Available online at www.sciencedirect.

com
Tunnelling and
Underground Space
Technology
incorporating Trenchless
Technology Research
Tunnelling and Underground Space Technology 24 (2009) 22–36
www.elsevier.com/locate/tust

Evaluating extent and causes of overbreak in tunnels

S.K. Mandal *, M.M. Singh
Blasting Department, Central Institute of Mining and Fuel Research, Dhanbad, India

Received 5 September 2007; received in revised form 15 January 2008; accepted 21 January 2008
Available online 18 April 2008

Abstract

Damage or overbreak not only endangers safety of structure but also increases cost of construction and time of completion. Drilling
and blasting being cost-effective for excavation of any underground structure should strictly adhere into specialized controlled blasting
pattern to minimize the unacceptable impact on peripheral in situ rock mass. The paper reveals that in addition to geo-technical prop-
erties of rock mass, in situ stress condition plays an important role in enhancing the magnitude of overbreak. Implementation of same
blast pattern throughout the length of tunnel results into different magnitudes of overbreak and the magnitude increases in highly
stressed zone. Furthermore, implementation of same controlled perimeter blast pattern along the tunnel cross-section may result into
different magnitudes of overbreak. Different magnitude of overbreak along the tunnel cross-section i.e., in left and right wall and crown
has been observed even with implementation of same controlled blast pattern throughout the tunnel cross-section. Feasibility and com-
patibility of drilling equipment with respect to tunnel cross-section also adds to the quality and magnitude of overbreak. Undersize dril-
ling equipment leads to angular drilling on either walls or crown and enhances the magnitude of overbreak. The paper with the help of
statistical and graphical analysis revealed that blast pattern for peripheral rock mass should consider geo-technical properties and in situ
stress condition of rock mass to minimize the magnitude of overbreak. The authors also emphasized that to contain magnitude of over-
break within allowable limit; the implemented blast pattern should be different for different sections viz., right wall, left wall and crown of
tunnel. Furthermore, in poor rock mass condition or in highly stressed zone, drivage of tunnel should be carried out in small sections and
in different phases until the excavation reaches the required excavation profile in that area. Excavation in small sections and in different
phases would lead to proper excavated profile and minimize overbreak and damage of peripheral rock mass.
Ó 2008 Elsevier Ltd. All rights reserved.

Keywords: Overbreak; Drilling and blasting; Detonating pressure; Foliation plane

1. Introduction the method over any other method of excavation. Research

and development work in various aspects of drilling and
Drilling and blasting, in-spite of having an inherent explosive technology have presently facilitated the excava-
destructive attitude and strict integral procedural approach tion engineers to have scientific implementation of this
is the most acceptable method for excavation of rock. This technology in excavation engineering design works.
method of excavation involves low capital investment and Though, overbreak enhances total cost of tunneling to a
possesses the characteristics of high progress rate for level of 15% or even more of the scheduled cost of con-
underground excavation works (Hallvard Holen, 2002; A struction, construction manual guidelines allows a magni-
technical review — D&B V Roadheaders, 2001). Compat- tude of 15–20 cm overbreak in crown and 10–15 cm
ibility and feasibility to any sudden required alteration in overbreak along sidewalls to avoid confrontation for pay-
dimension of excavation profile and/or geological ment between contractor and client and at the same time
constraints also adds to the popularity and suitability of facilitate drilling along periphery row for subsequent
rounds (Korea Highway Corporation, 2000; Talking
*
Corresponding author. Tel.: +91 3262206165; fax: +91 3262202429. technically of M/s Atlas Copco, 1990; Cunningham and
E-mail address: [email protected] (S.K. Mandal). Goetzsche, 1990).

0886-7798/$ - see front matter Ó 2008 Elsevier Ltd. All rights reserved.
doi:10.1016/j.tust.2008.01.007
 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36 23

