boom movements
− Accurate parallel holding
− Careful, smooth collaring
− Drilling control system
− Instrumentation
− Straight hole drilling tools

Sandvik Mining and Construction

Tunnel
profile quality

Sandvik Mining and Construction

Tunnel
profile quality

„ Definition of overbreak

Round length, LRnd (m)

Overbreak Volume,
VOB (m³)
Design Profile
Planned volume
per round,
Vplan (m³)

Design Profile

Look-out Angle, (º)

VOB (m³)
OBave (%) = x 100
Vplan (m³)

Sandvik Mining and Construction

Tunnel
profile quality

„ Causes of overbreak and underbreak

Overbreak due to
Drilled Blasting or Geology
Profile
Design
Overbreak due
Profile
to Drilling

Underbreak
due to Drilling
Underbreak
due to Blasting
and Geology

Actual Profile

Sandvik Mining and Construction

Tunnel
profile quality

„ Practical average overbreak results with

computerized drilling jumbos and
experienced excavation team

− In favourable, good rock conditions 10…15cm

− Typical results in fair rock conditions 20…25cm

Sandvik Mining and Construction

Drilling
Profile quality

„ Example:
− 1000 m long D-shaped highway
tunnel
− Cross section 100 m2
− Planned excavation 100 000 m3

Sandvik Mining and Construction

Drilling
Profile quality

„ Example:
− 1000 m long D-shaped highway tunnel
− Cross section 100 m2
− Planned excavation 100 000 m3

LEVEL OF NO DATA
INSTRUMENTATION INSTRUMENTATION CONTROLS
OVERBREAK 40 cm / 15 % 25 cm / 9.4 %
2 2
REAL CROSS SECTION 115 m 109 m
NUMBER OF HOLES 152 143
PULL OUT 88 % 95 %
3 3
SPECIFIC CHARGE 1.5 kg/m 1.3 kg/m
ADVANCE 234 m/month 259 m/month
EXCAVATION TIME 4.3 months 3.9 months
SHOTCRETE 50 mm 50 mm
UNEVENNESS FACTOR 1.35 1.15
REBOUND FACTOR 1.2 1.2
Example calculations shown more in detailed in A1.1 Instructions.

Sandvik Mining and Construction

Drilling
Profile quality
„ Example:
− 1000 m long D-shaped highway tunnel
− Cross section 100 m2
− Planned excavation 100 000 m3

LEVEL OF NO iDATA
INSTRUMENTATION INSTRUMENTATION CONTROLS
RELATIVE SAVINGS, EURO
DRILLING 0 + 2,158.-
EXPLOSIVES etc. 0 + 51,107.-
LOADING & HAULING 0 + 56,100.-
SHOTCRETE 0 + 92,064.-
CONCRETE (OVERBREAK) 0 + 841,500.-
TOTAL SAVING, EURO 0 + 1,042,929.-
TIME SAVING, MONTHS 0 0.4
Example calculations shown more in detailed in A1.1 Instructions.

Sandvik Mining and Construction

Worksite
references

Sandvik Mining and Construction

Worksite reference
Ralco - HEP

„ Worksite
− RALCO in Chile, 570 MW HE project
− Contracts: CR22 - Headrace tunnel
CR23 - Powerhouse cavern
− Contractor: NECSO & Graña y Montero
− Owner: Endesa Chile S.A.
− Project value: 540 MUSD
− UG excavation volume: 850.000 m3
„ Rock Conditions
− Volcanic & magmatic rocks: andesite, breccia,
basalt, gabbro, diorite, tonalite etc.
− Fractured & weathered rock mass incl. high content
of weak minerals

Sandvik Mining and Construction

Main
civil works

„ Underground Excavation Works

− 7.2 km Headrace Tunnel, Ø 9.8 m (excavation
diameter)
− 0.3 km Tailrace Tunnel, Ø 12.5 m
− Access tunnels & adits
− Manifolds, cable tunnels & draft tubes
− Powerhouse: 26 m x 46 m x 110 m
− 105 m high Penstock Shaft, Ø 9.8 m
− 120 m high Surge Tank, Ø 25 m
− Two gate shafts

Sandvik Mining and Construction

Sandvik
equipment
„ 2 pcs of 3-boom DATASUPER 316-150
− Computer controlled drilling
− New generation drilling control
„ 1 pc of 3-boom DATAMAXI 316 T
− Computer controlled drilling
− Old generation drilling control (-94)
„ 1 pc of 2-boom PARA 206-90 Jumbo
− TCAD instrumentation + basket boom
− New generation drilling control
„ 2 pcs of Commando 300 Trackdrills
− Water flushing kit
„ 1 pc of Ranger 500 Trackdrill
− Water flushing kit
„ 2 pcs of Rammer G 80 breakers

Sandvik Mining and Construction

Headrace tunnel
Drilling

„ 2 pcs of 3-boom DATASUPER 316-150

− Face, bolt hole & injection drilling
„ Tunnel Dimensions
− 7.2 km long, circular shape Ø 9.8 m
− Access from two adits
„ Excavation Method
− Full section in medium to good rock
− Top heading + bench in bad rock
„ Round characteristics
− Round length: 1.0…4.0 m
− Pattern: 118 pcs x ∅ 51 or 48 mm +
3 pcs x ∅ 102 mm
− Drilling cycle time: 2.5…3.0 h

