The face of innovation

Atlas Copco
Supporting your business
wherever you are
Rock & Soil
Reinforcement
third edition
www.rockreinforcement.com

Rock & Soil Reinforcement

Atlas Copco supplies the widest range of advance
cost-efficient rock reinforcement solutions for
mining and tunnelling, including fully-mechanized
Boltec rock bolting rigs, Swellex rockbolts, and
MAI self-drilling anchors.
Each and every product has been designed to help
maximize your tunnel advance and minimize costs
per drilled metre – and always with the highest
level of safety in mind.
Atlas Copco MAI
Because we’re a global organization, we have the
resources to be truly local.
Find out more at www.atlascopco.com and select
“Country”. Or give us a call. We’d be happy to listen
to your requirements, and even happier to meet them.
Talking Technically
Case Studies
Product Specifications
Third Edition

Phone: +43 4245 65 16 60

Fax: +43 4245 65 16 68 00

www.atlascopco.com
a technical reference edition
Printed matter no. 9851 6283 01b
RR3 CONT.qxd 19/7/05 8:33 Page 1

Contents
Foreword 99 Front Stabilization Using MAI Rock Anchors:
pre-reinforcement as a means of ground control in
2 Foreword by Federico Scolari, Vice President Marketing, Germany, Italy and Taiwan.
Atlas Copco Craelius. 104 Boltec at Kemi Mine: integrated process control
demands reliable and consistent mechanized
Talking Technically 109
rockbolting.
Overcoming Squeezing Ground at Mitholz:
supporting deformed strata while fresh support is
3 Innovative Solutions for Rock & Soil Reinforcement installed.
5 Investing in Rock Reinforcement 113 Mechanized Bolting at Zinkgruvan: better rock
7 Controllable Rock Reinforcement reinforcement improves production and safety.
11 Swellex Manganese Offers Improved Work Index 115 Seismic Tunnelling at Bolu: crucial motorway tunnels
13 Swellex Premium Line recover from earthquake using Self Drilling Anchors.
15 Hollow-Core SDA System 119 SDA in the Baltic States: novel uses for grouted SDA
17 Atlas Copco MAI Self Drilling Anchors as micropiles to support ancient buildings.
19 Symmetrix For Large Holes 124 Increasing Land Use: SDA applied to subsoil
22 Sacrificial Drill Bits stabilization prior to housebuilding in UK.
24 Mechanized Bolting 127 Soil Nailing UK Transport Routes: securing major
28 Using Rocket Boomers to Install Rockbolts road and rail infrastructure using SDA.
33 Connectable Swellex 129 Portal Support Using Swellex: stabilization of
35 Rockbolt Corrosion in Mining and Tunnelling entrances to Porte tunnel in Italy.
38 Grouting for Support in Tunnels 131 Driving From Budapest to Nürnberg: difficult tunnels
41 Rock Mass Stability with Swellex using advanced rock reinforcement techniques.
43 Secoroc Uppercut – New Tapered Equipment 135 Systematic Grouting at Oslo Subway: Craelius
45 Getting the Drift with Magnum SR Unigrout provides the perfect solution for water ingress.
47 Rock Mechanics and Rock Reinforcement
51 Swellex in Shear Stress
55 Using ROC Drillrigs to Install SDA
59 3-D Imaging for Rock Support Design Product Specifications
61 Introducing Swellex Hybrid
139 Swellex Manganese Line
144 Plasticoated Swellex
Case Studies 145 Swellex Premium Line
148 Swellex Hybrid
63 Swellex in Mining: project reports from Canada, 149 Swellex Face Plates & Washers
Portugal, Turkey and Peru. 150 Swellex Pumps
69 Removing Bottlenecks in Austria: upgrading the 152 MAI SDA
European highway system in Central Europe. 164 Tophammer Crawlers
73 Extreme Temperatures: rock reinforcement in 166 Boltec Rigs
permafrost in Northern Quebec and volcanic strata in 172 Rocket Boomer Drillrigs
Hokkaido. 174 Hydraulic MAI Bolt Support
75 Coated Swellex at Kvarntorp: longlife installation of 175 Hydraulic Rock Drills
rockbolts in a corrosive environment. 178 Hydraulic Feeds
77 Nuclear Quality Assurance: long-term tunnel support 180 Symmetrix Overburden Casing System
for the Exploratory Studies Facility at Yucca Mountain, US. 188 Unigrout Grout Plant
81 Versatility in Tunnelling: project reports from China, 189 Pusherleg Drills
Germany, Madeira, Spain, and Switzerland. 190 Secoroc Threaded Equipment
87 Rapid Support Close to the Face: reporting use of 204 Secoroc Tapered Equipment
Swellex at three important Italian TBM tunnelling sites.
91 Large Hydroelectric Projects: widely differing demands Front cover: Different applications involving rock reinforcement.
at sites in Austria, Bhutan, India, Philippines and Portugal. Atlas Copco reserves the right to alter its specifications at any
97 Top Combinations in Japan: reliable support in time. For latest updates contact our local Customer Centers or
sedimentary and volcanic rock formations in railway and refer to www.rockreinforcement.com
road tunnels.

Produced by tunnelbuilder ltd for Atlas Copco Rock Drills AB, SE-701 91 Orebro, Sweden, tel +46 19 670-7000, fax -7393.
Publisher Ulf Linder ulf.linder@atlascopco.com Editor Mike Smith mike@tunnelbuilder.com Picture Editor Jan Hallgren
jan.hallgren@atlascopco.com Contributors Anders Arvidsson, Claes Hillblom, Federico Scolari, Francois Charette, Gunnar
Nord, Hans Fernberg, Juha Hyvaoja, Jukka Ahonen, Lorne Herron, Mario Bureau, Mark Bernthaler, Olle Karlsson, Per-Olof
Einarsson, Sara Sjödin, Sten-Ake Peterson, all name.surname@atlascopco.com. Adriana Potts, adriana.potts@ntlworld.com.
Maurice Jones, maurice@tunnelbuilder. com. Wulf Schubert, Markus Potsch, Andreas Gaich, all surname@tugraz.at.

Designed and typeset by Sheldon Mann, Belvedere, Kent, UK

Printed by db grafiska, Örebro, Sweden Copies of all reference editions are available in CD-ROM format
from the publisher, address above. Reproduction of individual

ROCK & SOIL REINFORCEMENT 1

RR3/FORE.qxd 19/7/05 8:36 Page 2

Foreword
O
ngoing development of faster, safer and more exotic tunnelling techniques places a con-
stant pressure on manufacturers to provide more efficient rock support solutions which
will help the shortening cycle time.
The use of versatile drilling jumbos for mechanized installation of a variety of rock support
systems is part of the leading practice used in modern tunnelling. As ground conditions get more
and more demanding, emphasis is placed on flexible and intelligent support systems in which rock
and soil reinforcement is expected to contribute to the productivity and safety of the operation.
The trend has been to provide rock support/reinforcement systems that are easy to install, assure
efficiency and provide safety, both during and after excavation.
For the last 25 years, Atlas Copco has been offering the Swellex concept as a unique, safe and
reliable system of rock support. As the market leader in underground rock excavation technology,
Atlas Copco has also been developing safer and more efficient rock reinforcement products such
as the Manganese Line rock bolts, which are manufactured from a special type of steel. Another
development is the Swellex Premium Line of rock bolts, for use where high yield load and stiff-
ness are expected from the reinforcement system. The recent acquisitions of MAI and Rotex have
introduced a whole new range of products, which are now being developed for mechanized instal-
lation by both surface and underground drillrigs, creating fresh applications in rock and soil rein-
forcement.
Atlas Copco’s Rock Reinforcement Competence Centre at Feistritz/Drau, Austria brings togeth-
er the skills necessary for the development of superior rock reinforcement products to serve the
tunnelling, mining and construction industries worldwide. In 2005, the centre became a part of
Atlas Copco Craelius, which is active in ground engineering with Symmetrix and ODEX overbur-
den casing drilling systems, and Unigrout and Logac grouting equipment, and produces multipur-
pose drilling rigs such as the Mustang. The combined product portfolio includes Swellex and MAI,
bringing together all elements of the Atlas Copco rock and soil reinforcement strategy.
As a result, market-driven product development at this new facility is already setting the scene
for another quarter-century of development in rock reinforcement and ground engineering.

Federico Scolari
Vice President Marketing
Atlas Copco Craelius

federico.scolari@se.atlascopco.com

2 ROCK & SOIL REINFORCEMENT

RR3/RT1 24/6/05 17:01 Page 3

TALKING TECHNICALLY

Innovative Solutions for Rock and

Soil Reinforcement
Twenty Five Years On
Over the past 25 years, Atlas
Copco has developed a constant
stream of products that have pro-
vided innovative solutions to a
multitude of rock support and
reinforcement tasks, and solved
many difficult challenges for
miners and drilling contractors
around the globe.
Further developments are on
the way with the recent inaugu-
ration of a dedicated competence
and R&D centre for rock rein-
forcement in Feistritz/Drau,
Austria. Located at the headquar-
ters of Atlas Copco MAI, the
centre is dedicated to developing
cutting-edge products for rock
reinforcement and ground engi-
neering applications. Official opening of the new Atlas Copco rock and soil reinforcement competence centre at Feistritz/Drau,
Austria.

Leading the Way • Swellex Manganese for increased launched the Boltec 500, a new rig for
tensile strength and higher elongation fully mechanized rock bolting, primar-
When Atlas Copco applied for patents capacity ily to increase productivity and to
for the Swellex rock bolt in 1979, it • Swellex Premium Line for improve safety when installing the
was a significant milestone in rock improved yield characteristics and ten- bolts. Safety is an especially important
reinforcement technology. This inflat- sile strength with slightly less elonga- consideration on sites with poor rock
able bolt was extremely easy and tion. conditions.
quick to install in a 38 mm hole, and However, the extreme conditions of
provided immediate support. Specialized Rigs rock bolting, in which water and rock
The advantages proved to be so
effective that over the next decade At the same time as applying for Atlas Copco Boltec LC is a highly productive
several million Swellex bolts were patents for Swellex, Atlas Copco machine developed specifically for rock bolting.
used in demanding ground conditions
worldwide.
In the years that followed, this suc-
cess led to the development of several
new versions including:
• Coated Swellex with rust protec-
tion to withstand corrosive environ-
ments
• Super Swellex for larger hole
diameters and a 20-tonne load-bearing
capacity
• Connectable Swellex for tunnels
where the length of the bolt required is
more than the height of the tunnel
• Swellex Hanger for suspending
such facilities as conveyor belts and
working platforms

ROCK & SOIL REINFORCEMENT 3

RR3/RT1 24/6/05 17:02 Page 4
TALKING TECHNICALLY
Innovative two boom cable bolting rig drills with one boom while feeding and grouting cable with the other.
cuttings pour down along the drill
string and onto the rock drill, feed and
moving components, had a negative
effect on the service life of these rigs.
Their performance was affected even
more when cement-grouted bolts were
used, due to cement spilling out of the
hole onto the bolting unit.
In response to these challenges,
Atlas Copco continued to develop fur-
ther generations of more rugged and
reliable bolting rigs that had fewer
moving parts.
The current fourth generation rigs are
capable of impressive performances. For
example, the Boltec LC working in a
Finnish mine recently installed more
than 120 Swellex Manganese bolts in a
single 8-hour shift.
Boomer face drilling rigs also began
to be used for tunnelling in poor
ground, drilling holes for rock bolts as
well as for the installation of pipe roof-
ing systems and self-drilling anchors.
Swellex Still Supreme
As the Swellex patents have begun to
expire, other producers have made
repeated attempts to imitate the design
and features of the Swellex bolts, but
none have managed to achieve the
same quality.
Swellex remains supreme, and Atlas
Copco remains firmly at the forefront of
4 ROCK & SOIL REINFORCEMENT
this technology, continually setting new
standards and breaking new ground.
In 2002, the company added self -
drilling anchors (SDAs) to its ever
widening product range, through the
acquisition of SDA specialist MAI
Ankertechnik of Austria.
These fully-threaded anchors, fitted
with sacrificial drill bits, are designed
for exceptionally poor ground condi-
tions where holes collapse and con-
ventional bolts cannot be used. In
addition, they are used in combination
with crawler drillrigs for surface appli-
cations, such as soil nailing in slope
stabilization, and in ground engineer-
ing for foundation reinforcement.
Atlas Copco MAI SDA are now
commonly used with modified
Boomer drill rigs. In this case, the drill
rod and bit are replaced by an MAI
adapter, coupling, anchor rod and a
sacrificial drill bit.
Competence Centre
The recent opening of the dedicated
competence centre at Feistritz/Drau,
Austria heralds a new era for the
development of superior rock rein-
forcement products to serve tun-
nelling, mining and construction
industries worldwide.
A considerable amount of market-
driven product development will now
be possible, and customers around the
world can expect to see many new and
interesting products in this area
coming from Atlas Copco in the years
ahead.
The scene is now set for another
quarter-century of development in
rock reinforcement and ground engi-
neering.
On the following pages, Atlas Copco
presents some technical papers, case
studies and product specifications to
demonstrate this technology in action.
by Federico Scolari
Twenty five years of innovative solutions to rock
reinforcement problems.
RR3/RT2.qxd 24/6/05 14:54 Page 5

TALKING TECHNICALLY

Investing in Rock
Reinforcement
Safety and Economy
Time was, in tunnelling and
mining, that rock reinforcement
was considered a burden, a cost,
and a necessary pain. The aim
seemed to be to get around the
support work in the easiest and
cheapest way possible, and con-
centrate all efforts on excavating
the greatest amount of rock, in
the shortest time.
As the awareness of the con-
sequences of poor rock reinforce-
ment becomes more widespread
amongst clients, engineers,
miners and contractors around
the world, a sounder attitude to
this work is emerging. There is
now a wish to achieve the
required demands on quality, to
carry out the support and rock
reinforcement in the right order,
to properly monitor what has
been carried out, and to evaluate
the results of the rock reinforce-
ment effort. The latest Atlas Copco Boltec offers a new dimension in rockbolting safety.
As contractors and miners have
a reputation for looking after their
money, new ideas are born on The Atlas Copco focus is on total In a linear situation, for instance, if
how to carry out the support and economy, by fast installation of rock it takes 100 days for one man to dig a
reinforcement work in cost effi- support, adequately proven perfor- defined dyke, 100 men can do it in one
cient ways, and they are often pre-
sented as alternatives in their mance of reinforcement, and a tech- day. In tunnelling, life is not that easy.
quotations on underground con- nology that has the capacity to meet There may be only one face to work
struction projects. In mining, there modern quality demands. at, and there is usually little space for
is continuous ongoing evaluation In this presentation of the Atlas increased efforts at that face. The only
aimed at optimization of the exca- Copco approach, we discuss the cost remaining option for the tunnellers is
vation reinforcement method.
implications of the time taken for the to improve mechanization.
round in tunnel excavation, the quality The leading process has been
Practical Solutions of the Atlas Copco rock reinforcement drilling at the face. Since the introduc-
programme, and working environment tion of the original Swedish Method,
At Atlas Copco, as a supplier of rock and safety aspects. the drilling performance has improved
drilling equipment as well as rock dramatically. The introduction of
reinforcement tools and material, there Improving Performance heavy pneumatic drifters mounted on
is an ongoing drive to create new or articulated booms, followed by three
improved solutions to rock reinforce- Going back 20 years or so, and look- generations of hydraulic drill rigs, has
ment problems. This topic is generally ing into the time needed to excavate a further multiplied productivity.
broached at an early stage of a project round and how this has developed, If we consider a tunnel with 80 sq m
by the contractors, and is brought up will indicate the direction in which cross-section being driven in fractured
constantly by the mining industry. As tunnelling technology is going. limestone with clays strata, through
a result, Atlas Copco is right at the The round cycle is just as real today a couple of major faults, and with
core of practical solutions for rock as it was then. By doubling the 350 m overburden and significant
reinforcement, and this has con- effort, the time taken will reduce by water inflow, the drilling phase has
tributed to our approach. 50%. decreased from 40% of the total

ROCK & SOIL REINFORCEMENT 5

RR3/RT2.qxd 24/6/05 14:54 Page 6
TALKING TECHNICALLY
Figure 1. Development of face excavation over the last 25 years, showing the changes in time taken for
various components of the round.
drilling time 20 years ago, to just 20%
today.
Figure 1 illustrates the development
of drilling and ancillary face opera-
tions over 25 years. Not all the differ-
ent phases in the cycle have the same
development. Shotcreting shows a
positive trend on time reduction, while
mucking has a less noticeable devel-
opment. These figures would improve
for a smaller cross section. Scaling
shows a large increase in time, since
heavy hydraulic breakers now play an
important role in improving the pull of
the blasted round by cleaning off the
face, as well as trimming the profile of
roof and sides to make safe.
If we consider traditional, fully
grouted rockbolts, installed with a
jumbo or with an automatic bolting rig,
the increase in productivity does not
keep pace with the drilling. In our ref-
erence tunnel we can register a poor
saving of 10% in total time consump-
tion. Rock reinforcement, and in par-
ticular, rockbolting, is a bottleneck in
the excavation cycle, and this has to be
tackled in order to boost productivity.
Time is Money
In tunnelling the time related cost is most
likely in the range of 50- 60% of the total
cost. This means that, if no work is car-
ried out during the set construction time,
6 ROCK & SOIL REINFORCEMENT
with all resources mobilized and the staff
taking home their salaries, the cost will
be at least half of the forecast cost.
Conversely, if the work is carried out in
half of the set time, the reduction in cost
will be at least 25%.
Assume a tunnel of 1.2 km in
length, with a cross-section of 70 sq m,
will be excavated over a time period of
one year. This is an average advance of
100 m/month, at an estimated cost of
€5,000/m or €6 million in total. The
time related cost will then be at least
€3 million, or €2,500/m. If a reduction
in construction time of one month can
be achieved, it results in a reduction
of the cost by €250,000. Further,
assuming that the working time is
500 hours/month, then the cost saving
Rocket Boomer L1 C-DH drilling rockbolt holes at Auersmacher in Germany.
will be €500/h saved. Consequently,
there is a good incentive for looking
for cost saving measures, and rock rein-
forcement certainly is an area of interest.
Atlas Copco has taken this problem
seriously. Our approach is to provide
machines, rockbolts and know-how to
add value to your rock reinforcement.
We hope that the articles in this
brochure can explain how.
Investing in Rock
Reinforcement
The Atlas Copco commitment is
towards a safer and more ergonomic
working environment. This commitment
is translated into ergonomic machines
and reliable rockbolts. There are no
shortcuts in this process. Swellex offers
immediate support, with full column
contact, and pumps check the inflation
pressure of the bolts. Self Drilling
Anchors (SDA) are replacing manual
installation of rockbolts in collapsing
holes, where the manual job is more dif-
ficult. Boltec offers a new dimension in
rockbolting safety, while Cabletec does
the same for cable bolting.
Assuming that you have done
everything to optimize your face
drilling, and that your detonators and
explosives are the best available. You
have a modern ventilation system, the
most powerful mucking equipment,
and the most efficient shotcrete robot.
And you still stay with the most
conventional rockbolting system?
Then it’s time to invest in rock
reinforcement.
by Gunnar Nord
RR3/RT3 11/8/05 15:32 Page 7

TALKING TECHNICALLY

Controllable Rock
Reinforcement
Helping Rock to
Support Itself
Modern computer-based geot-
echnical monitoring techniques
indicate that the greatest relax-
ation or movement of the rock
mass occurs immediately follow-
ing excavation. They confirm
that, after a certain period, the
rock will establish a new equilib-
rium based on its own inherent
self-supporting capacity. The best
quality rock will remain self-sup-
porting for extensive periods of
time without the need for extra
support. As the rock quality
declines, support requirements
increase proportionally. The poorer
the quality of the rock, the greater
the degree of support required, Sequence of installation of a Swellex bolt.
and it becomes increasingly crucial
to install reinforcement as quickly
and as close to the face as possible functional. The basic underlying fac- immediate and full support action
after excavation. tors are: the inherent sensitivity of from the Swellex bolts. The moment
Engineers involved in the resin to heat, age and improper stor- the Swellex bolt is expanded in the
design of rock reinforcement sys- age; parameters during installation; hole, it interacts with the rock to main-
tems must satisfy ever increasing
hole annulus; cartridge damage during tain its integrity. The quality of the
demands to optimize the design
to gain maximum safety and insertion; injection nozzle alignment; bolt installation is automatically con-
economy. The primary objective presence of cracks and flowing water; firmed when the pump stops, and is
in the design of the support and levels of operator skill and care. independent of rock mass conditions
system is to assist the rock mass This is a highly unsatisfactory result or operator experience.
to support itself. Accordingly, in terms of worksite safety, and is Controllability means safety.
quality and time are the two
main parameters which must be
equally unfavourable in terms of econ- Control brings peace of mind at every
taken into account when deter- omy. Split-set type bolts may be quick step:
mining the type of rockbolt to be to install, but their anchorage capacity 1) Swellex bolts are manufactured
used for rock reinforcement, in is too low to keep stress concentration following a very strict quality
both mining and construction at distance from the rock face. control procedure using specific
applications. By contrast, the Swellex concept steels for which origin and com-
entails that the rock is secured by position are known and controlled.