The paper, here, discusses and analyzes the extent of

overbreak for ten tunnels excavated in four hydroelectric
Crown
projects. Out of these ten tunnels, six were from site A
where overbreak data were analyzed to evaluate the
possible causes of overbreak. For rest of the sites i.e.,
two from site C and one each from site B and D, extent
and characteristics of overbreak were evaluated with
respect to peripheral blast design parameters and improve-
Left Right
ment in blast pattern was made to contain the extent of Side Side
overbreak within allowable/acceptable limit. In these four
sites excavated profile was determined with the help of laser
profiler and thereafter, magnitude of overbreak was deter-
mined with the help of plannimeter (Fig. 1).
The plotted profiles, both excavated and designed, were Fig. 2. Schematic diagram of the different sectors of a tunnel cross-
divided into three sections viz., left, right and crown (120° section.
each), according to the schematic diagram shown in Fig. 2
and magnitude of overbreak was determined for each zone line area of tunnel cross-section along left wall; A11 is the
and total tunnel cross-section. Magnitude of overbreak for excavated area of tunnel cross-section along left wall; A2
each sector or section of tunnel viz., left wall, right wall and is the pay-line area of tunnel cross-section along right wall;
crown is determined in percentage of actual designed tunnel A22 is the excavated area of tunnel cross-section along right
cross-sectional area by using the formula represented in wall; A3 is the pay-line area of tunnel cross-section along
Eqs. (1)–(3), respectively. Using Eq. (4), the overall magnitude crown; A33 is the excavated area of tunnel cross-section
of overbreak was determined for each tunnel and is shown in along crown.
Fig. 3. To understand the characteristics, behaviour and
extent of overbreak for each sector statistical analysis in terms 2. Damage and overbreak
of normal distribution curve was also carried out
ðA11  A1 Þ The process of rock breakage, by blasting, takes place
Magnitude of overbreak for left wall ð%Þ ¼  100 by opening of tight and loose joints and generation of
A
ð1Þ new cracks. This generally occurs when the pressure pulse
exceeds the dynamic compressive strength of rock. Gener-
ðA22  A2 Þ
Magnitude of overbreak for right wall ð%Þ ¼  100 ation of cracks takes place when the gas pressure (P)
A exceeds the horizontal stress (r) across the plane of discon-
ð2Þ tinuities and extension of cracks depend on the acceptable
ðA33  A3 Þ theories for propagation of cracks viz., the tangential pres-
Magnitude of overbreak for crown ð%Þ ¼  100 sure induced by shock wave; reflection of shock wave from
A
ð3Þ free face or joint planes; wedging action at the crack tip due
to high temperature and pressure of gas energy entering the
ðA0  AÞ narrow radial crack tips. Since, the uncontrollable param-
Total overbreak ð%Þ ¼  100 ð4Þ
A eters i.e., geo-technical parameters (Rock Mass Descrip-
where A is the pay-line area of tunnel cross-section; A0 is tion, Uniaxial Compressive Strength, Joint Plane
the excavated area of tunnel cross-section; A1 is the pay- Spacing, Joint Plane Orientation, Joint Plane Aperture

Horizontal Pivot
scale
Pivotal Arm
Vernier
Pointer
scale
Arm for
Vertical rotation
scale

Fig. 1. Planimeter.
24 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36

60
Total Overbreak
50

40
Overbreak (%) --->

30

20
Site A
10

0
TRT from TRT D/s HRT D/s HRT D/s HRT U/s HRT U/s Site B SitC, HRT Site C, Site D
exit end fromMAT frominlet from adit I adit I adit II adit
adit
Sites ---->

Fig. 3. Total overbreak for different tunnels.

and filling material between joints) contribute towards con- (Paventi et al., 1996; Pusch and Stanfors, 1992). However,
trolling damage or overbreak in in situ peripheral rock- extent of damage should be within limit and should not
mass, an effective blast design with proper charge endanger the safety and stability of structure.
parameters and initiation sequence should be implemented The characteristics and extent of magnitude of damage