Sandvik Mining and Construction

Headrace tunnel
Performance

„ Working Time Arrangements

− 2 x 12 hours shift per day
„ Daily Advance per heading
− One round per shift blasted => 2 rounds per day
− 8 m per day in medium to good rock
− 2 m per day in bad rock

Sandvik Mining and Construction

Powerhouse
complex & tailrace

„ 1 pc of 3-boom DATAMAXI 316 T

− Face & bolt hole drilling
„ 1 pc of 2-boom PARA 206-90 + basket
− Face & bolt hole drilling
„ 1 pc of Ranger 500
− Bench drilling with vertical holes in the powerhouse
cavern, bench height: 5m
− Anchor hole drilling (long bolts)
„ 2 pcs of Commando 300
− Bolt hole drilling in the powerhouse cavern

Sandvik Mining and Construction

Shaft excavation
Method

„ Excavation of 2 m x 2 m pilot raise with

Alimak Raise Climber

„ Enlargening of the shaft

− 1-2 pcs of Commando 300 for drilling, bench height: 3
m
− 1-2 pcs of small excavators for loading blasted muck
into pilot raise
− Secondary loading below the raise
− Units lifted up/down with 10 ton winch
− Alimak used for workers transportation

„ Supporting of the shafts

− 3 m long, resin grouted bolts (Commando 300)
− 150 mm thick shotcrete layer
− Concrete lining

Sandvik Mining and Construction

Shaft excavation
Drilling

Sandvik Mining and Construction

Shaft excavation
Bolting
„ Drilling of the bolt hole
„ Manual installation of resin cartridges
„ Installing bolt utilizing feed and rock drill of
Commando 300
„ Mixing resin components utilizing rotation
motor of HL 300 and special tool between
shank / bolt
„ Pretensioning bolt by tightening the nut

Sandvik Mining and Construction

Sandvik rock tools
drill steel life
UNIT DRILLED SHANK ROD LIFE, COUPLING BIT LIFE,
METERS LIFE, drm drm LIFE, drm drm

Datasuper 1 (new generation 220.284 7.596 3.338 5.123 1.288

drilling control system)
Datasuper 2 (new generation 198.036 8.251 1.722 3.047 615
drilling control system)
Para 206 (new generation 127.515 9.809 2.024 2.965 759
drilling control system)
Datamaxi (old generation 50.896 3.181 1.184 2.213 653
drilling control system)
Commando 1 32.804 2.982 994 1.491 576

Commando 2 42.640 2.665 948 1.254 422

Ranger 500 25.726 3.675 953 1.225 476

∗ All values include breakage & loss of steel caused by improper operation or accident

Sandvik Mining and Construction

Full service
contract
„ Manpower and Service Tools
− 1 x supervisor + 1 x technical secretary
− 12 x servicemen for mobile equipment
− 1 x serviceman for Rock Tools
− 1 x drill master (6 months start-up)
− Tools, service containers & vehicles
„ Contract including
− Fixed operational costs for spare parts, maintenance &
drilling tools for drilling units
− Parts consignment stock for BrØyt & Rammer
− Equipment availability guarantee: 90 % for 1st year, 85 % for
following years
„ Taking care of
− Preventative maintenance
− Parts supply
− Drill steel & bit servicing
− Inventory control & cost collection
− Invoicing and payment follow-up

Sandvik Mining and Construction

Worksite reference –
Toulnustouc HEP
„ Worksite
− 526 MW Toulnustouc Hydropower Project in
Quebec Canada
− Contract: 8.3 km long Headrace tunnel
− Excavation volume: 1.4 Mm3
− Contractor: EBC Inc.
− Owner: Hydro-Quebec
− Contract value: 70 million$
„ Tunnel dimensions
− Cross section: 134.3 m2
− Horseshoe: h=11.86m x w=13.4m (now)
− Circle Top: h=13.0m x w=11.0m (in the beginning)
− New shape optimized hydraulic properties of tunnel,
pullout length, fragmentation and blast vibrations

Sandvik Mining and Construction

Method

„ Full section
− Round length: ~ 5.7m (pull % ~97-98 %)
„ 3-front excavation
− 3 faces in operation simultaneously
„ Excavation sequence
− Bolting (drilling & installation)
− Screening (wiremesh)
− Drilling (and primary manual scaling)
− Charging
− Blasting and ventilation
− Primary mechanical scaling
− Loading and hauling
− Final mechanical scaling
− Final manual scaling
− Geological surveying

Sandvik Mining and Construction

Main tunneling
equipment
„ 3 pcs of Axera T12 DATA-315 jumbos
− Face drilling and bolt hole drilling
− TF 500 x 20’ feeds + ∅ 46 mm rods
− TBB 5E basket boom
− TDATA control system
„ 1 pc of Caterpillar 988 G loader
− 6.5 m3 bucket
− 1 pc of Cat 988 F as a backup unit
„ 8 pcs of Caterpillar 773 trucks
− 50 ton dump box
„ 3 pcs of Caterpillar 235 excavators
− Mechanical scaling
„ Several lifting vehicles
− Bolt & wiremesh installation
− Charging
− Manual scaling