Controllability Means Safety High pressure water expands the Swellex bolt into contact with the strata.

Traditionally, the use of rockbolts has

been limited to reinforcing reasonably
solid rock. Poorly consolidated and
friable rock conditions have required
the use of expensive external support.
Independent surveys reveal that as
many as 50% of cement- and resin-
grouted rockbolts are so poorly
installed that they are virtually non-

ROCK & SOIL REINFORCEMENT 7

RR3/RT3 11/8/05 15:33 Page 8

TALKING TECHNICALLY

arch or beam. Reinforcement is unaf-

fected by the presence of water, or
joints in the rock mass.
Swellex rockbolts, and the quality
assured installation procedure, permit
rock reinforcement where expensive
external support is normally required.

Immediate Support
Modern drilling and excavation equip-
ment used in civil engineering and
mining applications has led to major
increases in efficiency and productivi-
ty. In fact, development has been so
rapid that conventional rockbolting
methods frequently act as production
bottlenecks.
Developments in the speed and
ease with which rock reinforcement
Plasticoated Swellex with cap and without cap.
can be applied to improve equipment
All the manufacturing parameters Swellex rockbolts reinforce and utilization, limit machine downtime,
are filed and linked to a number improve the condition of the interfac- and increase productivity, while simul-
on the Swellex bolt bushing for ing rock, increasing its load-bearing taneously complying with safety
traceability. capacity. requirements, is of interest to all those
2) Installation of Swellex bolts is Depending on the rock mass involved in tunnelling and mining.
controlled by sturdy Atlas Copco strength, the pressure exerted during The Swellex concept has kept pace
pumps to assure a perfect installa- installation may compact the rock sur- with these advances, with a single
tion. The new patented HC1 rounding the borehole, increasing the operator installing 50 to 100
pump, once started, will only stop friction along the bolt, and/or deform bolts/shift.
when the set pressure is reached, its profile to match the irregularities of Timing of the rock reinforcement
independently of the operator. the rock, providing a combination of measures is of particular importance in
3) Pull-tests can be performed at any strong mechanical interlocking and NATM, the New Austrian Tunnelling
time on Swellex bolts. Whether high friction. The resulting high Method. In brief, NATM can be
they were installed a year ago in a anchorage capacity makes Swellex expressed as a sequence of activities
corrosive environment, or 10 bolts an integral part of the supporting for tunnel development: drilling and
years ago in a dry area, it is possi-
ble to control their load bearing Mn24H hanger rockbolts for suspending utilities while reinforcing the rock.
and yielding capacity. Expertise
has also been developed for exam-
ining the bolts with a fibre optic
camera to control internal corro-
sion or shearing.
The Swellex concept is designed to
optimize the effectiveness of each
bolt, so the bolting operation matches
the required safety levels as planned
by the engineers. Alternatively, com-
pared to other rock support, the same
bolting effort using the Swellex
system can result in increased safety,
since each installed Swellex bolt pro-
vides full support.
Swellex rockbolts have been used
successfully to complete many tunnels
in difficult rock conditions while, at
the same time, greatly reducing sup-
port costs.

8 ROCK & SOIL REINFORCEMENT

RR3/RT3 11/8/05 15:33 Page 9
blasting; mucking and scaling; and
immediate initial rock mass support by
systematic rockbolting and shotcret-
ing.
The initial support system restricts
ground movements after excavation,
thereby maintaining the inherent
strength of the rock mass. This is the
essential idea behind NATM. The per-
manent lining is installed when the
rock has reached a state of equilibri-
um, and deformation has ceased.
Swellex rockbolts provide immedi-
ate support, as well as the ability to
accommodate large ground move-
ments at maximum load-bearing
capacity. Shear tests performed by
several international institutes have
shown that, depending on rock com-
pressive strength, Swellex bolts can
accommodate up to 90-100% of their
tensile strength under shear loading,
an exceptionally high figure. Joint
shear displacement at bolt failure can
be up to 35 mm/56 mm at a 90 degree
angle between the bolt and the surface
of the joint, showing that Swellex
bolts accommodate the same amount
of shear displacement as the diameter
of the drill hole, and even more in
softer rock.
The Right Protection
When it comes to choosing the right
product for longevity, or for use in a
corrosive environment, it is advisable
to proceed with caution. There are
many products that offer what appears
to be lifetime protection.
Unfortunately, in reality, the rock mass
properties such as water, joints, rock
movement, may be unknown, and the
quality of rockbolt installation may be
unquantifiable.
Conventional types of rockbolts
made from carbon steel are susceptible
to corrosion. As only 50-70% of resin
coated and grouted bolts are properly
installed, they do not represent a reli-
able solution against corrosion. Also,
there is extra delay and cost associated
with these bolts, compared to the
Swellex solution.
To help choose the right alternative,
Atlas Copco is using reputable corro-
sion institutes around the world to
assess the corrosion potential of
ROCK & SOIL REINFORCEMENT
Hybrid bolt for long anchorage in rock.
ground water around the rockbolt and
inflation water within the rockbolt.
It has been established that, for
medium term corrosion protection, the
bitumen coating is best. However,
plasticoated Swellex offers longterm
corrosion protection, independently of
the rock mass parameter.
If shotcrete or sealant are used, the
threat from atmospheric corrosion
diminishes. In the case of Swellex, it
will seal and protect the inside of the
bolt, leaving a reduced corrosion
potential to the external side only. If
there is no shotcrete or sealant applied
after bolt installation, caps can be used
to seal the bolt internally.
A real level of safety is achieved
with Swellex, as the corrosion is
assessed, and the bolt can be con-
trolled using pull test or internal visual
inspection over time.
Total System Approach
The cost and time involved in rock
reinforcement compels project engi-
neers to evaluate a total system
approach. The cost of the rockbolt
itself, or such properties as tensile
strength, are seldom of primary inter-
est. The decisive factors are the result-
ing safety, the total cost, and the time
required to fulfil the mission.
A productivity study comparing
Swellex to other bolts in a gold mine
TALKING TECHNICALLY
in Canada has proved that Swellex
boosted metres of advance by 10%
and reduced bolting costs by 10%. As
more bolts were installed per working
shift, fixed costs for manpower and
rigs were diluted, resulting in
increased metres of advance/shift with
improved safety. For similar reasons,
Swellex has became a standard in
most European countries and in Japan.
To summarize, when the Swellex
bolt is installed in heavily fissured
rock, the radial stresses enhance the
contact forces between blocks of rock
surrounding the bolt, leading to an
increase in rock mass strength. In
soils, Swellex bolts provide consolida-
tion immediately around the bolt,
leading to an increase in the strength
of the material, and improved anchor-
ing capacity of the rockbolt. In hard
rock, 0.5 m of anchored Swellex rock-
bolt gives a pullout resistance equal to
the breaking load of the bolt. A strong
anchorage capacity will help to dis-
tribute the stress around the excava-
tion and avoid stress concentration
close to the surface that can lead to
rock falls or strain burst.
There are Swellex rockbolts for
almost any environment and purpose.
Swellex Mn12 and Pm12 are perfect
for regular daily support in mining and
tunnelling. When high loading capaci-
ty is needed, Swellex Mn24 or Pm24
is the answer. Swellex Mn16 and
Pm16 are a cost-effective solution
when 43-52 mm drilling is preferred.
In highly corrosive conditions, or
where there are demands for long life,
Coated or Plasticoated Swellex may
be the choice. In situations where very
long bolts are required, or in confined
space, Mn24E Extendable Swellex
offers fast installation of up to 12 m-
long bolts.
Recent years have seen the devel-
opment of the Mn24H, a type of
Swellex that is part of the rock support
and is also used to hang heavy loads
without inducing unfavourable stress
in the bolt’s head bushing.
Atlas Copco is also proud of its
latest patented hybrid system of rock
reinforcement, see article in this issue.
by Mario Bureau
9
Document2 3/10/05 12:10 Page 1
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TALKING TECHNICALLY

Swellex Manganese Offers

Improved Work Index
Tough Newcomer
Atlas Copco’s Swellex rockbolts
have a long and successful his-
tory based on two simple advan-
tages for the customer: safety
and productivity. Swellex rock-
bolts are watertight, double-
folded, high-quality steel tubes,
which are expanded by a high-
pressure water pump through a
pre-drilled hole. The expansion of Wi Wi
the tube generates both contact
friction and mechanical interlock
between the steel and surround-
ing rock, giving immediate and
full-column rock reinforcement in
a simple and rapid way.
The latest range of frictional
bolts, marketed as Swellex Mang-
anese, will dramatically increase
performance, thanks to a new
steel composition and an innova-
tive heat treatment.
Figure 1. The excellent performance of the Super Swellex rockbolt is further improved by Swellex Mn24,
the corresponding bolt in the new Manganese Line.
New Tool
Atlas Copco research and develop- deformation and squeezing ground are Search For Excellence
ment has engineered a new generation all cases in which a bolt with a superi-
of Swellex bolt, which will better suit or capacity to follow the rock de- The Swellex range is based on several
the rock mechanical requirements. At formation can play an important role hole sizes. Standard Swellex is used in
the same time, it was decided to fur- in balancing and re-adjusting the strain combination with holes from 32 mm
ther increase the productivity, perfor- field towards stability. But elongation to 39 mm-diameter, while both Super
mance and reliability of Swellex without tensile strength is simply out and Midi Swellex work in the 43 mm
pumps. By these means, a quantum of the question. to 52 mm range.
leap forward in safety and perfor- Atlas Copco needed a new tool to A possible solution to increase the
mance has been achieved. measure the total performance of rock- Work Index was to increase the geo-
Loading capacity normally defines bolts, and a new parameter capable of metrical feature of the bolts.
a class of rock bolt. For example, combining capacity and elongation. Considering the Swellex position as
Standard Swellex is a 100 kN bolt, As the deformation is expressed in an established worldwide commercial
while Super Swellex is in the 190 kN percent (%) in the classical load defor- success, it did not make sense to
category. But other parameters can mation graph Atlas Copco is introduc- modify its well-accepted and fit-to-
influence the final performance of a ing the Work Index (Wi). The Work application dimensions. It was more
rockbolt, and especially its contribu- Index (Wi) as real work is defined by logical to work on material properties
tion to safety. the integral of load in function of the and production methods.
Experience in mining and tun- deformation also represented by the The steel used in Swellex is already
nelling operations has shown that area beneath the curve in Figure 1. a special type, with few impurities.
elongation is a very important parame- The Work Index (Wi) gives a truthful Well-established co-operation with a
ter in judging the performance of a picture of the total energy absorbed by leading steel supplier and with a pipe
bolt. In deep mines, strain concentra- the bolt before breaking down, or mill allowed a tailored technical speci-
tion areas, uneven load, progressive losing its function. fication to be developed for materials,

ROCK & SOIL REINFORCEMENT 11

RR3/RT4.qxd 23/6/05 9:05 Page 12
TALKING TECHNICALLY
Summary of
Swellex® user
benefits
● Swellex provides cost-
effective rock
reinforcement in most
rock types and conditions.
● Swellex installation
procedure ensures that
every bolt installed will
provide optimum
reinforcement.
● Swellex rock bolts are
quickly installed, and very
little training is required to
use the equipment.
● Swellex rock bolts provide
full column interlock with
the surrounding rock,
without the need for
mechanical locking
devices or grouting
agents.
● Swellex requires no
environmentally harmful
chemical grouts to anchor
the bolt in the rock.
● The quick and easy
installation, and the
assurance that every bolt
provides immediate full
load-bearing capacity,
makes Swellex the most
cost-effective rock
reinforcement.
12
and a series of alloys and high tensile
steels were considered. Only a limited
number of options can handle the
severe requirement of Swellex rock-
bolts with respect to radial deforma-
tion during expansion, and weldability
to assure perfect watertight contacts at
the bushings. It was decided to use a
better quality steel, with a higher man-
ganese content.
Produced in a cold forming mill,
the steel reaches a very high tensile
strength and high loading capacity,
but unsatisfactory elongation. A post-
production heat treatment is then used to
produce the extraordinary elongation
properties needed for the Swellex profile.
Improved Behaviour
Figure 1 compares typical load/
deformation curves for Super Swellex
and the new Swellex Mn24. In
particular, the regular Swellex steel
profile shows a classical behaviour for
carbon steel. Beyond the yielding
point (200 kN), the profile accepts a
large amount of deformation, but with
slightly lower strength. When a 20%
elongation is reached, the profile
breaks down.
The new, high-strength and fully
annealed Manganese Line now offers
Figure 2. After a series of experiments, a heat-
treated Manganese steel was chosen. This table
shows the results of the design efforts with
respect to tensile tests of the profile after
expansion to simulate real conditions.
a higher loading capacity and, at the
same time, enhanced elongation. Figure
1 shows that, beyond yielding point,
the manganese steel increases the load
capacity due to the hardening process.
The curve continues to point up-
wards until a 10% elongation is
achieved, then a long horizontal seg-
ment goes above the 30% level before
the profile breaks up. This extraordi-
nary behaviour gives the capacity to
absorb a substantially higher quantity
of energy, as indicated in the 80%
increase in the Work Index shown in
Figure 2.
Total Reliability
The heat treatment used during the
production of the new Swellex
Manganese Line further improves
repeatability of the performance
obtainable by the bolts. A large
number of pull tests, representative for
millions of rockbolts, show very little
variation in the results.
As a result, engineers, miners, rock-
mechanics and consultants can rely on
safe and quality controlled rockbolts,
through the entire process from manu-
facturing to installation.
by Federico Scolari
Work Index for
various types of
bolts.
ROCK & SOIL REINFORCEMENT
RR3/RT5 23/6/05 9:06 Page 13

TALKING TECHNICALLY

Manganese and Premium Lines

Continuous Mn12 Pm12

Improvement Yield Load kN (Rp02)

Min. Breaking Load kN
75
100
100
120
Atlas Copco has, over the years, Min. Elongation % 20 15
improved considerably the Working index 2000 1800
Swellex system. Rock engineers
are extremely conscious that the
behaviour and efficiency of rock Mn16 Pm16
bolts can be dictated by the prop- Yield Load kN (Rp02) 105 130
erties of the steel from which Min. Breaking Load kN 140 160
they are made. Min. Elongation % 20 15
Accordingly, rock bolts are no Working index 2800 2400
longer judged simply by their
maximum tensile strength. The
rock mass stresses surrounding Mn24 Pm24
underground excavations have Yield Load kN (Rp02) 150 200
to be tamed using energy rather Min. Breaking Load kN 200 240
than strength. Sometimes, it is Min. Elongation % 20 15
better to bend with the stress,
Working index 4000 3600
while in other instances stiffness
is preferable. It all depends on Comparison tables for Mn and Pm bolts.
the type of rock, excavation size,
geology, stress field evolution, striven over the years to develop sup- Mn Line
seismicity, corrosion and port systems using the best available
longevity required. steel for each application. Mn Line bolts are made out of high
Atlas Copco, which introduced
the Manganese Mn Line of Once the anchorage mechanism strength steel, profiled, welded and
Swellex rock bolts a couple of is understood, the best way to pre- heat-treated to survive extensive
years ago, has recently launched dict how the rock support will deformation at maximum strength for
the Premium Pm Line. interact with the rock mass is to high-energy consumption before
look at the steel load-deformation reaching failure. Furthermore, the
graph. plastic zone is characterized by a con-
Competence Centre It is preferable to assess graphs tinuous progression of the load that
from manufactured product instead of allows, when the bolt is installed in
The Rock Reinforcement Competence the virgin steel, as the manufacturing rock, a progressive debonding. As the
Centre team at Atlas Copco under- process will modify the property of diameter of the loaded section reduces
stands the requirements of different the steel and the way the support will
rock reinforcement situations, and has behave under load. Typical load/strain graphs for Pm24 and Mn24 bolts.

300
Pm24

250 Mn24

200

150
LOAD(kN)

100

50

0
0 5 10 15 20 25 30 35
STRAIN (%)

ROCK & SOIL REINFORCEMENT 13

RR3/RT5 23/6/05 9:06 Page 14

TALKING TECHNICALLY

under plastic deformation, a succes-

sion of new sections are progressively
released to work and stretch, provid-
ing extra energy absorbency and
avoiding rapid failure.
Mn Line bolts are therefore best
suited to an environment where rock
mass stress is high and unstable,
requiring good energy absorbency
capacity.
Typical applications for the Mn
Line are where deformation/stress of
the rock mass is unstable in time.
These situations occur in mining
stopes, deep mining, mining in a high
stress environment caused by poor
geology or faulting, and mining in
zones where movement is expected in
the walls or roof resulting in stress
increase with time.