to minimize the impact of detonation pressure on uncon- acceptable in ornamental or dimensional stone is different
trollable parameters in magnifying the magnitude of over- to that in civil construction projects or that caused in produc-
break (Liu and Katsabanis, 1993; Scoble et al., 1996; tion blasts in mines (Mandal et al., 2005; Olsson et al., 2002;
Lewandowski et al., 1996; Tariq and Worsey, 1996; Worsey Mario and Mohanty, 2001; Outcherlony, 1997; McHugh,
and Qu, 1987; Dunn and Cocker, 1995; Blasting Technol- 1983). For dimensional stone, comparative analysis between
ogy, 1990; Hallvard Holen, 2002). To achieve an effective magnitude of loss incurred due to damage and economic
undamaged periphery rock-wall, optimization of shock value of the recovered stone defines the permissible level of
and gas energy is essential to restrict and prevent wide damage. Similarly, permissible level of damage for under-
opening of joints. Shock wave, in general, is present only ground and open excavation in rock structures depends
up to a distance where non-reversible energy dissipation upon type of stability required for peripheral rock-wall
is observed i.e., the zone where rock medium behaves like structure. In underground or surface civil construction pro-
plastic rather than elastic (Olsson and Bergqvist, 1996). jects, since the damage transition zone i.e., the length or dis-
This is also known as Hugoniot elastic limit or crushed tance between zero and maximum damage around the
zone. It generally weakens the strength properties of excavated profile defines the deterioration in the integrity
in situ rockmass only up to a restricted distance from the of rock mass or safety of structure with respect to designed
borehole and depending upon blast parameters it generally support system, the same should be taken into consideration
varies between 2 and 8 times the diameter of blast hole. Gas in selecting proper sequence of operation and implementa-
energy, on the other hand, having the capability of extend- tion of suitable blast pattern. For any excavation work, mag-
ing cracks to about 10–100 times more than shock energy nitude of damage varies with type of blasting, explosive
are more dominant for extending fractures and should be concentration per hole, response of rock towards the impact
optimized to prevent damage of in situ peripheral rock of blasting i.e., rockmass characteristics and re-distribution
mass (Worsey et al., 1981; Colback and Wild, 1965; Dac- of stresses due to sudden dislodgement of in situ rock mass.
hnke et al., 1996; Harries, 1978; Henrych, 1979). Since, To restrict damage, various researchers have correlated
magnitude and intensity of gas driven stress wave varies damage of rock structure with magnitude of blast-induced
with its angle of incidence on joint plane, orientation of ini- vibration (Forsyth, 1993; Holmberg and Persson, 1979,
tiation pattern with respect to joint plane should be aligned 1980; Hustrulid, 1994; Hustrulid et al., 1992; Ouchterlony
to minimize the impact of gas generated stress wave on et al., 1993; Mandal et al., 2006, 2007). But, since frequency
joint or weak plane (Wu and Jianping, 2001; Wu and of vibration is very high for near field measurement and high
Gao, 1987; Wu and Liu, 1996). Characteristics and width frequency signals never superimpose on each other to mag-
of filling material also quantifies magnitude of transmitted nify or lower the magnitude of PPV, magnitude of PPV can-
stress pulse and limits the intensity and magnitude of dam- not be the only parameter to damage periphery rockmass
age caused by gas driven stress wave (Simha, 1993, 1996; (Bogdanoff, 1996). Researchers commented that since rock
Singh, 2000; Ryan Freeman and Brian Roberts, 2002; mass properties vary widely, its interaction with detonation
SNRA, 1995). In civil construction projects damage to of explosives is unique in each case and no empirical equa-
peripheral rock mass by the impact of blasting is inevitable tion can effectively predict or estimate rock mass damage
 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36 25