Sandvik Mining and Construction

Bolting

„ Axera T12 DATA-315 jumbo

− Bolt hole drilling with 2 or 3 drilling booms
− Bolt installation from basket
„ Lifting vehicle
− Bolt installation
„ Bolting characteristics
− Mechanical anchor bolts: 4m long (sometimes 6m
long)
− Hole size: 51mm
− Number of bolts: 10 pcs per round (average)
„ Bolting cycle
− Bolt hole drilling: 20 min
− Bolt installation: 40 min
− Total cycle: 60 min

Sandvik Mining and Construction

Screening

„ Method
− 10m x 3m wiremesh sheets
− Installation after bolting (Hydro Quebec
request)
− 80 x 1m long installation pins per round (hole
Ø 35 mm)
„ Equipment
− Installation: 2 x lifting vehicle
− Drilling: 1 stoper per lifter
„ Screening cycle
− Installation: 60 min
− Drilling of pins: 120 min
− Total cycle: 180 min

Sandvik Mining and Construction

Drilling

„ 2 pcs of Axera T12 DATA-315 jumbos

− 2 computerized drilling units are used for face
drilling side by side
− 95 % of the holes are drilled in AUTOMATIC
drilling mode
„ Round characteristics
− Round length: 5.7m (pull % ~ 97-98 %)
− Hole size: 57mm (earlier 51 & 54mm)
− Number of holes: 172 + 4 pcs
− All profile holes can be seen after blasting
„ Drilling cycle
− Rock type: very hard granite gneiss - uniaxial
compressive strength ~ 250 MPa
− Net penetration rate: 1.5-2.0 m/min
− Total cycle: 180 min

Sandvik Mining and Construction

Drilling
Drill plan

Sandvik Mining and Construction

Drilling
Boom sequences

Sandvik Mining and Construction

Drilling
Planned vs. actual holes

Sandvik Mining and Construction

Charging

„ 3 pcs of lifting vehicles + anfo-platform

− Mechanized charging
− 2 workers per lifter
„ Charging characteristics
− Field holes: anfo
− Profile holes: smooth blasting tubes
− Non-electric detonators
„ Charging cycle
− Total cycle: 110 min

Sandvik Mining and Construction

Loading and
Hauling

„ 1 pc of Caterpillar 988 G loader

− 6.5 m3 bucket
− 1 pc of Cat 988 F as a backup unit
„ 8 pcs of Caterpillar 773 trucks
− 50 ton dump box
„ Loading & hauling characteristics
− Trucks turn inside tunnel very close to the face
− Dumping into trucks from the side
− Four buckets per truck
„ Loading & hauling cycle
− Loading cycle time / truck: 2-2.5 min
− Turning & reversing time: 0.5-0.8 min
− Waiting time per truck: 0-1.0 min
− Loading & hauling capacity: 425 loose-m3 / hour =>
Total cycle: 170 min

Sandvik Mining and Construction

Scaling

„ Method (four different stages)

− 1st manual scaling from jumbo basket (during or after
drilling)
− Primary mechanical scaling on top of the muckpile
(before mucking)
− Final mechanical scaling for tunnel walls (after mucking)
− 2nd manual scaling (before bolting)
„ Equipment
− Scaling bars + jumbo basket boom
− Cat 235 excavator + 2 picks in bucket
„ Scaling cycle
− Manual scaling: 80 min (w/o 1st manual scaling, which is
incl. in drilling cycle time)
− Mechanical scaling: 170 min
− Total cycle: 250 min

Sandvik Mining and Construction

Performance

„ 3-front excavation
„ Working time arrangements
− 2 x 12 hours shift per day
− 5.7 days per week
„ Daily advance
− Average round cycle time: 16.7 hours
− 4 rounds per day => 23 m per day
„ Long-term performance
− Average weekly result: 20 rounds per week => 114
meters per week
− Best weekly result: 23 rounds per week => 131
meters per week

Sandvik Mining and Construction

Performance
daily advance

Sandvik Mining and Construction

Drill steel
life

„ Rock type
− Very hard granite gneiss ~ 250 MPa
„ Sandvik Drilling tools
− Shank (T38): 7304-7585-01
− Coupling (T38): 7314-3652
− Rod (T38-round46-T38): 7324-8561-20 => excellent
hole straightness !
− Bit (T38 / Ø57mm): 7514-5357-S45
− Reaming bit (Ø102mm): 7723-4802-S45
− Pilot adapter (R35): 7823-5647
Bit T38 - Ø57mm „ Service life
− Shanks: 6000 drm
Rod T38-round46mm-T38 − Rods: 3000 drm
− Bits (Ø57mm):
− average 420 drm
− max. life 600 drm
− regrinding interval 60 drm

Sandvik Mining and Construction