Premium Line
The Pm Line is also made of high
strength steel but having different
properties than the steel used for
the Mn Line. No heat treatment is
given to the Pm bolts, resulting in a
very stiff behaviour at high load,
because the yielding strength is
very close to the maximum tensile
strength.
Pm Line bolts are used where maxi-
mum control of the rock mass conver-
gence is targeted, and a high yielding
load capacity (Rp02) and stiffness are
required, as in civil tunnelling projects.
Choice of Reinforcement Type
Checking nut and plate on Swellex Premium bolt.
Typical applications for the Pm
Line are where deformation/stress of
the rock mass is stable in time and
high stiffness is required. These situa-
tions occur in tunneling, beam consol-
idation of strata in mining, mining
where the rock mass stress and move-
ment are low or stable in time, and the
yielding load will never be reached,
and mining and tunnelling in soft rock.
Atlas Copco is continuously invest-
ing in research and development to
offer the market the best rock rein-
forcement products with safety and
productivity in mind. The right steel
for the application adds safety and
productivity!
by Mario Bureau

Conditions Properties of Preferred Reinforcement/

reinforcement Support Types

Soft Rock and low to High Stiffness Swellex Pm Line

medium stresses

Soft Rock and high Stresses Yielding and high Swellex Mn Line +
Weathered hard rock or laminated/ anchorage Connectable and Hybrid
schistose rock and high stresses

Hard Rock and low to High Stiffness Swellex Pm Line +

medium stresses Swellex Hybrid cemented

Hard Rock and high Yielding and retention Swellex Mn Line +

Stresses capacity Swellex Hybrid non-cemented
for rock burst
(seismicity & strain bursting)

14 ROCK & SOIL REINFORCEMENT

RR3/RT6.qxd 23/6/05 9:32 Page 15
Hollow-Core Self Drilling
Anchoring Systems
Support Without
Casing
The Atlas Copco MAI Self Drilling
Anchoring System is a fully
threaded steel bar which can be
drilled and grouted into loose or
collapsing soils without the use
of a casing. The bar, or SDA,
features a hollow bore for flush-
ing, or simultaneous drilling and
grouting, and has a left-hand
rope thread for connection to
standard drill tooling.
The Atlas Copco MAI SDA can
be installed in a variety of differ-
ent soils and ground conditions
ranging from sand and gravel to
inconsistent fill, boulders, rubble
and weathered rock, as well as
through footings and base slabs.
Applications associated with
underground works include:
radial anchoring for stabilization
of tunnel circumference during
NATM-style excavation; as fore-
poles, spiles or umbrella for
advance protection of the exca-
vation; as root piles for reaction
load of steel support arches; and
for slope stabilization of the
tunnel portal.
MAI SDA Functional Parts
The system elements of the Atlas
Copco MAI Self Drilling Anchor
(SDA) are as follows:
The Atlas Copco MAI bar, which is
manufactured from API standard
heavy walling steel tubing, cold rolled
to form a standard ISO rope thread
profile. The rolling process refines the
grain structure of the steel, increasing
the yield strength, and producing a
durable drill rod suitable for a range of
applications. The standard rope thread
of the Atlas Copco MAI bar produces
an excellent bond between the bar and
grout, as well as enabling connection
to all Atlas Copco Boomer and surface
drill rigs, and use with a wide range of
drill steel accessories.
ROCK & SOIL REINFORCEMENT
TALKING TECHNICALLY
The MAI bar is produced in 12 m
lengths and then cut to size depending
on customer requirements. Standard
delivery lengths are 1 m, 2 m, 3 m,
4 m and 6 m. Recommended maximum
bar lengths depend on diameter and can
be up to 6.0 m. Additional lengths up
to 12.0 m are available on request.
The Atlas Copco MAI coupler, which
features a patented design that enables
direct end-to-end bearing between each
bar, reducing energy loss and ensuring
maximum percussive energy at the drill
bit. The coupler design has a thread
arrangement in which the top half of
the thread is rotated against that of the
lower half, providing a centre stop for
each bar. All couplers exceed the ulti-
mate strength of the bar by 20%.
To enable the correct seating of
each bar within the coupler, all bars
have a precision cut at right angles to
enable end to end bearing. A quarter
turn back of the coupler on the lower
bar will ensure optimum seating of the
upper bar within the coupler.
The Atlas Copco MAI hexagonal
nut, which is machined with chamfered
edges on both ends from high precision
steel, and tempered to meet any strin-
gent demands of the anchor specifica-
tions and the daily operations of
underground works. All nuts exceed
the ultimate strength of the bar by 20%.
The Atlas Copco MAI bearing
plate, which is a formed steel plate
with a centre hole, allowing articula-
tion of seven degrees in all directions.
All functional parts are constantly
tested, in line with the company’s rig-
orous quality assurance policy.
The sacrificial Atlas Copco MAI
drill bit is the most crucial part of the
anchor system, and is responsible for
the productivity of the installation.
Atlas Copco MAI maintains a large
range of drill bits to suit the changing
demands of geology encountered on
MAI SDA arrangement, showing threaded bar,
different projects. In order to improve
coupler, nut, plate and bit.
on performance and cost efficiency,
15
RR3/RT6.qxd 23/6/05 9:33 Page 16
TALKING TECHNICALLY
Installation sequence of MAI SDA.
data is collected from projects around
the world, and incorporated into the
design with the aim to improve pene-
tration rate and bit quality, and to
reduce manufacturing costs.
Overall Advantages of MAI
SDA
Advantages of the Atlas Copco MAI
SDA system are that it is particularly
suitable for very difficult and unstable
ground conditions, such as broken,
fissured and fractured rock formations,
or unconsolidated sands and gravels.
Re-drilling time due to collapsing
boreholes is avoided, and speed of
installation is high, with no primary
drilling required. The drilling, placing
and grouting of the anchor is per-
formed in one single operation,
reducing the drill labour compared to
cased boreholes.
Since conventional rotary-percus-
sion drilling equipment is used, the
method of installation is very similar
for all ground conditions, and the bolts
can be installed in all directions,
including upwards.
There is an option to use simultane-
ous drilling and grouting techniques
during installation, to consolidate any
surrounding loose ground.
The anchor bar consists of a full
length left hand rope thread, which
gives the flexibility to adjust the bar
length to the actual requirement. This
is especially useful if anchoring has to
be performed in a confined workspace.
Method of Installation
Self Drilling Anchors are installed
with air driven or hydraulic rotary per-
cussion drilling equipment, using a
16
borehole flush medium suitable for the
specific ground conditions.
There are three types of borehole
MAI PUMP
flush: 1) water flush for long bore- The One
holes in dense sand, gravel formation
or rock conditions, for a better trans- and Only
portation of large cuttings and cooling
of the drill bit; 2) air flush for short
boreholes in soft soil, such as chalk
and clay, where water spillage is to be
avoided; 3) simultaneous drilling and
grouting (SDG), for all lengths of
boreholes in all unconsolidated soil
conditions.
Using SDG, the grout stabilizes the
borehole during installation, providing
a better grout cover along the nail
shaft. The grout has good penetration
into the surrounding soil, so higher
external friction values are reached,
and the installation is completed in a
single drilling operation, saving time.
By utilizing a sacrificial drill bit,
the MAI SDA is drilled continuously
forward without extraction, until the
design depth is reached. To reach a
required nail length of 12-15 m, the 3
to 4 m standard rod lengths are easily
coupled together.
When using the first two flushing
media for the drilling operation, the
soil/steel interface has to be created by
grouting through the hollow stem of
the anchor rockbolt. The grout exits
through the flush holes of the drill bit,
and backfills the annulus around the
anchor that has been cut by the larger
diameter of the drill bit.
For simultaneous operation, the
flushing medium is already a grout mix,
which has the ability to harden after the
installation process is completed.
by Mark Bernthaler
ROCK & SOIL REINFORCEMENT
RR3/RT7 23/6/05 9:34 Page 17

TALKING TECHNICALLY

Atlas Copco MAI Self Drilling

Anchors
Productivity and
Problem Solving
The Atlas Copco MAI SDA is a
unique bolting solution for un-
stable ground conditions such as
sand, gravel, silt, and clays, and
in soft to medium fractured rock
formations.
When discussing productivity,
only projects facing such ground
conditions should be considered.
Conventional rockbolts, or soil
nails, generally have the dis-
advantage that, when being
installed in poor ground condi-
tions, unproductive time is spent
on measures such as: retrieving
expensive drill tools from col-
lapsed boreholes; repositioning
the drill feed to clean collapsed
boreholes; introducing the grout
hose to the borehole bottom, and
grouting the borehole; and
inserting the nail or rockbolt with
Integrated Rotary Injection Adapter (Ceminject) mounted on a Boomer.
the assistance of the feed system
of the drilling unit.
The Atlas Copco MAI SDA COP hammer and the anchor bar. borehole and optimum filling of the
system is designed to avoid most Drilling is carried out using water or annulus; improved protection against
such time losses. With an opti- air flushing, but, upon reaching the corrosion; and consolidation of gravel,
mized installation method, tail- planned borehole depth, a suitable fissures, fractures or voids surround-
ored to the project’s needs, the
ultimate aim should be to limit cement mix is immediately injected. ing the borehole.
the installation time to the actual By slow rotation while applying
drilling time of the borehole. backwards and forwards movement Time Saving
of the SDA, the grout is pushed under
pressure from the bottom of the bore- Atlas Copco envisages full mecha-
Atlas Copco MAI SDA hole towards the borehole mouth. It nization of the Atlas Copco MAI
Techniques mixes in the borehole to provide opti- SDA to reduce the installation time
mum backfilling of the borehole and increase its productivity. The
Post installation grouting annulus contact to the soil. The company is also interested in resolv-
A number of Atlas Copco MAI SDA advantage of this system is the reduc- ing particular site problems, and in
bolts are installed in one phase to limit tion of cement consumption in hori- advancing tunnel technology for typi-
the working time of the drilling equip- zontal boreholes. cal applications of Self Drilling
ment and make it available for other Anchors. These are, in particular:
drilling operations within the excava- Simultaneous drilling and grouting radial nailing of the tunnel circumfer-
tion cycle. The grouting is performed Similar to the successive grouting ence; forepoling for cylindrical tunnel
as an independent operation from a method, this system also requires the advance, using lengths of approxi-
separate support vehicle. use of a Integrated Rotary Injection mately 4 m with 1 m overlap and face
Adapter (Ceminject). However, stabilization using lengths up to 15 m,
Installation and successive grouting instead of drilling with air or water and root piles.
In order to utilize this system, an flush, a suitable grout mix is intro- Worldwide, underground projects
Integrated Rotary Injection Adapter duced. The following advantages are are designed with geological expecta-
(Ceminject) is mounted between the achieved: stabilization of the tions based on information received

ROCK & SOIL REINFORCEMENT 17

RR3/RT7 23/6/05 9:34 Page 18
TALKING TECHNICALLY
Time savings by using MAI SDA System.
from rather limited soil investigations.
Furthermore, today’s need to satisfy
the design requirements for infrastruc-
ture projects mostly doesn’t allow a
route selection that follows only good
rock conditions. This increasingly
demands flexibility by the contractor,
who may be forced to adjust at short
notice to unpredicted changes in geo-
logical conditions.
Construction sites today have the
option to cater for every eventuality,
and to maintain tools at site for every
type of ground condition. Prior plan-
ning by the site management to main-
tain sufficient quantities of Atlas
Copco MAI SDA available for use can
Delivery lengths of Atlas Copco MAI SDA.
18
allow an immediate intervention,
reducing time wastage and increasing
productivity.
The design of the Atlas Copco MAI
SDA also favours productivity in
terms of storage and handling.
Anchor bars with a continuous left
hand thread are delivered to site in
standard lengths of 2 m, 3 m, 4 m and
6 m, and can be assembled to the spe-
cific lengths required. Transport to
site, and onward to the working area,
is simplified, due to the short lengths
of the anchor elements and their
accessories.
by Mark Bernthaler
ROCK & SOIL REINFORCEMENT
RR3/RT8 23/6/05 9:53 Page 19
Larger and Deeper Holes With
Symmetrix
New World of
Construction
When Atlas Copco acquired the
Rotex company of Finland in
2004, it represented a major step
forward for contractors in the
field of overburden drilling and
related technologies. In addition
to its well-proven ODEX equip-
ment, Atlas Copco is now able to
offer Symmetrix, a unique
system that enables drillers to
drill deeper and larger holes than
ever before.
More Applications
The ODEX method of overburden
drilling with an eccentric bit is well
established amongst drillers, particu-
larly when it comes to shallow, small
dimension holes. Now, with the intro-
duction of the Symmetrix system,
Atlas Copco has opened the door to an
infinite number of applications where
casing drilling is the preferred solution
for forepoling, micropiling and other
types of ground engineering work.
Symmetrix enables drillers to go
larger and deeper than ever before.
Whereas the ODEX method is ideal
for drilling holes up to 273 mm in
diameter, Symmetrix handles the
installation of casings up to 1.2 m in
diameter, in holes of 100 m-deep (300 ft)
and beyond.
This unique capability gives con-
tractors the power to tackle any type
of casing advancing work, from
micropiling, tunnel forepoling, and
foundation piling, to opening ‘rat-
holes’ for oil and gas wells, as well as
horizontal casing drilling.
In addition, the Symmetrix
system is a perfect complement to
Atlas Copco’s extensive range of
DTH (Down-The-Hole) equipment.
The Secoroc DTH hammers for
ROCK & SOIL REINFORCEMENT
overburden drilling, the specially-
designed Mustang rigs for anchor
drilling and micropiling, and the
DTH products provided by Atlas
Copco Drilling Solutions in the
US, provide sufficient combina-
tions to meet most overburden
challenges.
Case for Casings
There is no doubt that the use of
drilled casings in underground con-
struction is becoming increasingly
popular worldwide, primarily due to
the expansion of building and infra-
structure growth in areas that are less
than ideal for such development.
Pile driving in dense urban condi-
tions can disturb surrounding structures
or utilities, and is often difficult to
estimate in terms of costs. This is
compounded by other problems, such
as ground settlement, soil compaction
and lateral soil displacement.
When using a drill casing, soil, rock
and other debris are removed within a
protective steel tube and brought to
the surface. For foundations, during
TALKING TECHNICALLY
Symmetrix RC system used in Turku, Finland.
the concreting process the support is
transferred from the temporary drill
casing, which is gradually withdrawn,
to the concrete that forms the pile
shaft. Likewise, the casing may be left
in place as additional structural sup-
port, or for protection of the pile. For
exploration and well drilling, the
casing can become the conduit for
bringing the debris to the surface.
For these reasons, designers and
owners turn to drilled casings, and DTH
drilling with Symmetrix is often the only
method that can drill through all ground
conditions, boulders and solid rock.
Symmetrix in Sensitive
Conditions
The Marina Palace Hotel, a large hotel
and congress center located in the old
city of Turku on the south western
coast of Finland, is going through a
main renovation scheme.
Part of the project is to enlarge the
parking capacity by building an under-
ground parking lot. Ground conditions
19
RR3/RT8 23/6/05 9:53 Page 20

TALKING TECHNICALLY

ROTARY MOTOR

Principle of the Symmetrix system

1) The casing tube is drilled to the

required depth.
COMPRESSOR

2) The pilot bit is withdrawn from the

CUTTINGS casing.

CASING PIPE 3) The casing is left in the hole as a

OVERBURDEN support for the pile.

DUAL WALL
DRILL PIPE

INTERCHANGE

CASING SHOE
SYMMETRIX BIT
in Turku are problematic, with
mainly post glacier clays at surface
overlaying sand layers containing
high water pressure. This is followed
by till containing very hard boulders
typically sitting on steeply inclined
non-weathered hard granite or dia-
base.
Completing a deep pile at Marina Palace Hotel,
Turku.
1 2
The old town is built mainly on
wooden driven piles. These are being
replaced by steel casings drilled all the
way to bedrock, for which several
underpinning projects are underway on
the northern banks of the Aura river.
In the Marina Palace Hotel parking
garage project, clay and till layers
reach 35 m-deep in the northern
corner of the site, and the till is 65 m-
3
deep on the southern riverside. For the
garage foundation, steel casings are
being drilled 1 m or 2 m into the solid
bed rock, which means that longest
casings are 67-68 m-long. Drilling
work is being carried out by Skanska
and their subcontractor, Sotkamon
Porakaivo. Casing sizes are from 140
mm to 508 mm, all of which are thick
walled to form load bearing members.
Most of these casings are in sensi-
tive conditions very close to existing
buildings and their foundations, so a
unique drilling system is required.
Atlas Copco Rotex has developed
reverse flushing drill bits in order to
control the air flushing in sensitive
conditions. Symmetrix RC is designed
to give the straightness the consulting
engineers require, control of flushing
media needed under existing founda-
tions, and high productivity in virtual-
ly any ground condition.
The Symmetrix RC system specified
by the supervising design engineering
company for the Marina Palace Hotel
job is being used on all four drillrigs.
Hard, rubber-like clays are normally
expected to be problematic, but sub-
contractor Sotkamon Porakaivo reports

20 ROCK & SOIL REINFORCEMENT

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TALKING TECHNICALLY

the locking mechanism and flushing

holes. The system consists of three
main components working together as
a single unit – a pilot bit with large
internal flushing holes and external
flushing grooves, a symmetrical ring
bit (reamer) with internal bayonet cou-
pling, and a casing shoe for driving the
casing.
The pilot bit is attached to the ring
bit with a bayonet coupling. Together
they rotate clockwise and cut a hole suf-
ficiently large to allow the casing shoe
to pull down the casing pipe. The ring
bit rotates freely on the casing shoe,
which is welded to the casing. During
drilling, the casing does not rotate.
Casings can be added to the string as
required. The flushing air is ejected
through the holes in the face of the pilot
bit, and returns immediately up wide
grooves between the pilot bit and ring
bit and the annulus between the casing
and the drill string. This ensures high
flushing velocity with low hole degrada-
tion.
When the hole is complete, the
pilot bit is unlocked from the ring bit
with a slight counter-clockwise
motion, and withdrawn up through the
casing. The casing can then be either
left in place or retrieved from the hole.