(Sjoberg, 1979; Sjoberg et al., 1997; Nyberg and Fjellborg, HRT, TRT, Power House, Transformer Hall and Pressure
2000; Nyberg et al., 2000). Yang et al., 1993a,b; Yang Shafts. These structures were constructed using ‘‘Drill &
et al., 1994 communicated that prediction of near filed vibra- Blast” method of excavation. This project commenced in
tion is very difficult and therefore, stress–strain analysis 1999 and was successfully commissioned in 2003. The
should be carried out for safety of structures. Furthermore, horse-shoe shaped head race tunnel, 7831 m long had a fin-
characteristics of wave signature being the resultant impact ished diameter of 7 m. Tail Race tunnel, 3464 m long was
of geology of strata, blast geometry, explosive parameters excavated by burn-cut method of blasting (Singh et al.,
and initiation pattern implemented at site, safe magnitude 2005). The explosive diameter was 40 mm. For HRT, the
of vibration recommended for a site cannot be universally average explosive consumption per blast varied between
true for all the sites (Blair, 2004). In this regard, Mandal 244 and 325 kg and specific charge consumption on an aver-
et al. (2007) communicated that vibration parameters viz., age was less than 1.6 kg/m3. For TRT, average explosive
acceleration and deceleration of peak hold, number of peaks, consumption per blast was about 214 kg with specific charge
time duration for peak hold, peak hold energy and cumula- consumption of 1.2 kg/m3.
tive wave energy transmitted to in situ rock mass should be
evaluated and ascertained for safety of structure. 3.2. Site B
Overbreak, on the other hand, is the result of damage and
can be quantified as extra cost involved for additional muck The project comprised of 7.7 m diameter horse-shoe
removal, shotcreting or application of extra support system shaped 10.571 km long headrace tunnel to generate
and/or extension of time schedule for stabilization of exca- 390 MW from three turbines of 130 MW each. Unforeseen
vated structure. Overbreak either occurs immediately after geo-mining problems due to poor interpretation of geolog-
blasting or with duration of time i.e., either dynamic or ical data, has led to time and cost overruns. The progress of
quasi-static type. The quasi-static type of overbreak is HRT also suffered due to poor rock conditions and tunnel
caused with lapse of time of excavation and is generally passing through weak zones. Break down of TBM also
caused by re-distribution of stresses and loosening or weak- hampered the progress of work. Due to irreparable condi-
ening of filling material between two blocky rock masses. tion of damaged TBM during the process of excavation,
This type of over-excavation is the result of interaction drilling and blasting method was later implemented to
between improper sequence of excavation, excavation pro- complete the tunnel excavation work (Singh et al., 2004).
file or shape and/or inadequate application of support with
respect to in situ stresses or poor assessment of rock mass 3.3. Site C
quality. Dynamic type of overbreak is sudden and propaga-
tion of crack is faster and is generally caused by the impact of This site is a hydroelectric project developed as run-of-
energy generated by detonation of explosive. Unfavourable river project on river Wangchu in South-West Bhutan in
direction of weak plane i.e., dipping of foliation plane Eastern Himalayas. The head race tunnel is a modified
towards free face, presence of alternate weak and hard strata horse-shoe shaped 6.8 m diameter and 23 km long. The ver-
with intermediate weak and non-cohesive composite filling tical cover of this tunnel ranged between 95 and 1100 m and
material and adverse ground water condition sometimes passed under dense forest. The tunnel alignment was mostly
aggravate the situation of overbreak and jeopardize the parallel or sub-parallel to the foliation trend of formation.
safety of structure. Dynamic type of damage may also occur Rocks along the tunnel alignment were generally folded into
when the magnitude of stress developed due to creation of open synforms and antiforms. The project area was within
void exceeds the strength properties of rock mass. Therefore, the central crystalline belt of Thimpu Formation and meta-
for safety of structures the design engineer should maintain sedimentary of the Paro Formation. Younger Shumar For-
proper alignment of underground structures with respect mation underlay these formations. The underground power-
to in situ stress and major weak planes. Furthermore, for house comprises of six turbine pits to generate 6  170 MW
an effective control of overbreak and enhance safety and sta- electricity (Singh et al., 2003).
bility of structures, a team of design and construction engi-
neers having experience in evaluating deterioration in rock 3.4. Site D
mass quality with respect to type of blasting should also be
a member of the team. With the collapse of underground diversion tunnels, the
river water was flowing over the dam body of block numbers
3. Brief information of the sites 11, 13 and 14, maintaining an up stream level of 764.30 m.
The continuous flow of water over the area and a threat of
3.1. Site A heavy water rush during monsoon season posed problem
for construction of other blocks viz., block numbers 15 and
This project is a run of the river project executed by 16 located towards the collapsed side of diversion tunnel.
National Hydro Electric Power Corporation Limited and To facilitate the construction of dam, plan was made to
was designed for 300 MW generation of electricity. The main divert water through a temporary outlet by constructing a
components of the project are: dam, desilting chambers, tunnel of 6.8 m diameter in block no. 11 of dam body. The
26 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36