Future Development
The technology of casing drilling is
constantly developing, and the
demand is increasing fast in many dif-
ferent applications.
Drilling close to existing structures.
One of the biggest growth areas is
in drilling in urban environments,
that Symmetrix RC has made drilling Symmetrix Secret where it is no longer possible to open
very easy and productive, with casings up the streets for further drilling work
going in very straight and fast all the So what makes the Symmetrix casing without disturbing vital installations.
way through clays, sands, boulders, advancing method so unique? Basically, Here, Symmetrix will have a major
till, and even into very hard bedrock. the secret lies in the patented design of role to play.
Large city subways are typical
What it means for the contractor cases where tunnel roofs have to be
Symmetrix systems come in a large number of versions and sizes to suit a wide pipe-drilled in order to connect one
range of applications. These include: piling; forepiling and micropiling using underpass to another. With Symmetrix
both temporary and permanent casing; underpinning with grouted columns; well on board, Atlas Copco is able to pro-
drilling; and horizontal casing drilling. For the overburden drilling contractor vide customers with state-of-the-art
this means: straight holes without risk of deviation; quick setup and high pro- casing drilling technology that can
duction rates; less torque required in all formations; easy to lock and relock; meet these challenges, and many more
convenient drilling at any angle; no jamming and lost bits; can be used in all besides.
ground conditions and at any angle down to 100 m (300 ft) and beyond; and
by Jukka Ahonen
significant economic savings.
Product Manager, Atlas Copco Rotex

ROCK & SOIL REINFORCEMENT 21

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Sacrificial Drillbits

22 ROCK & SOIL REINFORCEMENT

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ROCK & SOIL REINFORCEMENT 23

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TALKING TECHNICALLY

Mechanized Bolting and

Screening
Utilization is the
Key
For civil engineering applications
such as tunnelling, it is quite
common to use the same equip-
ment for all drilling requirements.
These days, a single drillrig can
accommodate drilling for face
blasting, bolt holes, protection
umbrellas, and drainage. As there
are normally only one or two
faces available for work before
blasting and mucking, it is diffi-
cult to obtain high utilization for
specialized equipment such as
mechanized bolting rigs.
By contrast, in underground
mining, especially where a
number of working areas are
accessible
using methods such as room and
pillar, high utilization of special-
ized equipment can be expected.
Specializing for Safety
There was a time when underground
mining and safety were terms not com-
monly referred to in the same sentence.
However, times have changed, and
today safety is given a place of promi-
nence in the operational priorities of
the mining industry.
Freshly blasted openings leave con-
siderable areas of loose rock, which
must be removed to prevent fall-of-
ground injuries. Improvements in
drilling and blasting techniques have
helped to significantly reduce the
amount of this loose rock. Scaling,
which is the most hazardous part of the
work cycle, is used to remove the visi-
ble loose rock.
Subsequent blasting might result in
additional rock falls, especially in frac-
tured ground conditions. Screening or
shotcreting, as a means of retention of
this loose rock, is often used in combi-
nation with rockbolting. Screening,
which is a time-consuming operation,
Mechanized bolting underway using Boltec.
is common practice in Canada and
Australia.
Since the 1960s and 1970s, consid-
erable effort has been spent on mecha-
nizing underground operational
activities, including the rock excava-
tion cycle. Within the drill-blast-muck
cycle repeated for each round, the
drilling phase has become fully mecha-
nized, with the advent of high produc-
tivity hydraulic drill jumbos.
Similarly, blasting has become an
efficient process, thanks to the devel-
opment of bulk charging trucks and
easily configured detonation systems.
After only a short delay to provide for
adequate removal of dust and smoke
by high capacity ventilation systems,
the modern LHD rapidly cleans out the
muck pile.
These phases of the work cycle
have been successfully mechanized,
and modern equipment provides a safe
operator environment.
By contrast, the most hazardous oper-
ations, such as scaling, bolting and
screening, have only enjoyed limited
progress in terms of productivity
improvements and degree of mechaniza-
tion. The development of mechanized
scaling and bolting rigs has been
slower, mainly due to variations in
safety rules and works procedure in
specific rock conditions.
To summarize, equipment manufac-
turers have had difficulty in providing
globally accepted solutions.
Nevertheless, there is equipment avail-
able to meet most of the current
demands from miners and tunnellers.
However, there is a perception that
equipment for full mechanization of
rockbolting is expensive, and a large-
scale consumer of parts and compo-
nents.
Mechanization Stages
Various methods of mechanized bolting
are available, and these can be listed
under the following three headings.
manual drilling and bolting
This method employs light hand held
rock drills, scaling bars and bolt instal-
lation equipment, and was in wide-
spread use until the advent of hydraulic
drilling in the 1970s. Manual methods
are still used in small drifts and tunnels,
where drilling is performed with hand-
held pneumatic rock drills. The bolt holes
are drilled with the same equipment, or
with stopers. Bolts, with or without grout-
ing, are installed manually with impact

24 ROCK & SOIL REINFORCEMENT

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New generation Boltec LC rig installing screen.
wrenches. To facilitate access to high
roofs, service trucks or cars, with elevat-
ed platforms, are commonly used.
semi-mechanized drilling and
bolting
The drilling is mechanized, using a
hydraulic drill jumbo, followed by
manual installation of the bolts by
operators working from a platform
mounted on the drill rig, or on a sepa-
rate vehicle. The man-basket, as a
working platform, limits both the prac-
tical working space and the retreat
capability in the event of falling rock.
In larger tunnels, the bolt holes are
drilled with the face drilling jumbo.
fully mechanized work cycle
A special truck, equipped with boom
mounted hydraulic breakers, performs
the hazardous scaling job, with the
ROCK & SOIL REINFORCEMENT
operator remotely located, away from
rock falls. Blast holes are drilled in the
face using a drill jumbo, and all func-
tions in the rock support process are per-
formed at a safe distance from the rock
to be supported. The operator controls
everything from a platform or cabin,
usually equipped with a protective roof.
Where installation of steel mesh is
undertaken, some manual jobs may
still be required. Mesh is tricky to
handle, because of its shape and
weight, and this has hampered devel-
opment of fully automated erection.
Quality of Bolting
In 1992, it was reported that indepen-
dent studies were indicating that as
many as 20-40 % of cement and resin
grouted bolts in current use were
TALKING TECHNICALLY
non-functional. Tunnellers were
reporting that they were not installing
bolts close to the working face,
because they might fall out when blast-
ing the round. Obviously, a large pro-
portion of rockbolts were being
installed for psychological reasons,
rather than for good face support and a
safe working environment.
However, by using a mechanized
installation procedure, the quality of
installation improves. The bolt can be
installed directly after the hole has
been drilled; the grout can be measured
and adjusted to the hole size; and bolt
installation can be automated, which is
especially important when using resin
cartridges, where time and mixing
speed are crucial.
It can be proved that mechanization
and automation of the rockbolting
process offers improved quality and
safety.
While mining companies and equip-
ment manufacturers, especially in
Canada, focused their development on
improving semi-mechanized roof sup-
port, evolution in Europe concentrated
on fully automated bolting.
During the 1990s, progress acceler-
ated, and today, around 15 % of all
bolting in underground mines world-
wide is carried out by fully mecha-
nized bolting rigs.
However, compared to mechaniza-
tion of face drilling and production
drilling, this level of acceptance is far
from impressive, and the industry has
been slow to accept the principle. The
more obvious positive safety aspects of
mechanized rockbolting have been
sidelined by considerations relating to
the scale of operations and the type of
equipment available. Hence the higher
acceptance in mining, where several
faces are operated simultaneously. For
tunnelling applications, where the rate
of advance is of prime importance, the
economic criteria might be different.
Also, as there are more functions
incorporated into the average rock-
bolter when compared to a drill jumbo,
maintenance takes longer, and more
parts and components have to be
replaced. Bolting units are exposed to
falling rock, or cement from grouting,
both of which impact upon mainte-
nance costs.
25
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TALKING TECHNICALLY

Significant Improvements
When Atlas Copco introduced its new
series of mechanized rock bolting units
in late 2001, a wide range of radical
improvements was incorporated.
Based on the unique single feed
system with cradle indexing, the new
mechanized bolting unit, MBU, is con-
siderably more robust, and less sensi-
tive to falling rock, than its
predecessor. Holes are easy to relocate,
and the stinger cylinder improves col-
laring and the ability to install bolts
under uneven, rugged roof conditions.
Major re-engineering has resulted in
30% fewer parts. Less maintenance
and stock inventory are required, and
high availability has been recorded.
Furthermore, the chain feeds used in
the new Boltec series feature an auto-
matic tensioning device, which guaran-
tees even and strong feed force for the
rock drill, while a stinger cylinder
improves collaring and the ability to
work under uneven roof conditions.
The completely redesigned drill
steel support provides sufficient space
for bolt plates passing through, and
facilitates extension drilling.
The most outstanding benefit, how-
ever, is the computer-based rig control
system, RCS. This system, which has
already been successfully incorporated
on the latest Boomer and Simba series
of drillrigs, offers simplified fault detec-
tion, operator interactivity, and the basis
for logging, storing and transferring of
bolt installation production and quality
data.
The Boltec is equipped with the
new rock drill, the COP 1532, which is
short and compact, and features a
modern double dampening system
which, combined with the RCS, trans-
mits maximum power through the drill
string. The long and slender shaped
piston, which is matched to the drill
steel, permits high impact energy and
long service life of all drilling consum-
ables.
Versatility and Ergonomics
Modern bolting rigs can handle instal-
lation of most types of rockbolts, such
as Swellex, as well as resin and
cement grouted rebars. Using the new
Boltec MC equipped with screen handling arm.
Boltec series based on RCS, the opera-
tor copes easily with the more
demanding cement grouting and resin
cartridge shooting applications, by
controlling all functions from the
cabin seat. Up to 80 cartridges can be
injected before the magazine needs
refilling. Also, because meshing is
often carried out in combination with
bolting, an optional screen arm can be
fitted parallel to the bolt installation
arm, to pick up and install the bulky
mesh screens. Up to 10 different pre-
programmed cement-water ratios, and
various additives, can be remotely
controlled.
The new generation rigs offer the
operator a modern working environ-
ment in a safe position. Low posi-
tioned, powerful lights provide
outstanding visibility of the entire
drilling and bolting cycle.
The new Boltec family has two
members: the Boltec MC, for bolt
lengths of 1.5-3.5 m and roof heights
up to 8 m; and the larger Boltec LC for
bolt lengths of 1.5-6.0 m, primarily for
large tunnelling projects having roof
heights of up to 11 m.
The initial positive response from
operators and mechanics confirms that
the new generation of Boltec will pave
the way for further acceptance of
mechanized bolting.
Screen Installation
In Canadian mines the combination of
rockbolts and screen, or wire mesh, is
commonly used for rock support. Since
rock reinforcement is potentially one of
the most dangerous operations in the
work cycle, mechanized rockbolting
has become more popular. A computer-
ized Boltec MC, equipped with screen
handling arm, has been in use for a
couple of years at Creighton Mine,
installing screen with split-set bolts.
In general, the screen is 3.3 m-long
x 1.5 m-wide, and is installed in both
roof and walls, down to floor level.
Typical spacing of bolts is 2.5 ft. Three
different types of bolts are used,
depending on rock conditions, and all
bolting must be done through the
screen, with the exception of pre-bolt-
ing at the face. In general, galvanized
split-set are used for wall bolting,
while resin grouted rebar or mechani-
cal bolts are used in the roof, and
Swellex in sandfill.
Once the screen handling arm has
picked up a screen section and fixed it
in the correct position, the powerful
COP 1432 hydraulic rock drill quickly
completes the 35 mm diameter, 6 ft and
8 ft holes. The bolting unit remains
firmly fixed in position after the hole is
drilled, and the cradles are indexed,

26 ROCK & SOIL REINFORCEMENT

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moving the bolt, with plate, into posi-
tion. The bolt feed, combined with the
impact power from a COP 1025
hammer, is used for installing split-set
bolts. The complete rock reinforcement
job is finished in just a few minutes.
Boltec MC Flexibility
The Boltec MC delivered to the
Creighton mine is capable of handling
several types of bolts: split-set, mechan-
ical-anchors, resin grouted rebar and
Swellex. The switch of accessories
between different bolt types takes 5-10
minutes. To minimize water demand
during drilling, water-mist flushing is
used. The Boltec MC can also be
equipped with a portable operator’s
panel connected by a 50 m-long cable.
Cartridge shooting is remote con-
trolled for the Boltec MC, and up to 80
cartridges can be injected before refill-
ing is needed. A unique feature is the
possibility to use two different types of
cartridges, with fast or slower curing
times, housed separately in the dual
cartridge magazine. The operator can
select how many cartridges of each
type to inject into any hole. For
instance, he can inject two fast curing
cartridges for the bottom of the hole,
and follow up with slower-curing car-
tridges for the rest of the hole, all with-
out leaving his operator’s panel!
Cabletec L for Cable
Bolting
Atlas Copco has developed a fully
mechanized rig for drilling and cable
bolting by a single operator. The first
unit is in operation at Outokumpu’s
Kemi chromite mine in northern
Finland, and a second unit has gone to
Chile. The Cabletec L is based on the
long hole production drilling rig Simba
M7, with a second boom for grouting
and cable insertion.
The booms have an exceptionally
long reach and can drill a line of up to
4.7 m of parallel holes from the same rig
setup. Likewise, the booms can reach up
to 7.8 m roof height, allowing the
Cabletec L to install up to 20 m-long
cable bolt holes in underground mining
applications such as cut and fill mining
and sub level stoping. Furthermore, the
ROCK & SOIL REINFORCEMENT
Cabletec
Stoping sequence at Kemi underground mine. Cabletec drilling upwards, and Simba drilling downwards.
drill unit can rotate 360 degrees and tilt
10 and 90 degrees, backwards and for-
wards respectively. The new rig is
designed on proven components and
technology featuring two booms - one
for drilling and the other for grouting
and cable insertion. It also features an
on-board automatic cement system with
WCR (Water Cement Ratio) control. All
these features facilitate a true single
operator control of the entire drilling and
bolting process. The two boom concept
has drastically reduced the entire drilling
and bolting cycle time and, by separat-
ing the drilling and bolting functions, the
risk of cement entering the rock drill is
eliminated. The operator is able to pay
full attention to grouting and cable inser-
tion, while drilling of the next hole after
collaring is performed automatically,
including pulling the rods out of the
hole.
Cabletec is equipped with the well
proven COP 1838 ME hydraulic rock
drill using reduced impact pressure
with R32 drill string system for 51 mm
hole diameter or R35 for 54 mm holes.
Alternatively, the COP 1638 rock drill
can be used. Maximum hole length is
Cabletec main technical
data
Length: 13.9 m
Width: 2.7 m
Height: 3.3 m
Turning radius: 4.3m / 7.5 m
TALKING TECHNICALLY
Simba
32 m. The cable cassette has a capacity
of 1,700 kg and is readily refilled
thanks to the fold-out cassette arm. The
cement mixing system is automated,
comprising a cement silo containing
1,200 kg of dry cement. The cement is
mixed according to a pre-programmed
formula, resulting in a unique quality
assurance of the grouting process. The
cement silo capacity is adaptable for up
to 20 m-long, 51 mm-diameter holes.
To date, most holes have been
drilled in the 6-11 m range, for which
the rig has grouted and installed cable
at a rate of more than 40 m/h.
Depending on type of geology and hole
diameter chosen, the drilling capacity
can vary between 30 and 60 m/h.
Conclusion
Rock support, including scaling, bolt-
ing, screening, and cablebolting, is still
the bottleneck in the working cycle in
underground mining and tunneling
applications. Clearly, any reduction in
the time required to install the neces-
sary support has a direct impact on the
overall cycle time, and consequently
the overall productivity and efficiency
of the operations. The fully mecha-
nized bolting rig of today, incorporat-
ing all of the benefits of modern
computer technology, constitutes a
major leap towards improved produc-
tivity, safety and operator environment.
by Hans Fernberg
27
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TALKING TECHNICALLY

Using Rocket Boomers to Install

Rockbolts
Adaptability for
Drilling and
Installation
When a contractor undertakes an
underground drill/blast excava-
tion project, it is of utmost
importance to have the most
suitable equipment available,
both for blast hole drilling, and
for rockbolt drilling and installa-
tion. For most situations, the
Atlas Copco Rocket Boomer is
the best possible unit to choose.
This is true, not only for its
drilling capacity, but also for its
adaptability to semi-mechanized
installation of some of the most Atlas Copco Rocket Boomer, with its very capable BUT booms, is suitable for all kinds of rock
frequently used rock bolt sys- reinforcement.
tems, such as Swellex rock bolts
and MAI Self Drilling Anchors with Swellex chuck, or, for mecha- keep the feed at the drill hole, and
(SDA). This affords the contractor nized insertion, the new Swellex recover the drill steel by the RAS grip-
the option of using a single drill- chuck mounted on the COP hammer. pers; attach the Swellex chuck to the
rig to cover all face drilling and
rockbolt installation operations. For mechanized handling of the drill COP hammer; manually locate the
On some contracts, this can steel, a Rod Adding System (RAS) Swellex bolt with faceplate in the drill
make the difference between can be mounted on the feed. For semi- steel support at the top; insert the
profit and loss. On bids, it can mechanized installation, the following Swellex bolt into its final position in
provide the margin for the con- cycle of operations can be used: select
tractor that swings the award.
a drill steel length that is slightly The new Atlas Copco Swellex Pm24C
longer than the length of the bolt to be and Mn24C features improved work
Swellex Rockbolts installed; drill the bolt hole at the absorption capacity by way of elongation
chosen spot, and to the full length; and load taking.
Regardless of manufacturing origin,
installation of rockbolts of lengths of 4
m and upwards is normally a heavy
and troublesome operation. The
Swellex Pm24 or Mn24 rockbolt is no
exception. However, by adding a few
optional items, a standard Atlas Copco
Rocket Boomer can be modified to
take care of most of this work. It will
insert the Swellex Pm24 or Mn24 into
the hole, fully inflate it to optimal
capacity, and even test it! Not only is
it quick and easy, but also safer than
the traditional manual method. Top of
the list of optional components is a
service platform to assist with the high
level holes. An onboard Swellex
hydraulic pump is advisable, and, for
manual insertion, a Swellex handle

28 ROCK & SOIL REINFORCEMENT

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TALKING TECHNICALLY

using the feed and the COP rock drill;

1. The first SPEEDROD
is drilled into the rock.
2. The gripers lift the second
1 rod into place and drilling
continuous.
3. When the hole is finished,
the RAS system uncouples
and removes the rod.
2 full 24 t load.
grip the bottom of the string with the
BSH 110, and attach the bottom end
section of the connectable Swellex,
with faceplate; feed it into place using
the rock drill and Swellex chuck; con-
nect the Swellex pump, and inflate the
bolt. It will take a few seconds to fully
expand the complete bolt. When the
pump stops, the bolt is ready to take its

Swellex Hybrid
The Swellex® Hybrid consists of a
3
Swellex bolt coupled with one or more
MAI Self Drilling Anchors (MAI
Mechanized Road adding RAS. SDA®). A special connection cou-
pling welded on to the Swellex bolt,
the drill hole, using the feed-force drill rods. Recommended drill hole enables it to be inflated and the SDA
from the hammer; and inflate the diameter is 45-48 mm, with maximum portion to be grouted. After inflating
Swellex bolt using the on-board 51 mm, using R28 drifter rods with a the Swellex bolt, the rock mass
hydraulic Swellex pump. All done, coupling diameter of 44 mm. The between the face plate and the Swellex
and ready for the next bolt! installation sequence is as follows: is pre-tensioned to the desired value.
drill the bolt hole a little bit longer than The rock mass is then exposed to con-
Connectable Swellex the full bolt length; recover the drill finement pressure and the hole annu-
string, and remove it from the feed; lus grouted through the centre hole of
When there is a need for very long place the top-section of the Swellex the SDA. In this way, the pre-ten-
bolts to be installed in a narrow drift, Pm 24C or Mn 24C into the drill steel sioned support element is grouted for
tunnel or cavern, the solution can be support, and feed the bolt section into full protection and long lasting
the Swellex Pm or Mn 24C con- the drill hole, either manually, or using anchorage.
nectable rock bolt. This system com- the COP rock drill; grip the bolt with
prises three different types of bolt the BSH 110, or the retainer; thread in Installation sequence of the new Atlas Copco
section that can be combined to practi- the required number of middle sections Swellex Hybrid.
cally any required length. Each of
these three sections is characterized by
its function. The first section is sealed
at its top end and threaded at its bottom
end. The middle sections are threaded
at both ends, and the bottom section is
threaded at one end and designed to fit
into the Swellex chuck at the other.
The sections are threaded together to
form a tight connection. Installing
Swellex Pm or Mn 24C utilizes the
same optional components as for the
installation of long Swellex bolts, with
the addition of either the BSH 110
Swellex version, or by using a Swellex
retainer to keep the connectable
Swellex in place when tying in
Swellex sections. The RAS system can
greatly assist handling of the Swellex
Pm 24C or Mn 24C sections, using its
two gripper arms attached to the BMH
feed, which are remotely controlled by
the Boomer operator. The bolt hole is
drilled to full depth using extension

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TALKING TECHNICALLY

Swellex® Hybrid rock bolts are

recommended for rock support in tun-
nelling, civil engineering and mining
applications where active (pre-ten-
sioned) support is required to preserve
rock mass structure, and grouting is
needed for long life expectancy. The
system is ideal in weak ground and
around structural discontinuities. It is Composition of the Atlas Copco Self Drilling Anchor (SDA).
also recommended as a problem solver
for long anchorage requirements.