diameter was computed by comparing the efficiency of tun- and widening method and lately in one stage by burn-cut
nel discharge for a constant up stream elevation and at the method of blasting. During two-stage blasting wedge-cut
same time increased the time to raise the blocks to their max- pattern was adopted. The number of holes for full face blast-
imum level and prevent overtopping of water. The tunnel ing varied between 80 and 85 holes. The explosive consump-
was driven between EL 732 and 738.80 m. The length of tun- tion per blast varied between 60 and 65 kg. For burn-cut
nel was about 113 m (Singh et al., 2006). Initially the pro- pattern, number of holes in a blasting round varied between
posed schedule of excavation was by piloting and widening 90 and 100. Average explosive consumption per blast for
method. But, however, after reviewing the characteristics burn-cut blasting varied between 75 and 85 kg. The diameter
of vibration generated by long delays i.e., each delay having of drill holes and explosive used for the blasts were 45 and
an independent impact on dam body, the tunnel of 6.8 m 40 mm, respectively. The burden and spacing of periphery
diameter was excavated in one round. Depth of hole for each row of holes varied between 0.4–0.6 m and 0.4–0.5 m,
round varied between 2.5 and 3 m. respectively.

4. Blasting practices at each site 5. Analysis of total overbreak

Both the tunnels (HRT and TRT) of Site A were horse- For site A, same blast pattern was implemented at all
shoe shaped with a finished diameter of 7 m. The tunnels locations. In this site it was observed that average magni-
were excavated by burn-cut method of blasting with charge tude of overbreak for HRT driven towards downstream
hole and dummy hole diameter of 45 and 89 mm respec- was less than that driven towards upstream end (Table
tively. The explosive diameter used at this site was 1). Comparative analysis of average overbreak between
40 mm. Long Delay Detonators, with delay timing of HRT and TRT indicated that average overbreak for later
about 500 ms or more were used in blasting operations. was more than HRT (Fig. 3). Scatter plots of overbreak
In HRT, the explosive consumption per blast varied for each HRT for site A is shown in Fig. 4. From Fig. 4
between 244 and 325 kg. The specific charge consumption, it is observed that except for Fig. 4d and other occasional
on an average, was less than 1.6 kg/m3. The average pull events for Fig. 4a–c, the magnitude of overbreak for most
per blast was more than 80%. In TRT, average explosive of the events was less than 10%. For Fig. 4d, magnitude of
consumption per blast was about 214 kg with specific overbreak for each event was high at initial stage and latter
charge consumption of 1.2 kg/m3. The peripheral blast was almost constant and similar to that observed in other
geometry comprised of 0.4 m and 0.4–0.5 m spacing and HRTs. High magnitude of overbreak in the initial stage
burden respectively. In all, about 14 delay numbers were possibly indicated a poor selection of blast pattern with
used to fire all the holes in one blasting round. respect to geo-technical properties and/or in situ stress
The horse-shoe shaped 7.7 m tunnel for Site B was direction and magnitude around the zone of excavation.
mainly driven in quartzite rock with huge amount of verti- Improvisation of reduced charge consumption along
cal cover. Burden-cut pattern of drilling was followed for periphery rows, change in blast design pattern and
drivage of this tunnel. The diameter of burn and charge improvement in rock mass condition at latter stage reduced
holes was usually 89 and 42 mm. Thirty-two millimeter the magnitude of overbreak for rest of its length. Consider-
diameter explosive was used for the blasts. The spacing ing the implemented blast pattern to be optimum, the occa-
and burden for the periphery row was usually 0.5 and sional enhanced magnitude of overbreak, as observed in
0.6 m, respectively. The number of holes and total charge this site was due to wedging action i.e., formation of wedge
fired in a blasting round varied between 95–118 and 220– by joint planes or shear zones crossing the tunnel profile or
375 kg, respectively. A total of 12–13 delay numbers of sev- combination of various other unfavourable geo-technical
eral quantities for each was used in a round of blast. parameters encountered during excavation of tunnel. The
At site C, for both adit and HRT, burn-cut and wedge- difference of average overbreak between downstream and
cut pattern was implemented for excavation of rock. About upstream was due to difference in unfavourable direction
90–100 numbers of holes were blasted in a round. For poor of foliation plane and direction of in situ stress with respect
rock mass condition and high magnitude of overbreak, to tunnel alignment. Since, geo-technical parameters
depth of hole for each blast was restricted to a maximum encountered within the tunnel are generally almost uni-
of 3.0 m. The total charge fired in a round of blast was form, except with some local variation, it can be ascer-
about 120–130 kg. The charge concentration for periphery tained that magnitude and direction of in situ stress
holes was about 0.1 kg/m. A total of 13–14 delay numbers played an important role in magnifying the characteristics
of several quantities for each was used in a round of blast. and extent of overbreak. Hence, in addition to geo-techni-
At this site, for various occasions it was observed that over- cal properties, alignment of tunnel with respect to in situ
break was minimum just after blasting, but, however, the stress should be considered to contain overbreak within
magnitude of overbreak increased with advancement of permissible limit. The scatter diagram for TRT driven from
face and also while mucking the blasted muck. exit end indicated sinusoidal characteristics of increase and
For site D, drivage of 6.8 m circular tunnel through the decrease of overbreak whereas that driven from Main
concrete body was firstly driven in two stages viz., pilot Access Tunnel (MAT) end showed a steady decrease in
 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36 27

Table 1
Details of overbreak for each tunnel
Parameters Site A Site C Site B Site D
TRT from TRT D/s HRT D/s from HRT D/s HRT U/s HRT U/s HRT Adit HRT Dam
exit end from MAT inlet adit from adit I from adit I from adit II outlet
Number of 511 10 285 419 349 429 26 41 30 20
data
Average 8.22674 12.9472 3.199579 4.11376 4.43469 7.25702 20.26141 51.86876 13.8018 10.13528
Standard 4.44146 5.307 2.4906 3.0154 3.05244 4.6973 28.5081 35.16372 18.0521 7.11917
deviation

a b
25 25
Overbreak of HRT fromD/s, Adit I Overbreak of HRT U/s
from adit I
20 20
Overbreak (%) --->

Overbreak (%) --->

15 15

10 10

5 5

0 0
0 500 1000 1500 2000 2500 0 50 100 150 200 250 300 350 400
Chainage(m) ------> Chainage(m) ---->

c d
20 40
18 Overbreak for HRT D/s from Overbreak of HRTU/s from adit II
inlet end 35
16
Overbreak (%) ---->

Overbreak(%) ---->

14 30
12 25
10 20
8 15
6
10
4
2 5
0 0
0 50 100 150 200 250 300 0 50 100 150 200 250 300 350 400 450 500
Chainage(m) ----> Chainage(m) ----->

Fig. 4. Scatter diagram of total overbreak of HRT, Site A.

a b
30 30
Total overbreak of TRT from exit end Total overbreak of TRT from MAT end
25 25
Overbreak(%) ---->

Overbreak(%) --->

20 20

15 15

10 10

5 5

0 0
0 500 1000 1500 2000 2500 3000 680 690 700 710 720 730 740 750
Chainage(m) ----> Chainage(m) ---->

Fig. 5. Total overbreak for TRT, Site A.

magnitude of overbreak (Fig. 5). The characteristic of over- of support system with respect to geo-technical parameters
break for Fig. 5 a was possibly due to presence of shear and failure of rock mass due to due to inadequate applica-
zone crossing the tunnel obliquely and/or poor assessment tion of support system and development of abutment pres-
28 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36

sure. A higher magnitude of overbreak in the initial stage the normal distribution curves shown in Fig. 6. For
of TRT driven from MAT end was due to improper blast Fig. 6b, d–f, the characteristics indicated that though the
pattern with respect to built-up of excessive mining- average magnitude of overbreak was high, the concentra-
induced stress by construction of various structures (pres- tion of such magnitude was for few numbers of events.
sure shafts, powerhouse, transformer hall etc.,) in that However, for TRT driven from MAT end (Fig. 6c) and
zone. However, at latter stage, magnitude of overbreak HRT driven towards downstream from adit I (Fig. 6a),
reduced due to non-influence of mining-induced stresses the smooth curvature at the top of normal distribution
with respect to blast pattern implemented at site. The aver- curve indicated that more number of events had higher
age magnitude of overbreak for TRT was higher than HRT average magnitude of overbreak. Therefore, to contain
because TRT was either driven through low cover zone i.e., overbreak within permissible limit, magnitude of stress
eroded surface profile with open joints or highly pre- developed (in situ or due to excavation of same or other
stressed zone. The characteristics and behaviour of over- structures) and geo-technical parameters should be evalu-
break for each tunnel of site A can be understood from ated prior to implementation of any blast pattern. More-

a HRT D/s from adit I b 49

HRT D/s from inlet adit

0.5

-0.1 -1
1
1

c TRT D/s from MAT end d 49

HRTU/s from adit I

0.7

-1
-0.1 1
1

e TRT from exit end f 39 HRTUSfrom Adit II

45

-5
-1
1
1

Fig. 6. Normal distribution curve of each tunnel, Site A.

 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36 29

over, impact of stress distribution on the joint planes due to from powerhouse end. The bus-duct galleries at Tala pow-
evacuation of material should also be analyzed prior to erhouse were excavated in 6 sections with depth of holes
implementation of any blast pattern. In the pre-stressed varying between 2.5 and 4 m (Fig. 7). At this site, excava-
zone minimization of overbreak can be achieved by imple- tion of subsequent section was executed only after excavat-
mentation of reduced blast geometry and charge concen- ing the working section up to required profile and
tration along the periphery and buffer rows and supporting the excavated section as per design.
excavating the required cross- section in different stages Comparing magnitude of overbreak for all the sites, it
or sections. The excavation of bus-duct gallery from power was observed that magnitude of overbreak for HRT and
house end at Tala Project, Bhutan illustrates the impor- adit for Site C was more (Fig. 3). However, when compar-
tance of excavation in various stages. Minimum magnitude ison of magnitude of overbreak between adit and HRT of
of overbreak was observed while driving bus-duct galleries site C was made it was observed that magnitude of over-
break was more for adit. Poor rock mass response towards
detonation of explosive and wrong planning regarding
alignment and direction of adit with respect to the struc-

Stage II
Single phase,
hole depth 4 m
Stage IV Stage III
Single Single
phase, hole phase, hole
depth 4 m depth 4 m
Stage I
Two phases each of
2.5 m hole depth
(Wedge-cut

Stage V
Single stage, hole depth 4m

Fig. 7. Schematic diagram showing the stages of excavation in highly

stressed zone. Note: Subsequent stage would proceed only after completely
excavating and supporting the previous stage. Fig. 8. Schematic diagram of overbreak in the crown, Site C.

a
180
Total
riesover
1 break
160
Overbreak (%) ---->

140
120
100
80
60
40
20
0
0 5 10 15 20 25 30 35 40 45
Blastdata ---->

b 90
80 Series1
Total Overbreak
70
Overbreak (%) ---->

60
50
40
30
20
10
0
0 5 10 15 20 25 30 35
Numberof data ---->

Fig. 9. Scatter plot of overbreak for Site C.

30 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36

tural properties of rock mass and direction of in situ stress was well within acceptable limit, except for few blasts. High
possibly caused such high magnitude of overbreak (Fig. 8). magnitude of overbreak for adit to HRT was possibly due
The scatter diagram and normal distribution curve of over- to poor rock mass characteristics, presence of shear zones
break for both adit and HRT of site C are shown in Figs. 9 along tunnel alignment, unfavourable direction and magni-
and 10 respectively. In comparison to magnitude of over- tude of in situ stress with respect to tunnel alignment,
break for adit to HRT, magnitude of overbreak for HRT improper implementation of blast pattern with respect to

a b
300 1000
Left Side RightSide Crown Left Side RightSide Crown

-30
30
-
1
1

Fig. 10. Normal distribution curve of overbreak for different zones of tunnels for site C.

a 130
Left Side Right Side Crown
115

100

85
Overbreak (%) --->

70

55

40

25

10

-5
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41
Blast data --->

b 9
Left Side Right Side Crown
8

7
Overbreak (%) --->

0
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Blast data ---->

Fig. 11. Sector wise overbreak for tunnels of Site C.