Swellex Hybrid
The Swellex ®Hybrid consists of a
Swellex bolt coupled with one or more
MAI Self Drilling Anchors (MAI
SDA ®). A special connection cou-
pling located between Swellex and
SDA enables the Swellex bolt to be
inflated and the SDA portion to be
grouted.After inflating the Swellex
bolt,the rock mass between the face
plate and the Swellex is pre-tensioned
to the desired value.The rock mass is
then exposed to confinement pressure
and the hole annulus grouted through
the centre hole of the SDA. In this way,
the pre-tensioned support element is
grouted for full protection and long
lasting anchorage.
Swellex Hanger
Swellex® Pm 24H is a versatile rock-
bolt having a flanged head which has a
female M30 or M36 thread. The bolt
Atlas Copco SDA system is built around the Boomer, with add-on standard options, and backed up by Atlas
Copco worldwide presence, know how and support.
has a static load carrying capacity of
200 kN and is designed for hanging ser-
vices while reinforcing the rock. After
the bolt has been installed by using an
inflation adapter, a forged eyebolt
(M30/M36) is screwed on. Utilities can
New Swellex PM24 Hanger rockbolt.
then be suspended directly from the
eyebolt. The bolt, with faceplate,
becomes part of the rock support pat-
tern, with all the advantages of Swellex.
Swellex® Pm 24H hanger rockbolts
are recommended for rock support in
tunnelling, civil engineering and
mining applications where suspending
utilities in an underground excavation
is needed. The bolts are designed as
anchor points for hanging utility pipes,
ventilation columns and rails, while at
the same time reinforcing the rock.
Cables can also be passed through the
eyebolts to form lacing or trusses in
rockburst prone ground, or to reinforce
friable or weak formations. Swellex®
Pm 24H can be installed using a stan-
dard Swellex pump combined with an
inflation adapter.

Self Drilling Anchors

System
In 2002, Atlas Copco incorporated the
MAI series of rock bolts into its prod-
uct range. Products like MAI Self
Drilling Anchors (SDA) can be used in
ground formations that are so soft,

30 ROCK & SOIL REINFORCEMENT

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Atlas Copco semi-mechanized MAI bolt installation from a Rocket Boomer.
fractured, or weak that a normal drill
hole will collapse before a standard
rock bolt can be inserted. The SDA
system comprises standard items like
the sacrificial bit, a variety of bolt sec-
tions, couplings, faceplate and spheri-
cal nut. Atlas Copco has developed
some components and functions for the
Rocket Boomer to make it the perfect
tool for installing SDA. The standard
feed on the Boomer should be equipped
with the new BSH 110 drill steel sup-
port. This is used to guide the bolt
when drilling, and when extending the
SDA bolt sections. The new BSH 110
is designed to leave a minimum of the
bolt protruding from the rock face, thus
utilizing the full length of the installed
bolts. The BSH 110 has remote-con-
trolled functions for guiding, gripping
and drilling, giving the operator full
control of the bolting sequence from
the drilling position. The BSH 110 is
fully compatible with any BMH 6000
feed. For those worksites where a lot of
SDA drilling will be done, the COP
1238 or COP 1838 rock drills can be
fitted with a special SDA shank adapter
and a conversion kit. The SDA shank
adapter has a female end to eliminate
the need for a loose coupling sleeve,
saving time when unthreading the bolt.
This makes handling easier when
extending the SDA bolts, boosting pro-
ductivity and improving safety. At
work sites where SDAs are not in daily
use, a suitable solution is to use a shank
connector to simplify the handling of
ROCK & SOIL REINFORCEMENT
SDAs on a standard Boomer. The
shank connector is added to the shank
adapter on the hammer, and should be
chosen to match the thread that is used
on the SDA. Most frequently used
threads are R32 and R38, but also com-
binations for the R51 and T76 SDA
systems are available. Once the SDA
activity is finished, the shank connector
is removed and normal drilling can
resume.
Length of anchor protruding after installation, depending on BSH 110 used.
SDA length outside tunnel face = 405
565
COP 1838
SDA length outside tunnel face = 281
565
COP 1838
TALKING TECHNICALLY
BSH 110
The BSH 110 is a hydraulic drill steel
support providing gripping and guid-
ing functions. The BSH has to be
equipped with the rubber bushing and
steel bushing halves to match the SDA
dimension.
The standard BSH 110 will manage
anchors up to size R51. There is also a
special version, BSH 110 available for
SDA installation, which minimizes the
part of the bolt protruding from the
rock and can fit SDA bars up to the
dimension of T76. All versions of
BSH 110 have to be equipped with
special SDA bushing halves when
handling SDA.
Installing SDA
Most current rockbolt installation
methods are manual. However, when
the operation is assisted by a Rocket
Boomer, productivity and safety are
greatly improved. Using the optional
equipment available for the standard
Boomer, a typical SDA bolting semi-
mechanized sequence will be as follows.
1) Modify the rock drill by attach-
ing a suitable SDA shank adapter and
BSH 110B
256
BSH 110SDA
301
31
RR3/RT11 19/7/05 8:45 Page 32
TALKING TECHNICALLY
Two-man operation for simultaneous drilling and grouting of SDA using a Rocket Boomer and MAI m400NT
grout pump.
an SDA COP kit that match the thread
on the MAI SDA bolt.
2) Place the MAI bolt section on the
feed with the selected MAI bit, and
thread the bolt into the shank adapter
female end. The BSH 110-SDA should
be in position to guide the bolt.
3) Start drilling, and adjust the pres-
sure to match the chosen bolt type and
the prevailing ground conditions.
Normally, the percussion pressure for
SDA drilling is less than half, some-
times only one third, of the hydraulic
pressure set for blast hole drilling. The
SDA shank adapter makes it possible
to drill the bolt close to the tunnel wall.
4) Grip the bolt with the BSH, and
hold it in position while adding anoth-
er MAI bolt section, prepared with a
suitable anchor coupling.
5) Once the MAI bolt section is
connected, open the BSH and contin-
ue drilling. When the last section of
the MAI bolt is being drilled, the BSH
110-SDA should be fully opened, to
allow the shank adapter to drill the
MAI bolt deep enough to leave about
280 mm of the bolt protruding.
Grouting SDA
The installation sequences described
above use water flushing for drilling.
The commonly used method for MAI
bolts is post grouting. This is carried
out manually from the Boomer basket,
or any other service platform, by
connecting a grouting unit to the
protruding end of the MAI bolt.
32
Suitable and flexible grouting units
are the MAI M400 grout pump, and
the Atlas Copco Craelius UNI-
GROUT E 22. The grout is pumped
into the hollow MAI bolt, and is dis-
tributed through the MAI drill bit into
MAI m400NT grout pump.
the drilled hole, filling cavities and
cracks along the bolt. This complete-
ly fills the hole, forming a strong
adhesion between the MAI bolt, the
cured grout, and the surrounding
ground formation. Once the grout has
cured for 8-12 h, the MAI bolt can be
post-tensioned to the required torque.
However, MAI bolt installation can
also be undertaken with continuous
grouting, using a grout pump m400NT
and the new integrated injection
adapter - Ceminject.
There is usually a need to alter-
nate between flushing with water
and grout. In underground installa-
tion, especially for radial bolting, it
may be inconvenient to do the
grouting during drilling as this may
create a mess of grout on the feed,
and make it difficult to remove
excess grout mix used for flushing.
The alternative method offered by the
Ceminject system is to flush the bore-
hole with water while drilling the SDA,
and to commence grouting only after
reaching the design depth, while main-
taining a slow rotation mode of the bolt
still fixed to the drifter. This ensures
good in-situ mixing and penetration of
the grout around the bolt, optimizes the
friction contact with the rock/soil, and
reduces wastage of grout mix.
by Olle Karlsson
Installation of anchor system using a Rotary
Injection Adapter.
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TALKING TECHNICALLY

Connectable Swellex
Alternative to
Cable Bolts
The Mn24C connectable rock bolt
is a relatively new addition to the
Swellex family. With a profile
made of Mn24 tubing, the sec-
tions of Mn24C are coupled
together with threaded connec-
tions that can support loads at
least as high as the profile
strength. Through an ingenious
assembly, the Mn24C combines
the exceptional ease of installa-
tion of Swellex with the length
capability of coupled bars or
cable bolts. Advantages of
Mn24C rockbolts are ease and
speed of installation, and quality
assurance of installation and per-
formance. Many mine operators
already consider Connectable
Swellex Mn24C threaded connection was launched in 2003.
Swellex Mn24 to be the best
solution to their ground control
problems in stoping. Although total cost ranged between C$13/m and saving is sizeable with long cable
manual installation does not C$35/m, a high standard deviation that bolts, it is not appreciable with lengths
appear attractive on a large scale,
operators are extremely interest- can be explained by disparities in the of less than 8 m-10 m, when Mn24C
ed in replacing their time con- costing systems across the sample becomes a good alternative.
suming cable bolting operations mines.
with the simpler and safer Swellex The market for very long cable Time is Money
system. With a semi-mechanized bolts is not targeted, as longer bolts
installation, Connectable Swellex
is very competitive, and is are usually installed by mechanized A comparison has been made for
deemed profitable in both North means. However, while the time typical underground mining practices,
America and South America.
Installing Connectable Swellex into a pilot drive.

Market Study
The following conclusions resulted
from a market study performed in
1995 in Canada on 71 responses from
109 underground mines, some 68 of
which are mining metal and industrial
minerals, excluding potash and salt.
The most-used mining method
reported was longhole stoping, fol-
lowed by Vertical Crater Retreat,
Sub-Level Caving and Cut & Fill.
An estimated 870,000 m of cable
bolts are installed every year in
Canada’s hard rock mines. Most mines
using cable bolts range in output
between 1,000 t/day and 5,000 t/day.
The average total cost of drilling and
installing the cable bolts was reported
at C$23.00 ± C$6.60/m. However,

ROCK & SOIL REINFORCEMENT 33

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TALKING TECHNICALLY

Table 1. Comparison of typical installation performances for Cable bolts and Mn24C.

Cable Bolts Cable Bolts Mn24C Mn24C Mn24C

Manual Manual Manual Semi-Mechanized Semi-Mechanized
Installation Installation Installation Installation Installation
Drilling – Installation Simultaneous
Separate Installation

Calculation Base: Calculation Base: Calculation Base: Calculation Base: Calculation Base:
40 double Cable 60 single Cable 60 Connectables 60 Connectables 60 Connectables
bolts 6 m long bolts 6 m long 6 m long 6 m long 6 m long

Drilling (Long Hole): Drilling (Long Hole): Drilling (Long Hole): Drilling (Long Hole): Drilling (Long Hole):
1.3 shifts x 1 man 1.4 shifts x 1 man 1.4 shifts x 1 man 1.4 shifts x 1 man 1.4 shifts x 1 man
64 mm diameter 50 mm diameter 50 mm diameter 50 mm diameter 50 mm diameter
holes holes holes holes holes

Installation: Installation: Installation: Installation: Installation:

2 shift x 2 men 3 shift x 2 men 2.3 shift x 2 men 2.3 shift x 1 man 1.4 shift x 1 man

Grouting: Grouting: Details: installation Details: installation

1.25 shift x 2 men 2.6 shift x 2 men time is 10 min. time is 10 min.
and is performed after and can be performed
all the holes are drilled. between each
hole drilled.

Plate tensioning: Plate tensioning:

0.5 shift x 2 men 0.5 shift x 2 men

Total: 9.8 man-shifts Total: 13.6 man-shifts Total: 6.0 man-shifts Total: 3.7 man-shifts Total: 2.8 man-shifts

Elapsed time: Elapsed time: Elapsed time: Elapsed time: Elapsed time:
5.0 shifts 6.0 shifts 3.7 shifts 3.7 shifts 2.8 shifts

Supplies: cables, Supplies: cables, Supplies: Supplies: Supplies:

grout tube, grout, grout tube, grout, Connectables, Connectables, Connectables,
plate, barrel and plate, barrel and retainers, plate and retainers, plate and retainers, plate and
wedge wedge $0.50/m for seals $0.50/m for seals $0.50/m for seals
and pumps parts and pumps parts and pumps parts

Drilling costs: Drilling costs: Drilling costs: Drilling costs: Drilling costs:
$5.80/m $5.00/m $5.00/m $5.00/m $ 5.00/m
Supplies cost: Supplies cost: Supplies cost: Supplies cost: Supplies cost:
$8.50/m $6.40/m $17.00/m $17.00/m $ 17.00/m
Install.: Install.: Install.: Install.: Install.:
$11.20/m ($45/h) $12.20/m ($45/h) $4.60/m ($45/h) $2.30/m ($45/h) $1.40/m ($45/h)

Total: $25.50/m Total: $23.60/m Total: $26.70/m Total: $24.40/m Total: $23.40/m

installing manual or semi-mechanized
cable bolts, using a 40 double strand
cable bolts block or a 60 single strand
cable bolts block. It was assumed that
the support capacity required by the
designed pattern of double strand
cable bolts would be met by an array
of 60 Mn24C rockbolts. The cost
analysis presented in Table 1 shows
that, in a semi-mechanized installa-
tion, using Mn24C rockbolts to
replace short cable bolts of less than
8 m-long saves a good deal of time. In
addition, quality control is better, and
training is very simple. Analysis of
Table 1 shows also that, for an Mn24C
price of C$16.50/m for the bolts, the
combined system would have an
operating marginal cost similar to cable
bolts. Increase in productivity still has
to be analyzed in term of costs saving.
Conclusion
Productivity and costs analyses have
also been carried out to assess the
competitiveness of the Mn24C rock-
bolts with cable bolting.
Field testing in Canadian mines
demonstrated higher productivity in
ore extraction and development, due
to the flexibility of installation of the
Mn24C bolts. Perfect installation by
non-specialized crews, with immedi-
ate support over the entire length of
the bolt, contributed to a higher
efficiency. Quality of installation was
not jeopardized by geological cracking
and voids, or water, and there was no
wait for curing before tensioning.
The increase in productivity can be
utilized to accelerate development of
stopes, adding flexibility to mine plan-
ning, and facilitating the timely
extraction of ore and its delivery to the
mill. The added productivity would
also mean less overtime and schedul-
ing conflicts.
To summarize, Mn24C is not only a
very efficient means of ground sup-
port, it also underpins a smooth
mining operation.
by François Charette

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TALKING TECHNICALLY

Rockbolt Corrosion in Mining

and Tunnelling
Observing Corrosion
The phenomenon of corrosion of
rockbolts in an underground
environment is a subject that is
attracting more and more atten-
tion from engineers and project
owners. Field observations have
shown that, in some conditions,
unprotected rockbolts corrode
freely and rapidly. A closer look
at the overall conditions at moni-
tored sites highlights the diffi-
culty in predicting the life of the
bolts. Often, water conditions are
not taken into account. Although
water supply can be non-corro-
sive at source, the process of re-
circulating water often gathers
corrosive ions, and renders the
water more aggressive toward
steel components.
At Atlas Copco, it was recog-
nized that theoretical predictions Figure 1. Pull testing to verify long term mechanical properties of Swellex rockbolt.
of a rockbolt’s life could only be a
first assessment of applicability metallurgically non-homogenous, or corrosion, where aggressive airborne
of non-protected ground support.
Ultimately, extra protection is where certain types of rock minerals contaminants are deposited on rockbolts
needed to isolate the rockbolt are in contact with the bolt. Crevice and any metallic surfaces. Water inflow,
from an aggressive environment. corrosion can occur with confined and chemicals in water, microbial species,
This can increase the effective life closely spaced metal surfaces, such as and fumes from both diesel engine
of the ground support, and secure at the interface between bolt collar and exhausts and explosive blasts, are the
its long-term performance.
Observed field performance in face plate. It has also been observed most common factors that will impact
known conditions can provide an that, in highly corrosive environments, on the corrosion rate of rockbolts. Level
extremely instructive insight of uniform and localized corrosion can of isolation from external agents will
the global corrosion process, and occur simultaneously. also determine the rate of corrosion.
on the means to alleviate its Galvanic corrosion is another type The major blame for corrosion in
effect on ground support.
of corrosion where dissimilar metals water lies with chloride and sulphate
are in contact in the presence of an ions. Very high concentrations of these
Corrosion Underground electrolyte, either liquid water or ions have been measured in both civil
vapour. A more appropriate descrip- engineering and mine tunnels, all over
Corrosion can be either uniform on the tion may be bimetallic corrosion. the world. Iron sulphide minerals,
exposed steel surface, or very localized. Graphical representation of the principally pyrite and chalcopyrite, are
Uniform corrosion is characterized by a types of corrosion likely to attack present in most metal mines, whereas
regular loss of metal from the corrod- rockbolts is presented in Figure 2, an extremely high chloride and
ing surface, while localized corrosion modified after Dillon (1982). sulphate ions concentration is more
will produce metal loss in a very con- In the main, environmental factors typical of Australian mines. Oxidation
fined area of the exposed surface. will determine the type of corrosion and of pyrite produces sulphuric acid, and
Under uniform corrosion, a rock- the mode of attack. From the point of mine waters with pH as low as 2 can
bolt will be radially thinned from the view of mechanism of attack, there are be produced. Also, water flow, and
outside or the inside, or, in the case of two main modes of attack in under- changes in ions concentration over
split tube stabilizers, from both sides. ground environments: corrosion in time, will affect passivation. Use of re-
Localized corrosion by pitting can be water, where the bolts are in contact circulated water increases the potential
seen in areas where the bolt surface is with running water; and atmospheric for corrosion problems.