 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36 31

geo-technical properties of rockmass and poor assessment

a 90
of support system. This was well understood and felt by
80 Total overbreak
observing the twisted steel arch supports at some locations.
70
In this tunnel, at several locations it was observed that

Overbreak (%) --->

60
magnitude of overbreak was nominal just after blasting 50
and the magnitude increased with evacuation of blasted 40
muck and advancement of face. For adit, normal distribu- 30
tion curve for left wall indicated that though, the average 20
magnitude of overbreak was less, more number of events 10
had almost similar magnitude of overbreak, indicating a 0
0 5 10 15 20 25 30 35
need of improvement in blast design pattern in that region Blast data --->
with respect to geo-technical properties and in-stresses.
b 35
However, for right wall, though, the magnitude of average
30

Overbreak (%) --->

Total overbreak
overbreak was more, the narrow peak indicated that a very
25
few numbers of events had such high magnitude of over-
break. The occasional high magnitude of overbreak for this 20

was possibly due to either presence of localized weak zone 15

or inaccuracy in drilling. The normal distribution curve for 10
crown indicated high magnitude of average overbreak and 5
more number of events had such high overbreak magni- 0
tude. The characteristics illustrated to evaluate geo-techni- 0 5 10 15 20 25
Blast data --->
cal parameters, support design and subsequent excavation
design and blast pattern to contain magnitude of overbreak Fig. 12. Scatter diagram of total overbreak for tunnels: (a) Site B and (b)
well within acceptable limit. The comparative assessment Site D.
of normal distribution curve for three sections (left, right
and crown) for HRT of site C, are shown in Fig. 10b. was high. In-spite of same drilling pattern for both left
The average magnitude of overbreak was more for crown and right wall, the excessive overbreak along left wall pos-
and was less for left and right wall. In both left and right sibly indicated unfavourable direction of foliation plane or
wall, though, the average magnitude of overbreak was less in situ stress along left wall. Characteristics of Normal Dis-
number of events having such high magnitude of overbreak tribution Curve for each sector for site B is shown in
was more than that observed for crown. This possibly indi- Fig. 14a. The curve indicated a steep rise for right side
cated poor blast design with respect to rock mass charac- and a slow rise for crown and left side. The curve for right
teristics and unfavourable direction of in situ stresses wall indicated that magnitude of overbreak nearer to aver-
with respect to tunnel alignment. The analysis revealed that age was for very small number of event. The occasional
to contain magnitude of overbreak well within acceptable such magnitude of overbreak was possibly due to either
limit, basting engineer should implement proper blasting error in drilling or presence of unavoidable weak and/or
pattern with respect to in situ stress condition of strata. joint planes along the tunnel profile. However, for other
Furthermore, regularly assessment of magnitude of over- walls viz., left and crown, number of events having such
break should be evaluated with respect to implemented magnitude was more. The characteristics of overbreak in
blast design to improve the blasting pattern and contain left wall and crown indicated that either geo-technical
magnitude of overbreak within acceptable limit. Implemen- properties or error in accuracy of drilling or impact of
tation of adequate support system should also be evaluated in situ stress or a combination of them resulted into such
as it sometimes endanger safety of structure and incur addi- high magnitude of overbreak. To further reduce the magni-
tional cost and time for completion of safe excavation tude of overbreak in these walls (left and crown), the char-
work. The bar-chart showing the magnitude of overbreak acteristics of curve indicated a need of implementing low
for left wall, right wall and crown for both adit to HRT blast geometry and less charge concentration along the
and HRT of site C is shown in Fig. 11. periphery. Furthermore, rock type for this site being
The average magnitude of overbreak for HRT of Site B quartzite and quartzite being weak and brittle to load,
was less than HRT of site C, but, was more than site D magnitude of overbreak was more due to the combined
(Table 1, Fig. 3). The scatter diagram of total overbreak impact of basting and in situ stress or re-distribution of
and sector wise overbreak for site B is shown in Fig. 12a stress during excavation. Presence of unfavourable direc-
and 13a respectively. Except for some occasional instances, tion of foliation plane and intermediate hard and weak
the total overbreak magnitude was well within 20% of tun- strata sometimes caused deviation of holes (as observed
nel cross-sectional area. The occasional high magnitude of from hole markings on wall) and enhanced the magnitude
overbreak was mainly due to crossing of shear zone along of overbreak in these regions. Therefore, to avoid over-
the tunnel alignment. Sector wise analysis of overbreak break due to deviation, a specialized drilling attachments
revealed that the magnitude of overbreak for left wall should be implemented for drilling along periphery.
32 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36

a 40
Left Side Right Side Crown
35

30

25
Overbreak (%) ---->

20

15

10

-5
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29
Blast data ---->

b 0.25

Left Side Right Side Crown

0.2

0.15
Overbreak (%) --->

0.1

0.05

-0.05

-0.1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
Blast Data ---->

Fig. 13. Sector wise overbreak for tunnels: (a) Site B and (b) Site D.

a b
230 300
Left Side Right Side Crown Left Side Right Side Crown
Right Wall
Right wall Left wall
Crown
Left wall Crown

-3 0 -30
1 1

Fig. 14. Normal Distribution curve of overbreak for tunnels.

The tunnel for site D was driven in concrete i.e., pres- per initiation pattern or charge concentration, but, was
ence of no foliation plane or shear zone and with minimum mainly due to lack of drilling accuracy i.e., all the holes
in situ stress. The magnitude of overbreak for this site was along the periphery line were drilled with more look-out
less than site B and C but more than site A. The scatter plot angle. Smooth and undamaged excavated profile and drill
of total overbreak for site D is shown in Fig. 12b. It was marking at several locations indicated inaccuracy in
observed that overbreak in this area was not due to impro- drilling. Furthermore, difficulty of site condition and
 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36 33

application of under capacity boomer (H126 with COIP and right wall. The higher magnitude of overbreak in the
1238 hammer of Atlas Copco) for such tunnel diameter crown was due to implementation of under capacity drill
was the main reason for overbreak. Due to difficult loca- machine and angular drilling (look-out drilling) in the
tion of site (machineries were lowered to the site by cable crown. Analysis of Normal Distribution Curve for each
crane and men reached the working place with the help sector indicated that left side and crown had wider range
of tower crane) under capacity drilling equipment had to of events having average magnitude of overbreak. Since,
be implemented for excavation work. The photograph of the drilling equipment had only one boom and had to drill
the site along with location of tunnel is shown in Fig. 15. all along the face, the drilling personnel found difficulty in
The undamaged roof concrete (slab of 0.7 m thick) along drilling along the left wall and so such higher magnitude of
the crown indicated proper blast pattern to retain such overbreak was observed along left wall.
thickness of concrete in the crown. Such small thickness Comparing overall sector wise overbreak for HRT of
of concrete had to be left on crown because the dam was each site it can be concluded that for all the tunnels, mag-
constructed by heightening the concrete layer each of nitude of overbreak along the right wall was less in com-
1.5 m thick and the bottom of the tunnel was along the parison to that observed for left wall (Table 2, Fig. 16).
base of one slab of concrete layer. The overbreak in the Furthermore, magnitude of overbreak for crown region
tunnel was only due to inaccuracy in drilling due to impro- was maximum to that observed for both left and right wall.
per selection of boomer with respect to tunnel dimension. It This possibly indicated that in addition to magnitude and
was also understood that blast pattern, if not properly direction of in situ stress, characteristics of foliation plane
implemented, provokes the geo-technical properties to for both left and right wall should be considered for proper
cause overbreak. Sector wise overbreak and Normal Distri- implementation of blast geometry and charge concentra-
bution Curve for each sector for site D are shown in Figs. tion for these sectors. Furthermore, the controllable
13b and 14b respectively. Comparative sector wise analysis parameters viz., burden, spacing, delay timing between
of overbreak for this site indicated a higher magnitude of the buffer and periphery row and charge concentration
overbreak in the crown and almost same magnitude in left should be adjusted to achieve an acceptable magnitude of

Fig. 15. Location for excavation of tunnel at Site D.

34 S.K. Mandal, M.M. Singh / Tunnelling and Underground Space Technology 24 (2009) 22–36

Table 2
Comparison of sector wise overbreak for three tunnels
Name of Overbreak
Site
Left side Right Side Crown
Number of Average Standard Number of Average Standard Number of Average Standard
data deviation data deviation data deviation
Site C, 41 10.212 5.9423 41 13.7205 15.59108 41 26.52435 24.826466
ADIT
Site C, 26 4.092666 1.623283 26 2.979262 1.622193 26 4.093193 1.201412
HRT
Site B, 30 5.353572 8.87776 30 2.422965 2.686466 30 5.549908 5.4142
HRT
Site D 20 3.24865 3.02806 20 1.76224 2.04325 20 5.821246 3.941965

30 overbreak within allowable limit. The average magnitude

Left Side of overbreak for all the sectors of adit was more than
25 Right Side HRTs, indicating the impact of either low cover zone or
Crown
Overbreak (%) --->

20 weak and eroded top soil or poor assessment of geo-techni-

cal properties of rock in that region. For safe operation of
15
any adit, proper assessment of geo-technical properties of
10 rock and distribution of stresses after excavating the
5
designed profile should be properly evaluated prior to
implementation of any blast design and support system.
0 For minimization of overbreak in adits or in highly stressed
Site B Sit C, HRT Site C, adit Site D
Name of Sites ---> zone, excavation should be carried out in stages. Further-
more, advancement of face should be carried out only after
Fig. 16. Comparative assessment of sector wise overbreak. excavating any particular cross-section up to the required
profile and fully supporting the area as per the design.
For safety and stability of structures adequate capacity of
overbreak. Crown of any tunnel being the most stressed support system should be designed and implemented to
zone, blast geometry and charge concentration for this sec- cater the change in stress developed after blasting and evac-
tor should be further reduced to contain magnitude of uation of material.
overbreak well within acceptable limit.
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