ROCK & SOIL REINFORCEMENT 35

RR3/RT13.qxd 23/6/05 10:05 Page 36
TALKING TECHNICALLY
Figure 2. Types of corrosion encountered on rockbolts (from Dillon 1992).
Corrosion Potential
Queries about the life expectancy of
rockbolts are frequently received by
Atlas Copco from its customers.
While the only way to assure long-life
performance under aggressive condi-
tions is to coat the bolt to isolate it
from the environment, the need to
know the expected life span in tempo-
rary bolting applications has stimulat-
ed research and development in the
Rock Reinforcement group. A new
approach was elaborated, consisting of
three steps that allow a high level of
control on the bolt’s performance.
First, preliminary analysis of corro-
sion potential is carried out, using
field data and standards in the field of
Figure 4. Snapshot of inside view of Swellex bolt with borehole camera – no
corrosion visible inside the Swellex profile.
36
corrosion, such as DIN 50 929. This
first step allows the tunnel owner, or
mine operator, to make a first decision
on the need for corrosion protection.
Next, during the operation of the
tunnel or mine, regular testing can be
performed, in order to assess the real
corrosion rate of the rock support.
Third, if the tests showed that the
environment is corrosive enough to
reduce the effective life below that
required by the customer, the use of a
corrosion protected Coated Swellex is
recommended.
Table 1 presents theoretical corro-
sion rates calculated with the norm
DIN 50 929 for underground sites in
Sweden, Japan, Canada and Australia.
Typical tests performed include water
Figure 5. Snapshot of inside view of Swellex bolt with borehole camera –
corrosion visible inside the Swellex profile.
Figure 3. Fibre optics borehole endoscopic camera.
analysis, destructive pull tests and
profile endoscopy with a fibre optics
borehole camera (Figure 3). Figures 4
and 5 show the interior profile for two
Swellex bolts, corroded and non-cor-
roded. Pull tests, performed with the
equipment shown in Figure 1, will
provide an index of load capacity at
the collar of the bolt. It has been
observed with the borehole camera
that corrosion is limited to the first 30
cm from the inflation bushing, so the
loading capacity of the bolt inside the
rock mass is almost always kept above
its rated value. In relatively non-
aggressive environments, non-coated
Swellex bolts have proved to retain
their minimum loading capacity for
over 10 years.
Corrosion Protection
Atlas Copco Coated bolts are covered
with Corrolastic Expander Paint
839BX. This paint has been tested by
ROCK & SOIL REINFORCEMENT
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TALKING TECHNICALLY

Table 1. Corrosion Rate Assessment of Unprotected Steel for Underground Sites Using DIN 59 929

Sites Ca (mg/l) Cl (mg/l) SO4 (mg/l) HCO3 (mg/l) pH Assessed Corrosion Rate
German DIN 50 929 for
Uniform/Pitting (mm/year)

Mine A Canada 600 540 1610 NA 7.8 0.1/0.5

Mine B Canada 540 870 61700 NA 3.4 More than 0.1/0.5
Kapuzineberg
Sweden 22 2661 1.3 NA 6.95 0.1/0.5
Ritto Japan 13 2 3 52 6.7 0.1/0.5
Aspo Sweden N/A N/A N/A N/A N/A 0.1/0.5 for non-coated
0.02/0.1 for Coated
Swellex
Mine C Australia 140 1200 420 100 7.9 0.05/0.2
Mine D Australia 350 10 8300 38 3.0 0.1/0.5

the Swedish Corrosion Institute in
extremely aggressive environments,
and proved not to be affected by high
chloride or sulphuric acid levels for
periods over 10 years. In Table 1, the
Swedish Corrosion Institute has assessed
that the life span (at Aspo) of a Coated
Swellex in a very aggressive environ-
ment would be of more than 20 years.
The most critical parameters in corro-
sion protection are the characteristic
corrosion sensibility of the coating, and
the physical state of the coating with
reference to scratches and indentations.
Tests performed by the Swedish
Corrosion Institute for Swellex
immersed in sulphuric acid have
shown that, while the corrosion rate
of unprotected Swellex would be
0.5 mm/year in the simulated environ-
ment, the Coated Swellex showed no
traces of general corrosion, and pitting
at scratch locations stayed very local-
ized. In these conditions, corrosion in
unprotected areas would not migrate
to a protected area, the coating mini-
mizing corrosion and controlling its
spread.
It has been demonstrated that corro-
sion is a very complex process, and
corrosion rates are very hard to predict
CORROSION POTENTIAL ASSESSMENT STEPS
1. PRELIMINARY ANALYSIS USING DIN 50 929
2. FOLLOW UP OF PERFORMANCE OF ROCKBOLTS – CAPACITY
MEASUREMENT – ENDOSCOPY – WATER ANALYSIS TO MONITOR
CHANGES IN CONDITIONS
3. RE-ASSESSMENT OF ADEQUACY OF CORROSION RESISTANCE
TOOLS: WATER ANALYSIS, PULL TESTING, BOREHOLE CAMERA
accurately. However, predictive meth-
ods can be helpful to evaluate the need
for corrosion protected rockbolts.
Field observations, followed by pro-
tective coating of the rockbolt where
necessary, can be used to control cor-
rosion, both in temporary and perma-
nent rock reinforcement applications.
This approach to corrosion of rock-
bolts has been developed by Atlas
Copco to deal with the need for life
expectancy assessment in the mining
and construction industries.
Case Study at Aspo
The 4 km-long subsea tunnel driven to
access the site of the Aspo nuclear
waste research laboratory at
Oskarshamn, Sweden required some
rock reinforcement, despite high quali-
ty rock over most of its length. In
areas requiring support, rockbolts,
rockbolts with wire mesh, and rock-
bolts with wire mesh and steel fibre
reinforced shotcrete were used. Test
drilling showed that rock reinforce-
ment would get more difficult as the
tunnel progressed, because fissure
zones and saltwater leakage would
place high demands on holding power
and corrosion resistance. At a depth of
300 m, the sodium chloride content of
the seawater increases dramatically to
1.5%.
Sydkraft Konsult chose Swellex for
the job, because of their high degree
of versatility and quality of installa-
tion. The corrosion protection on
Coated Swellex met their demands for
long duration use, and they found the
quick and simple installation, with full
support over the entire length of the
bolt, extremely reassuring. Short
90 cm Swellex bolts were used for net
fixing, and 2.4 m-long Swellex bolts
were used for the main rock reinforce-
ment duties.
The views of the project manage-
ment were borne out by a study car-
ried out by the Swedish Corrosion
Institute to estimate the risk of corro-
sion of Swellex rock bolts used at
Aspo laboratory, from which the fol-
lowing conclusions were made.
Bolts with an intact corrosion pro-
tection layer are not attacked for many
years. In places where the layer is
damaged, there is a risk for general as
well as local corrosion. The attack
will, however, be limited and, as such,
less significant for the strength of the
bolt. The time for fracture due to gen-
eral corrosion for a 2 mm-thick bolt
can be considerably longer than 20
years, mainly due to low oxygen con-
tent in the water. The attack will, how-
ever, be limited and, as such, be less
significant for the strength of the bolt.
by François Charette

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TALKING TECHNICALLY

Grouting for Support in

Tunnels
Eighty Years of
Development
Atlas Copco Craelius has been
active within the area of grouting
for over 80 years. The company
originally started to develop and
manufacture grouting equipment
in an attempt to rescue expensive
holes. These generally occurred
when entering poor, fractured
rock, in which the drill string
showed signs of getting stuck, or
flushing fluids were lost.
Later on, grouting tools would
accompany Atlas Copco Craelius
diamond drilling equipment on
large international tunnelling
projects.
Today, grouting encompasses
so much more than traditional
ground injection in tunnels,
although it is still generally
defined as an injection under
pressure of fluid material into
fractures and cavities in rock, soil
or artificial structures. Depending
on the composition and mix of
the injected material, it will react
physically and chemically to sta-
bilize, strengthen, or seal the
ground or the structure. In
Scandinavia, the lower cost of Cycle of events in face excavation and support.
tunnels compared to the rest of
Europe is not only due to better
rock quality, but also because Drilling for Grouting in and with a maximum deviation of
grouting is classified as part of 3-5% from the intended target. This
the support. Tunnels involves starting with guide rods, and
It is generally accepted that Grouting is often considered as a hin- then using a rod adding system. Bigger
high grouting pressure, developed drance in the progress of the tunnel rod sizes are needed to ensure better
primarily by the French for use in
the Alps, increases the grouted advance. Instead it should be seen as a stability compared to blast hole drilling.
volume and strengthens and tool for the next step, and as one of the The diameter is normally 51-64 mm.
seals planes of weakness. Better most important parts of the final rock When the ground is of poor quality,
economy is expected using high support. it is harder to drill the holes, and the
pressures, by way of reduced The intention is to use the cement need to drill straight holes is much
drilling costs and a higher output
to stabilize, strengthen or seal the greater. In such ground it is also
of fresh, stable grout, especially
when using microcements. ground mass around the tunnel. It is a essential to place the grout where it is
Low pressure grouting, devel- waste of time and money to blast and required.
oped by the Americans for the sed- excavate the rock far outside the Where possible, grout holes should
imentary formations in the USA, required profile, and then replace be drilled at right angles to the main
and by the British in the coalfields, overbreak with concrete. fissures, in order to intercept as many
is designed to avoid further
damage to the strata by cracking Grout holes for pregrouting in tun- as possible. This is important when
or widening existing cracks. nels are 15-25 m-long, and should end post-grouting in tunnels, as well as in
3-4 m outside the theoretical contour, traditional surface grouting.

38 ROCK & SOIL REINFORCEMENT

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Grouting of the curtain cone.
This demand is difficult to meet
when pre-grouting in tunnels, where
spacing is reduced to ensure that
fissure planes, with an unfavourable
orientation to the grout holes, will be
grouted properly. Here, the diameter
of the drillhole has very limited influ-
ence on the grouting result.
Because of the stiffness of the
drill string, larger hole diameters in
general result in straighter, albeit more
expensive, holes. The setting of
packers is more expensive and diffi-
cult in large diameter holes, as is the
grouting.
General requirements for drilling
equipment in tunnelling work are as
follows. If possible, drill all holes
from a single set up, and with two dif-
ferent rod sizes and three different
hole diameters for blast hole, cut hole
and grout hole. Use a service platform
and a rod adding system (RAS) with
rod magazine: drilling for a grout
round may involve handling some 5 t
of drill steel. A positioning control
instrument is a necessity, together with
good working lights, and an elevated
sound-protected cabin for full view of
the face. A stepless mix of flushwater
and air is advisable, bearing in mind
that one drill rig uses 200-300 lit/min
of water. High pressure cleaning
equipment will be necessary for the
grout holes and the drilling and grout-
ing equipment.
Grouting is too often planned and
carried out as an off time shift, when
the drilling equipment is elsewhere.
Thus, when there is a need for addi-
tional grout hole drilling, this cannot be
undertaken immediately. Consequently
the driller cannot easily pass his
information and observations to the
grouting technician.
ROCK & SOIL REINFORCEMENT
Grouting in Tunnels
Tunnels are constructed for many dif-
ferent purposes, and under widely
varying geographic and geological
conditions. Tunnels carrying fluids, be
it fresh water or sewage, should not
leak; and all tunnels should resist the
inflow of water from the surrounding
ground.
The latter requirement may be
necessary to avoid draining natural
water into the tunnel, which could
lead to a general lowering of the
ground water table in a wide area
above its alignment. Movement of the
water table may result in subsidence
and damage to existing surface struc-
tures, loss of capacity of drinking
water wells, and similar undesirable
consequences.
In other instances, especially in
unstable ground containing running
material under pressure, or in karst
formations, grouting may be necessary
to stabilize, strengthen and seal the
strata.
Tunnels that have to be watertight,
as well as tunnels in weak ground that
have to have a long service life, are
usually lined. This lining is often
placed concurrently with the tunnelling
process itself, particularly in TBM
bored tunnels where it is constructed
of rings of prefabricated segments.
Even in bored tunnels, where the
excavated shape and diameter are
controlled within narrow limits,
there will be a slight annular gap
between the outside of the lining
and the inside of the bore. Grouting
behind the lining serves the purpose
of filling this gap, so that the lining
will support the ground from the
beginning, without settlement. This
TALKING TECHNICALLY
contact grouting method also serves
to seal the joints between the lining
segments.
Pregrouting
The cost for pregrouting can be
5-10 % of the cost of postgrouting for
reaching comparable and satisfactory
results.
The main reason is that both the
grout pressure and the grout flow can
be fully utilized in undisturbed rock
whereas postgrouting always is done
against a free surface, often cracked
up from blasting and excavation.
Investigation drilling is done during
the actual tunnel work and parallel
with the pregrouting in order to inves-
tigate the rock properties, like cracks,
fissures and fissure systems, occur-
rence of water, and soft or weathered
rock, for the next 50 metres or so.
Pregrouting means that the rock is
treated ahead of excavation.
These two operations are repeated
until a satisfactory result is achieved.
The pregrouted zone should always
go beyond the area that is disturbed by
blasting, bolting or excavation.
Grouting and pregrouting of tunnels
have three different purposes:
stabilization, strengthening and seal-
ing of the ground.
Stabilization grouting creates a
skeleton of grout in weak parts or
areas of the rock, to avoid sliding in
cracks, fissures or bedding planes.
This type of is grouting is to support a
temporary construction or when a con-
crete casting is done at a later stage.
Strengthening grouting is done for
reinforcing a tunnel permanently. In
most cases it is less expensive to uti-
lize and strengthen the existing rock
structure compared to replacing it with
a new construction of concrete.
Sealing grouting is strengthening
grouting developed to almost water
tightness. Sealing grouting is divided
into different sealing classes depend-
ing on permissible water inflow.
In Scandinavia normal tunnels are
said to present insignificant problems
when the leakage is in the range of
less than 5 lit/min per 100 m. If
it exceeds 10-20 lit/min per 100 m,
then significant problems will occur.
39
RR3/RT14.qxd 23/6/05 10:07 Page 40
TALKING TECHNICALLY
Drammen Case Study
At the Norwegian port of Drammen, a
second single-tube 2.3 km-long tunnel
with bi-directional traffic flow was
required to relieve congestion on the
north bank of the river. The tunnel is
on a curved alignment beneath the
Bragernes Ridge, an outcrop of igneous
rock comprising 50% porphyry and
50% basalt. The main face had an
excavated arched cross-section of
70.5 sq m, which included a large drain.
The main contractor was Selmer,
for client Statens Vegvesen Buskerud,
the local agency of the Norwegian
State Highways Authority.
A condition on the construction of
the tunnel demanded that there be no
interference with the water table, and
the tunnel itself be kept dry. The maxi-
mum ingress of water allowed before
grouting was 30 lit/min/100 m towards
the tunnel ends, and 10 lit/min/100 m
in the centre section.
The grouting sequence commenced
with the drilling of 27 m-long, 51 mm-
diameter holes ahead of the face to test
for water. These were drilled by an
Atlas Copco Rocket Boomer 353S,
using threaded extension steel, which
was manually attached. Generally, ten
forward holes were drilled, with a
10 m overlap, allowing 17 m advance
between events.
The contract envisaged injection of
2,370 t of grout to achieve the objective
Container mounted grout mixing and injection system to be carried on a truck.
40
water flows, a major operation for
which Selmer invested in a sophisti-
cated Atlas Copco Craelius truck-
mounted Unigrout E 400-100 WB.
This comprised a containerized
mixing and pumping plant with exter-
nal cement feed and additive hoppers,
and liquid additive tank. Inside the
container were two Cemag units, and
two 400 lit/min Pumpac units, with a
single 400 litre Cemix WB weight
batching mixer. The unit’s nominal
capacity is 4 t/h of dry cement, but up
to 66 t of cement was successfully
injected into a particularly wet round
over a 15 h period.
Pumping and Logging
The Atlas Copco Craelius Pumpac
System is based on a double acting
pump principle. The system has been
made simple and user-friendly by way
of modularized parts, independent and
stepless variable pressure and flow,
easy and fast change of valve assem-
bly units, and environmentally friend-
ly hydraulic fluid. Then the whole life
cost is kept to a minimum by system
adaptability. The system features a
hydraulic switch-over system, inte-
grated in the hydraulic cylinder, and a
split cotter fast-locking system of the
two piston rods for easy dismantling
of the cylinder assembly. Three sizes
of electric motors are available:
7.5 kW, 15 kW and 22 kW. There are
two sizes of grout cylinders: 110 mm
and 150 mm diameter; and two types
of valves: ball valves for normal
grouting applications, and disc valves
for when a smooth flow and minimal
pressure drop are required. Main-
tenance is easy, by way of a self
cleaning cement fluid end, water
flushing of cement and hydraulic
piston rods, and only one 46 mm
wrench for servicing the cement pump.
The Logac system is a computer
based logging system for sampling
and storing of data during the grouting
operation. The recorder is housed in a
cabinet with a Craelius Flow Pressure
(CFP) meter unit equipped with cable
and quick coupling for easy connec-
tion. The CFP meter unit consists of
an electromagnetic flow-meter and a
pressure-meter. The logged parameters
are flow, pressure, volume, time, real
time and hole number. The standard
flow meter operates in a range of 0-
200 lit/min with a maximum pressure
of 40 and 100 bar respectively. The
standard pressure sensor covers a
range of 0-100 bar. All parameters are
shown in real time on the Logac 4000
recorder display, and stored on a PC-
card. The Logac 4000 samples data six
times per second, and stores it on the
card every 10th second. The card can
be kept as a permanent record for
future references, or reused over and
over again. The control panel consists
of an on/off switch for the recorder, a
display, a separate button for each of
the eight groutlines, and a 10-key
keypad. Each groutline shows time,
real time, flow, pressure and volume.
There is a button to show either one
single line, or all eight lines simultane-
ously, and two diodes, one for telling
when logging is on, and the other for
informing when the memory card is
90% full.
One reason for Selmer’s success at
Drammen was that they could continu-
ously pump high volumes of stable
grout at high pressures. A normal
pumping rate is 110-120 lit/min at 50-
60 bar, and they used 80 bar as stop
criterion, and sometimes even 90 bar.
The water/cement ratio ranged from
1.0 to 0.5.
by Sten-Äke Pettersson
ROCK & SOIL REINFORCEMENT
RR3/RT15.qxd 23/6/05 10:09 Page 41

TALKING TECHNICALLY

Rock Mass Stability with

Swellex
Early Strength
Means Early
Support
According to Konda and Itoh, the
rock mass in a tunnel is unstable
between the face and 0.5D
behind the face, regardless of
rock types. Collapses occur most
often when the stress/strength
ratio of rock mass is smaller than
5, especially in sedimentary rock.
Discontinuities, caused by joints
in the harder igneous and meta-
morphic rocks, have also resulted
in rock falls up to 0.5D behind the
face. The risk of collapse in this
area grows with increasing cross
section of the tunnel.
Steel Fibre Reinforced Shot-
crete (SFRS) was recommended
to increase the rock stability in
the Tomei tunnel. The 28-day
strength of this shotcrete was
36N/mm2, using a steel fibre
mixture ratio of 0.7%. However,
early strength would be required
to give the necessary support.
Unfortunately, attempts to in-
crease the early strength of
shotcrete may induce micro-
cracking, with negative effect Pull-out testing of rockbolts in the underground laboratory.
on the long-term stability of
the concrete, particularly where
the initial deformation speed after installation, and also has greater said that the Swellex rockbolt is very
of the rock is high. control effect of displacement and suitable for support of a discontinuous
Without early shotcrete
strength, rockbolts become the rock mass plasticity, compared to rock mass.
main support. However, since grouted rockbolts. For stabilization of Comparisons between 4 m and 6 m
standard rockbolt grouting the region up to about 0.5D behind lengths of Swellex were also carried
materials require time to harden, the face, the Swellex rockbolt is a out. No difference in support effect
they don’t have much effect on more effective device than the grouted between the two lengths was found,
the initial stability of the rock
mass. rockbolt. offering the possibility of shorter bolt
The Swellex rockbolt also has more lengths if Swellex is used. This is
control over the shear behaviour of because Swellex completes the natural
Tomei Study joints compared to the grouted rock- arch immediately after installation.
bolt, because Swellex exhibits support
In a study on the Tomei tunnel in faster. As a result, it contributes to the Numerical Modelling
Japan, the influence on support of the formation of the natural arch, by
rockbolt installation method was improving stress continuity around the Face stabilization methods using
investigated by means of numerical tunnel, as well as displacement con- Swellex at Tomei were also confirmed
modelling. trol. Because one of the main roles of by means of numerical modelling.
It was found that the Swellex rock- the rockbolt is to improve discontinu- Tests determined the bonding stiff-
bolt exhibits more support effect right ous rock mass to continuum, it can be ness and bond strength of Swellex and

ROCK & SOIL REINFORCEMENT 41

RR3/RT15.qxd 23/6/05 10:09 Page 42
TALKING TECHNICALLY
Laboratory testing has determined the relationship
between curing time and load capacity for grouted
rebars.
grouted rockbolts as input for numeri-
cal modelling. Using these values,
two-dimension and three-dimension
models simulated pull-out tests.
The rockbolt axial force generated
at the tunnel crown in the case of
grouted rockbolts was 1 kN immedi-
ately after installation, rising to 32 kN
maximum. In the case of Swellex,
30 kN was generated immediately,
rising to 38 kN. For Swellex, the axial
force is more than 60% of the maxi-
mum value from the beginning, and is
about 1.6 times that of grouted rock-
bolts.
Overall distribution of rockbolt
axial force was measured at 1 m,
10 m, 20 m, and 30 m behind the face.
Using grouted rockbolts, almost no
axial force was generated from crown
to sidewall immediately behind the
face. At 10 m (0.5D) behind the face,
30 kN was generated at the crown
and 82 kN at the sidewall. Using
Swellex, 33 kN was generated at the
crown, and 66 kN at the sidewall right
Displacement contour, rockbolt axial force, longitudinal, for grouted rebars.
42
behind the face. At 10 m behind the
face, 50 kN was generated at the
crown and 131 kN at the sidewall.
For both cases, loads on rockbolts
do not increase more than 1D behind
the face, due to the convergence ten-
dency of rock mass displacement.
Except for right after installation, axial
force generated is about 1.5 times
larger for Swellex than for grouted.
Natural Arch
The difference of crown settlements
for grouted bolts and Swellex was
0.5 mm, 1.2 mm, and 1.5 mm at 1 m,
10 m, and 20 m behind the face,
respectively.
Using grouted bolts, a plastic
region of about 4 m is generated from
the crown to the sidewall section. In
the case of Swellex, the plastic region
near the crown tends to decrease, and
the value is controlled at about 2 m.
Where there is no support, the value is
6 m at the crown, and 4 m at the side
wall section.
The tunnel is stabilized by generat-
ing a natural arch of the surrounding
rock mass, preserving its continuity
for tangential stress. In the case of the
Swellex rockbolt, since the continuity
for ground stress of the arch section is
greater than when using grouted rock-
bolts, it is thought to have a major
effect on tunnel stabilization.
Joint shear displacement is generated
within 4.0 m of the tunnel profile, and
this can be controlled immediately
using a 4 m-long Swellex bolt. With
grouted rockbolts, shear displacement
Displacement contour, using shorter Swellex rockbolts.
extends to more than 4 m, due to the
time lapse for grout hardening.
When using Swellex rock bolts,
maximum bonding with the strata is
achieved right after installation, so the
required bolt length is shorter than
with grouted bolts.
Summary
The excellent support effect of
Swellex rockbolts can be summarized
in four points as follows.
Compared with grouted rockbolts,
Swellex exhibits a much greater sup-
port effect right after installation, and
contributes to stabilization of the rock
mass near to the face. In a continuous
rock mass, Swellex has a greater con-
trol effect over the plastic region. In
heavily jointed rock, Swellex con-
tributes more to the formation of the
natural arch by controlling the shear
behaviour of joints, improving the
stress continuity of the rock mass.
Swellex controls tunnel deformation
better, and exhibits excellent support,
making it superior to the equivalent
grouted rockbolt.
Because stabilization of the rock
mass close to the face was a key point
for the Tomei tunnel, Swellex rock-
bolts were specified. Swellex enables
a tunnel structure to be stabilized by
support, without the impediment of
curing time for shotcrete and grouting
materials. By installing Swellex bolts
immediately after excavation, it is
possible to avoid rock instability.
by Federico Scolari
ROCK & SOIL REINFORCEMENT
RR3/RT16 23/6/05 10:10 Page 43
Secoroc Uppercut – High
Quality Tapered Equipment
Designed for
Pressure
Increasingly powerful pneumatic
and hydraulic rock drills place
great demands on rock drilling
tools, a fact that is well known to
drillers working in mining and
dimensional stone applications.
This is the reality that has guided
Atlas Copco Secoroc in the
design of its range of Uppercut
tapered equipment.
At the heart of these innova-
tive products there is a formid-
able steel grade and specialized
manufacturing technique. The
unique heat treatment process
employed helps to release the
internal stresses of the steel and
give it greater bending resis-
tance, while retaining high dura-
bility. The result is a tapered rod
that’s better suited to the stress-
es and strains of modern rock
drills.
All in all, you won’t find
longer lasting rods on the market
today!
Features of Secoroc Uppercut tapered rod.
ROCK & SOIL REINFORCEMENT
Tough Rods for a Tough Life
Rods have a tough life, transferring the
percussion energy from rock drill to
bit, and then into the rock. They’re
also subjected to high bending stress,
not to mention corrosive water in the
flushing hole. These harsh facts have
not only guided Atlas Copco Secoroc
in its selection of steel quality, manu-
facturing technique and heat treatment
processes, but also in their decision to
have a rolled-in stainless lining
throughout the entire length of the
flushing hole. Even the drifted flushing
hole at the shank end is lined in the
same way. The flushing hole is also
protected by special anti-corrosion oil
as standard, to prevent corrosion and
risk of rod breakage. And for even
greater protection, Uppercut rods have
surface hardened shank and tapered
sections for high wear resistance on
those parts exposed to severe stresses
during drilling.
Secoroc tapered rods are already
renowned for their superior fatigue
TALKING TECHNICALLY
strength and resistance to bending
stress, and, with the Uppercut range,
have improved material properties still
further.
Question of Degrees
Different taper angles are used for dif-
ferent rock formations and rock drills.
A wide taper angle is normally used
when drilling with high impact
hydraulic rock drills in medium hard
to hard and abrasive rock formations.
Taper angles of 11 degrees and 12
degrees are common on modern rigs.
A narrow taper angle of 7 degrees is
used for low impact rock drills and
softer rock formations. This angle can
also be used to counter spinning prob-
lems when using 11 degrees or 12
degrees equipment. In addition, a 4
degrees 46 minutes angle is available for
very soft rock, to prevent bits from spin-
ning or becoming detached when using
pneumatic or hydraulic rock drills.
Secoroc Uppercut rods are available
with 22 mm hexagonal rod section and
43
RR3/RT16 23/6/05 10:10 Page 44
TALKING TECHNICALLY
Uppercut tapered rod and button bit ready to drill.
shank length 108 mm for 4 degree 46
minute, 7 degree, 11 degree and 12
degree tapers. Uppercut rods with 25
mm hexagonal rod section and shank
length 159 mm are available with 12
degree taper.
High Performance Bits
Secoroc bit design and production
processes are in a state of constant
refinement. The Secoroc Uppercut
Range of Uppercut tapered rods and bits from Atlas Copco Secoroc.
44
range comprises button and cross-type drilling costs, and is taking market
bits in an extensive selection of design share from integrals, especially in
configurations. These designs can be mining applications and the dimen-
used in a variety of rock formations sional stone industry.
for maximum productivity.
Moreover, there are two new by Jan Lindkvist
models, with an extra front button for
improved hole straightness, higher
The Secoroc Uppercut
penetration rate and longer service
life. Furthermore, the Secoroc range of
Rod
ballistic button bits is in the process of ● Special anti-corrosion oil to
being extended to meet ever more protect the flushing hole of
diverse demands. the rod
● Surface hardened taper
Prepared for the Future end for high wear
resistance and a longer
Secoroc Uppercut tapered equipment service life
can be used in all types of applications ● Stainless steel flushing
and rock formations. The lowest tube lining to prevent
cost/metre drilled, a claim that has corrosion and breakage
long been synonymous with Secoroc ● Drifted flushing hole with
products, is now lower than ever with stainless steel lining at the
this range, along with higher drilling shank end prevents
productivity. breakage and increases
Tapered products, which first appeared service life
on the scene in the 1960s,
● Surface hardened shank
can readily handle the impact energy from end for high wear
modern pneumatic and hydraulic rock resistance and a longer
drills, while they are also ready to cope with service life
the stronger rock drills currently on the
● Z708 steel for superior
drawing board.
fatigue and bending
Nowadays, tapered equipment is
strength
favoured for increased penetration
rate, longer service life and lower
ROCK & SOIL REINFORCEMENT
RR3/RT17 23/6/05 10:11 Page 45

TALKING TECHNICALLY

Speedy Rock Reinforcement

Using Magnum SR
Thread System for
the Future
The tried and tested thread sys-
tems, R25, R28 and R32, have
served underground drillers well
for many years. However, with
the introduction of ever-more
powerful hydraulic rigs, these
battle-worn solutions started to
show weakness. Rod breakage at
the bit end, either just behind the
skirt or on the last thread, was
becoming distressingly common.
Why? Because it’s the most vul-
nerable part of the rod.
Consequently, bits were lost,
leading to costly downtime. Even
worse, holes often had to be re-
drilled, reducing productivity.
Putting it bluntly, drifting and
rock bolting equipment was
struggling to cope with the
power of the new rigs. It was
high time for fresh ideas.
Extensive development by
Atlas Copco Secoroc came up
with the new Magnum SR range,
which counters problems with
breakage and offers performance
to match that of the modern drill
rig.

Thread of Innovation
To solve the problem, Atlas Copco
Secoroc faced two choices: either
increase the dimensions of the rods
and bits in the same way as everybody
else, or find a new way. Being notori-
ously stubborn innovators, the choice
was easy.
During the creative process, three
important insights emerged. First, the
hole sizes should remain as for drilling
with standard equipment. Second, the
bits should be easy to uncouple. And
third, the old thread design had to be
left behind.
As with all genuinely groundbreak-
ing endeavours, the solution was
deceptively simple. The secret of the
Magnum SR thread design is that the
Magnum SR used in a bolting application.
diameter is larger at the end of the
thread and smaller at its tip. By adding
considerably more steel at the end of
the thread, the new design was given a
distinctive, conical shape. This con-
cept not only upped the fatigue resis-
tance of the rods, but also reduced the
tendency to deviate during collaring.
The Magnum SR thread design also
has the added bonus that the bits are
very easy to uncouple and change,
saving time and equipment, and result-
ing in more holes drilled. Magnum SR
has proved a big hit with operators.
The new Magnum SR system for drift-
ing and rockbolting, specially designed
for the new generation of powerful drill-
rigs, delivers more and straighter holes
per shift and has a considerably longer
service life than any competing system.
Field Tests Worldwide
Extensive field tests with the Magnum
SR were carried out on four conti-
nents, and involved more than a half
million metres of drilling over a
period of one year.

ROCK & SOIL REINFORCEMENT 45

RR3/RT17 23/6/05 10:11 Page 46
TALKING TECHNICALLY
Magnum SR bit ready to drill.
The system was put through its
paces in mines, and in a variety
of tunnelling projects. The results
were unequivocal: service life and
rig availability both enjoyed sharp
increases.
The tests showed that the Magnum
SR systems increased service life by
25-100% on the rods, gave better ser-
vice life of the bits, and created very
high operator acceptance due to easy
46
uncoupling of the drillbits. This result-
ed in higher drilling productivity,
thanks to easy collaring, straighter
holes and better equipment availability
during the drilling cycle.
Expanding Family
The Magnum SR thread system was
first introduced with the SR35, which
has a comprehensive selection of
products for hole diameters of
43-64 mm.
The next addition to the family was
the Magnum SR28 range. Tests have
shown that SR28 is perfect for the
rapid drilling of holes for rockbolts,
but can also be used for small hole
drifting. This new line replaces the tra-
ditional R25 system in 33-35 mm
drilling.
Tests in rockbolting have shown
convincing increases in service life for
both SR28 rods and bits. As with all
other Magnum SR products, the bits
are easy to uncouple, and as a result
the drillstring is subjected to fewer
damaging shockwaves, facilitating
rapid changes and more holes drilled.
All together, that means less downtime
changing bits and rods, and more time
spent drilling.
Magnum SR35, together with
Magnum SR28, are ultimately aimed
at helping drillers advance their tunnel
or drill rockbolt holes quicker than
ever before. The most recent member
of the family is SR32, which is spe-
cially designed for hole diameters of
38-41 mm.
Dawn of a New Era
The trend in drifting and tunnelling
is clear: the rounds are getting
longer, and the rigs more powerful.
Magnum SR was designed to with-
stand the high pressures so typical
of today’s underground drilling
operations.
Although Magnum SR is relatively
new to the market, the enthusiasm
with which it has been received, and
the performance that it delivers, have
given an indication of the direction in
which the product is heading. Atlas
Copco Secoroc is genuinely confident
that Magnum SR heralds the dawn of
a new era in drifting and tunnelling, as
well as for rockbolting.
The success of this innovative
system is beyond dispute. Drillers
using it are not only drilling more
and straighter holes than before,
they’re also finding that Magnum
SR lasts longer than any competing
solution.
by Anders Arvidsson
ROCK & SOIL REINFORCEMENT
RR3/RT18 23/6/05 10:12 Page 47
Rock Mechanics and Rock
Reinforcement in Mining
Behaviour of Rock
Rock mechanics or geomechanics
is a term often used to include all
the steps that lead to define and
control the behaviour of rock
around excavations. From the
geological and mechanical defini-
tions, through rock mass charac-
terization, to the design of
reinforcement and calculation of
factors of safety, rock mechanics
provides the basis for the assess-
ment of reinforcement needs.
Rock Engineering
In the context of definitions, it is often
more accurate to talk about rock engi-
neering, as components from geologi-
cal, civil, mechanical and mining
engineering are combined to create the
process presented in figure 1.
This global process can be very
detailed, or quite basic, depending
upon the magnitude of the mining
operation and the available resources.
The fundamentals include: the defini-
tion of the structural fabric of the rock
mass including aspects such as joints,
faults, shear zones; the evaluation of
the mechanical parameters of the
intact rock and structures; the identifi-
cation and quantification of the failure
modes based on stress and structural
analysis; the influence of the excava-
tion mode; and the design of the rock
reinforcement itself.
Differently formulated, it could be
said that stresses and rock structures
are the two most important factors
affecting the stability of any excava-
tion in natural strata material.
Combination of various stresses
regimes and fragmentation will dictate
the behaviour of the excavation (see
figure 2). Rock stresses intensity can
vary from very low to very high, and
intensity of fragmentation from mas-
sive rock to sugar cube structure or
ROCK & SOIL REINFORCEMENT
TALKING TECHNICALLY
Rock Mass Characterization
Rock Mass classification and identification of failure modes
Structural failures and gravity Failure caused by overstressing
Shear analysis of critical structures Determination of in-situ stress
Evaluation of failure zones Mechanical properties of rock masses
Calculation of “factor of safety” Evaluation of zones of high stresses
Calculation of reinforcement needs Calculation of reinforcement needs
Influence of blasting Influence of blast and dynamic events
Reinforcement design Reinforcement design
Figure 1. (above) General process encompassed by the general definition of rock mechanics application to
the design of structures in rock.
Figure 2. (below) Simplified description of rock mass conditions and rock failure (from Hoek E., P.K. Kaiser
and W.F. Bawden. 1995. Support of Underground Excavations in Hard Rock. Balkema p215).
intensely schistose. Low stress levels High stress levels
Massive rock will draw
most of the intact rock
strength, but will also
accumulate load and
Massive rock
can fail violently under
the right conditions (see Massive rock subjected to low in situ Massive rock subjected to high in situ
stress levels. Linear elastic response stress levels. Spalling, slabbing and
figure 3). Very frac- with little or no rock failure. crushing initiates at high stress
tured rock will tend to concentration points on the boundary
and propagates into the surrounding
yield to stresses, and rock mass.
often deforms in a
problematic manner
(figure 4). Obviously,
Jointed rock
excavation shape, size
and orientation also
Massive rock, with relatively few Massive rock, with relatively few
affect the response to discontinuities, subjected to low in discontinuities, subjected to high in
the acting forces at situ stress conditions. Blocks or situ stress conditions. Failure occurs
wedges released by intersecting as a result of sliding on discontinuity
play. discontinuities, fall or slide due to surfaces and also by crushing and
gravity loading. splitting of rock blocks.
Optimized
Heavily jointed block
Excavation
Although rock mechan-
ics is a relatively new Heavily jointed rock subjected to low in Heavily jointed rock subjected to high
situ stress conditions.The opening sur- in situ stress conditions.The rock mass
science that deals with face fails as a result of unravelling of surrounding the opening fails by sliding
the mechanical behav- small interlocking blocks and wedges. on discontinuities and crushing of rock
Failure can propagate a long way into pieces. Floor heave and sidewall closure
iour of rock material, it the rock mass if it is not controlled. are typical results of this type of failure.
47
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TALKING TECHNICALLY

This applies especially for the rock

reinforcement and support aspects.
Some rock reinforcement and sup-
port that can be perfect for static con-
ditions may become quite inadequate
when confronting seismic events or
high stresses and deformations. It is
then important to be able to predict
future conditions, and use rock rein-
forcement that will still be adequate
when conditions change, or will warn
when in-situ conditions are close to
exceeding the rating of the device.

Rock Reinforcement
Rock reinforcement devices and sur-
face support are used to control the
rock masses within a certain range,
Figure 3. Rubble created from a dynamic failure of Numerical Modelling allowing safe and economical access
a mine roof. to the excavated areas.
Long term excavation planning can Historically, before the 1900s, typi-
is now regularly used to optimize the benefit from detailed analysis like cal roof support in mines was timber
performance of mining excavations in numerical modelling. Stress regimes posts and beam. Then, as early as
rock. Using rock mechanics leads to a can be predicted and mining 1905, roof bolts were reportedly used
better understanding of the behaviour sequences optimized to keep the stress in coal mine roofs in the United
of the rock masses, which in turn leads level at a comfortable level: not too States. In late 1920, systematic rein-
to a more effective and safer opera- high to create seismic events, and not forcement of mine roofs was intro-
tion. Stress analysis is also more com- to low to create major structural insta- duced to allow the use of mechanical
monly performed on site, and results bilities. For day-to-day operation, full-revolving loading shovels, by pro-
are easier to analyze thanks to the use numerical analysis will give results viding room to manoeuvre free of con-
of powerful desktop computers. that must be confirmed by field obser- ventional timber posts. Inclusion of
The design process should also be vation, but can be used to plan with channel irons, fastened by rock bolts
repeated at later stages of the mining the right kind of conditions in mind. to support large area of roof led to the
operation, as field conditions will principle of “suspension roof sup-
almost always change for the worse. Figure 4. Ground conditions leading to yielding ports”. The need for early support to
It is critical that the correct assess- walls and roof. secure the lower roof layer to avoid
ment of failure mode is made, as this
understanding will lead to proper
reinforcement instead of using a long
and arduous trial and error methodol-
ogy.
As an example, when hard and
massive rock fails, producing small
fragments like those seen on figure
5, it is often a sign that the rock is
overstressed and is rupturing in a
brittle and uncontrolled way. This
could be the precursor of seismic
events and dynamic failure, which
most rock reinforcement would be
unable to control. It is also a fact
that, as long as well-recognized
brands of rock reinforcement are
used, the support devices rarely fail
as a result of poor material quality,
but rather as a result of inadequate
applications.

48 ROCK & SOIL REINFORCEMENT

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TALKING TECHNICALLY

loosening the upper layers, as well as

the creation of roof beam action, laid
the foundations of modern rock rein-
forcement principles.
Around 1945, expansion shell
anchors appeared in England, Holland
and US, and by 1949 rock bolts began
replacing timber supports in US
mines at a rapid rate. By end of 1952,
over 2 million rock bolts per month
were being installed. In Canada, sys-
tematic bolting of roof in coal mines
began in 1950. By the end of the
1950s rock bolts were in use every-
where, thanks to the systematic use of
modern carbide tipped steels for fast
hole drilling.
Rapid installation, compared to
timber sets, was also compatible with
mechanized mining methods. Between
1952 and 1962 the introduction of
grouted slot and wedge bolts, fully Copco introduced the EXL Swellex, Figure 5. Slabs created by the violent failure of a
grouted untensioned deformed bars, as an all around high performance yield- mine roof during a small rock burst.
well as the hollow core groutable ing friction rock bolt.
expansion shell rock bolt, provided a In 2003, Atlas Copco and MAI large range of operational possibili-
strong argument in favour of perma- joined their efforts and introduced the ties. Surface retaining supports like
nent reinforcement with rock bolting. Swellex Pm Line and the mechanized shotcrete and reinforcing mem-
During the 1960s, experiments were installation of SDA anchors. Today, branes are now adding another
made with epoxy and polyester resins as Self Drilling Anchors that were first dimension to the reinforcement of
bonding media. By 1972, prepackaged developed for ground engineering underground excavations, and their
polyester resin systems were developed, applications are slowly gaining ground use in combination with rock bolts
tested and marketed. Immediately as an alternative in extremely poor provides a counter-effect to stresses,
active, full-length reinforcement of rock ground conditions. water and time.
masses became possible. For long reaching reinforcement,
Quality of installation remained an cable bolts, coupled rebars and,
issue, and lengths of bars, as well as more recently, connectable friction Figure 6. Estimated support categories based on
resin quality and setting times, created bolts (Swellex Connectable) and the tunnelling quality index Q (after Grimstad and
difficulties in installing the reinforce- Self Drilling Anchors, provide a Barton, 1993).
ment system. Exceptionally Extremely Very Very
Poor Fair Good Ext. Exc.
poor poor poor good good good 20
100
Modern Rock Bolts ted are
a
2.3 m 2.5 m
2.1 m
re 1.7 m
50 shotc 1.5 m 10
ing in
spac 1.3 m
By 1979, J.J. Scott introduced the Bolt 1.2 m 7
splitset rock bolt, and in 1980 Swellex 1.0 m
5
Span or height in m

20
bolts were introduced by Atlas Copco. (9) (8) (7) (6) (5) (4) (3) (2)
These two products started the use of 10 4.0 m
ESR

3
m

m m
friction anchored rock bolts in under- m m 3.0 m
m

m
m

m m
0m 90
m

0 a
40

0
25 15 12 are
50

ground excavation. 5 2.0 m ete

d 24
tcr
ho
During the 1980s, the cone bolt, a 1.5 m
in
uns
yielding rock bolt better adapted to ing
ac
2 1.3 m lt sp 1.5
rock burst events, was introduced in Bo
1.0 m
1
the South African mines, and its appli- 1
0.001 0.004 0.01 0.04 1 0.4 10 4 10 40 100 400 1000
cation in other continents is still under Rock mass quality Q = RQD x Jr x Jw
Jn Ja SRF
development.
Around the same time, recognizing REINFORCEMENT CATEGORIES 6) Fibre reinforced shotcrete, 90 - 120 mm, and bolting
1) Unsupported 7) Fibre reinforced shotcrete, 120 - 150 mm, and bolting
the need for support in moving 2) Spot bolting 8) Fibre reinforced shotcrete, >150 mm, with reinforced
3) Systematic bolting ribs of shotcrete and bolting
ground, Atlas Copco introduced the 4) Systematic bolting with 40-100 mm unreiforced shotcrete 9) Cast of concrete lining
5) Fibre reinforced shotcrete, 50 - 90 mm, and bolting
Yielding Swellex. In 1997, Atlas

ROCK & SOIL REINFORCEMENT 49

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TALKING TECHNICALLY
Adaptable Design
Rock reinforcement and rock mechan-
ics applications are inter-related as the
design of an excavation and its rein-
forcement is an implicit process in
which most parameters are interde-
pendent. The design of excavation
also gets new “blood” with advances
in technologies. Better long hole
drilling equipment provides straighter
boreholes that allow larger stopes
with less development and better
blasting control, and improvements in
dilution and stability go hand in hand.
However, recognizing that ground
conditions are going to change brings
the need for easily adaptable design
methods of rock reinforcement. In
this case, empirical methods can help
rapid and sound decisions.
Figure 6 presents a rock rein-
forcement design method based on
the tunnelling index Q. Fast and
reliable ground control practices can
make the difference between a prof-
itable extraction and a marginal one.
50
Conclusion
Rock mechanics in mining has
evolved tremendously over the last 15
years with the availability of numeri-
cal models that run on desktop com-
puters, and the very active transfer of
knowledge and technology between
research and mining operations. In
fact, the practical application of rock
mechanics in everyday mining is often
considered a normal part of the extrac-
tion process.
Rock mass classifications are used
systematically in most mining opera-
tions in North America, and opening
sizes and shapes are carefully
designed and planned to fit both the
equipment requirements and the sta-
bility limits.
It is true that mining operations are
often working at the limits of stability
of excavations, but then the profitabil-
ity of mining demands that knowledge
and applications are at the forefront
allowing the best overall performance .
By developing local expertise and
sharing it through conferences and
publications, rock mechanics people
are always pushing the limits of per-
formance of excavations.
In order to get the full benefit of
rock mechanics application and rock
reinforcement systems, the two must
be linked and interconnected in a way
to provide feedback information and
data for each other.
During the past two decades, the
impact of accidents and damages has
been better understood. It has been
recognized that the safer the environ-
ment, the better the productivity and
working relations. Social costs are
now considered as valuable, and
minimized. An objective of mining
operations all over the world is to
eliminate working injuries. As rock
fall incidents are often fatal, they
should be avoided by using integrat-
ed bolting systems to provide opti-
mum reinforcement and support
solutions.
by Francois Charette
ROCK & SOIL REINFORCEMENT
RR3/RT19 18/8/05 14:00 Page 51
Performance of Swellex Rockbolts
in Dynamic Loading Conditions
Avoiding Dynamic
Failure
Dynamic failure of rock under-
ground can generate high levels
of kinetic energy and expulsion
of rock from the opening surface.
Rock material reaches velocities
of a few metres per second and
in those conditions, the rock rein-
forcement is more than often
destroyed or at least mobilized in
excess of its working range,
resulting in caving or closed-in
excavation contours. Rock rein-
forcement used in those condi-
tions must be able to sustain the
energy burst, as well as retaining
the rock adequately before and
after the event. In order to assess
the Swellex capability in dynamic
failure conditions, laboratory
testing programmes have been
undertaken to quantify the per-
formance of Swellex rock bolts in
dynamic loading conditions.
Testing Configuration
Figure 1 shows the testing apparatus
used to simulate the action of seismic
events on Swellex rock bolts. All
impact tests were performed on 2.1 m-
long Swellex Mn12 bolts. The static
weight of moving part was one metric
tonne, or 1000 kg. In field failure, the
Swellex bolts are usually broken at a
distance varying from 10 cm to 50 cm
from the head bushing. Failure of the
bushing weld almost never occurs in
the field. To try to reproduce the fail-
ure pattern observed in the field, the
Swellex bolts were inflated in two
steel tubes, with the top tube generat-
ing the anchorage. The second (see
Figure 1) shorter, impact tube also
generates some friction above the
bushing and plate assembly, which
dampens the impact. The rationale is
that, since no bolts are breaking at the
bushing weld in field events, it must
be that the bulking occurs at such a
ROCK & SOIL REINFORCEMENT
TALKING TECHNICALLY
Testing Procedures
a
The basic test procedure was: 1)
turning on the electro-magnet and
lifting the weight at the appropriate
height above the impact position on
the bolt; 2) initiating the datalogging
system (when used) to measure
impact load; 3) turning of the elec-
tro-magnet to release the moving
weight; 4) if no failure, or complete
sliding of bolt inside tube, the weight
is hooked up again and lifted up for
the next drop. The load data was
Figure 1. Testing apparatus with a) original
configuration and b) modified configuration for
distributed impact, and c) completed test with
modified configuration.
b
c
distance from the head as to mobilize
load from the anchorage and retaining
force generated by the bushing-plate
ensemble.
The friction inside the steel tube
was not sufficient to create failure of
the bolt profile, and this highlighted
the need to better simulate steel/rock
anchorage capacity. However, this
reduced friction demonstrated interest-
ing behaviour that has led to a better
understanding of anchorage require-
ments in dynamic loading.
51
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TALKING TECHNICALLY

maximum dynamic strength differs

A: Impact from maximum static strength.
A B: Sliding of bolt inside tube section
C: Harmonic oscillation of weight
A summary of impact testing is pre-
Load
after sliding has stopped. sented in Figure 2, including an
B impact test where the recording equip-
The typical measurements of the ment was successful in picking up all
tests are:
Impact load
of the information. Table 1 presents
C Sliding Load typical results from the laboratory test-
Final load on load cell ing programme.
(should be equal to the
moving mass, i.e. 1 tonne)
Time Time of sliding
Analysis Of Energy
Time to failure (when it Absorption Capacity
occurs)
Table 2 summarizes testing results on
Swellex Sample A1 various types of rock reinforcement
fixtures. Static steel properties can be
Load (tonnes)

25
used to preliminary assess the theoreti-
15 cal energy absorption capacity, but it
5 has been found that load and deforma-
-5
tion are different from static tests.
0.95 1.05 1.15 1.25 1.35 1.45 1.55 Measurements show that the impact
time (s)
load exceeds the ultimate static tensile
strength by a factor of about 1.5, while
Figure 2. Typical signature of impact test on Swellex bolts: a) Typical phases of an impact test; b) actual when shearing was observed (Figure 3),
impact test with sliding of bolt inside steel tube. the impact load exceeded the ultimate
shear strength, taken as 60% of tensile
measured at time intervals of according to the load level. If the load strength, by a factor of about 1.4.
0.00005 seconds. reaches, or exceeds, the ultimate From the tests performed during the
strength, then the bolt simply breaks. spring of 2004, the bolts showed only
Impact Tests Analysis However, based on the test results, minimum yielding for loads exceeding
Table 1. Typical Impact Tests Results
Upon starting the test, the weight is
elevated to a pre-determined height
Result Test 1 Test 2 Test 3 Test 4
above the impact point. After being
released, the weight accelerates until it Impact Load (T) 10.4 15.3 17.8 18.2
reaches the impact point. At this point,
K(kJ) 9.1 8.6 6.1 9.1
the impact load is measured. Under
the impact load, the bolt starts to Status of bolt Failed in Failed in Failed in Slided
deform, but almost simultaneously, it shear shear and tension
also starts to slide inside the steel tube. tension
The sliding reduces the load on the
bolt, so that it does not fail if it is not Table 2. Theoretical energy absorption capacity based on quasi-static
pinned or restrained. During sliding, load -strain properties
frictional energy is dissipated accord-
ing to the friction generated on the Description Peak Load Displacement Energy
wall of the tube. As the weight slows (kN) (mm) Absorption
(kJ)
down, the friction coefficient increases
19 mm resin-grouted rebar 100 – 170 10 – 30 1–4
toward its static value, and the bolt is
16 mm cable bolt 160 -240 20 – 40 2–6
finally stopped. The momentum cre-
16 mm, 2 m long mech. Bolt 70 – 120 20 – 50 2–4
ates harmonic oscillations in the bolt,
16 mm, 4 m debonded cable 160 – 240 30 – 50 4–8
which acts as a stiff spring, and these
16 mm grouted smooth bar 70 – 130 50 – 100 4 – 10
are damped very rapidly. When the
Standard Swellex bolt 105 – 110 25 – 35 2–4
bolt is clamped or fixed so that it
Mn12 Swellex bolt 120 – 125 45 – 100 5.4 – 12.5
cannot start to slide at both ends, if the
Mn24 Swellex bolt 220 – 240 80 – 120 18 – 29
transmitted load at the restricted loca-
Split Set bolt 50 – 100 80 – 200 5 – 15
tion does not reach the ultimate
16 mm cone bolt 90 - 150 100 - 200 10 – 25
strength of the steel, the bolt only
deforms elastically and plastically, (Data from Kaiser, 1995)

52 ROCK & SOIL REINFORCEMENT

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TALKING TECHNICALLY

more than 50% of their maximum

static strength. In fact, in dynamic
testing, Swellex bolts elongated only
32 mm with a load of about 17 t on the
test to failure, absorbing about 5.3 kJ
of energy, which is similar to the
energy absorption capacity calculated
from static testing.
When the rockbolt was not
restrained, loading was not accompa-
nied by failure. The energy that a rock
bolt can accept is smaller when the bolt
is pinned inside the tube (Figure 4),
stretches to failure at the first blow. By
contrast, when the bolt is able to slide
slightly in order to avoid critical defor-
mation, the impact energy that can be
accommodated is quite a bit higher.
The mechanical properties of the Figure 3. Failure of Swellex bolt in shear.
bolts’ components can give instructive
insights on the energy absorption sliding is restrained. Profile deforma- energy through sliding, its energy
capability of a given bolt type. Table 2 tion during the tests ranged from 42 to absorption capability is enhanced.
gives some typical results from Kaiser 55 mm when the bolts broke. The Results from NTC’s tests on Swellex
(2, 3, 4) and from Noranda impact was localized on the head only (2003) and Cone bolts (1998) show
Technology Center (5). These results so the higher strength of the profile that, on a single event, it is possible
take in consideration only the elastic- could not be mobilized. to dissipate over 9 kJ with a Standard
plastic behaviour of the shank/body of Results from Kaiser et al. (3) as size Mn12 Swellex, which might be
the bolts when submitted to a static well as from Ortlepp and Stacey (1), more with rougher tubes and longer
load: the dynamic capacity is inferred outline the fact that most reinforce- bolts, and about 22 kJ with the Cone
in considering that the same load- ment fixtures have limited capacities bolt tested at NTC (Kaiser). These
deformation relationship would exist of absorbing energy when using values exceed by far any strain
during dynamic events. deformation/yielding properties, and energy accumulation mechanism. It is
In Table 3, results from dynamic values range from 1 to 25 kJ of important to understand that, in
testing are presented and, from energy at most. However, when a dynamic loading, ultimate load and
Ortlepp and Stacey (1), Swellex reinforcement fixture dissipates deformation are not the same as in
anchored in steel pipes could absorb Figure 4. Failure of bolt at pin location.
4 – 5 kJ of energy when sufficient
anchorage is provided, or when the
Table 3. Energy absorption
capacity from dynamic testing

Bolt Type Source Single

Event

Cone Bolt Kaiser Variable

(NTC) from and al. with
Kaiser and Max: 22 kJ
al.

Swellex Ortlepp 4.1 – 5.1 kJ

and
Stacey

Rebars Ortlepp 4.1 – 5.5 kJ

and
Stacey

Swellex Atlas 9 kJ
Mn12 Copco/
2.1 m NTC

ROCK & SOIL REINFORCEMENT 53

RR3/RT19 25/6/05 13:28 Page 54
TALKING TECHNICALLY
static loading, but the deformational
energy absorption seems to be quite
similar.
Tests results from NTC and Atlas
Copco also demonstrated another
important fact. This is that maximum
energy can be absorbed when the fric-
tion properties are tightly matched to
the strength of the material. When this
right combination is reached, the bolt
head will move just before the
shank/bolt body enters the deformation
phase. This allows maximum energy
absorption without failure of the unit,
and provides a consistent energy
absorption capacity, coupled with
stable static load bearing capacity,
equivalent to the rated capacity of the
bolt.
Conclusion
Dynamic testing at the laboratory has
shown that Swellex bolts can accept
and dissipate a reasonable amount of
energy without failing, and still provide
an adequate load capacity, as long as
the anchorage length is adequately
54
coupled to the static anchorage capaci-
ty. This operation was successful with
steel tubes instead of rock. The next
step is to increase the friction against
the bolt in order to simulate an anchor-
age capacity of 130 to 180 k/m, and
repeat the same testing with Mn24
bolts.
It is also very interesting to consid-
er what kind of energy dissipation
could be achieved when using an
Mn24 instead of an Mn12 bolt. As the
bolt itself is twice as strong, the maxi-
mum load could be doubled, and,
since the friction could be adjusted in
order to provide the right anchorage
capacity, the energy absorption could
certainly be in the order of +18 kJ per
event.
The conclusions obtained from
these laboratory tests is being
applied to the Hybrid Swellex bolt
that combines the controllable slid-
ing ability of the Swellex with the
strength and reliability of MAI
bars.
by François Charette
References
1. Charette, F. Performance of
Swellex rock bolts under dynamic
loading conditions, The South
African Institute of Mining and
Metallurgy. Second International
Seminar on Deep and High Stress
Mining, Johannesburg 2004.
2. Ortlepp, W.D., Stacey, T.R.
Testing of tunnel support: Dynamic
load testing of rock bolt elements to
provide data for safer support
design (GAP423), June 1998.
3. Kaiser, Canadian Rockburst
Design Handbook, 1995.
4. Kaiser et al, Drift Support in
burst-prone ground, CIM Bulletin,
March 1996.
5. Kaiser, Support Against Rock
Burst – Short Course 1995–2003.
6. Falmagne, V. Etude de fais-
abilité: tests d’impact sur Swellex.
Centre Technologie Noranda, Mai
2003.
ROCK & SOIL REINFORCEMENT
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TALKING TECHNICALLY

Slope Stabilization with Self

Drilling Anchors
Soil Nailing for
Reinforcement
Soil nailing is used to reinforce
and strengthen ground which has
questionable stability. Soil is gen-
erally a poor structural material
because it is weak in tension.
Steel, on the other hand, is strong
in tension. The fundamental con-
cept of soil nailing is to effectively
reinforce soil by installing closely
spaced grouted steel bars into a
slope or excavation, as construc-
tion proceeds from the top down.
A soil nail is therefore commonly
referred to as a “passive” anchor-
ing system, meaning that it is not
pre-tensioned, as is normal with
ground anchors.
Unstable slopes or excavations
consist mostly of unconsolidated
soils or deteriorated rock forma-
tions. To install conventional soil
nails, a cased borehole drilling
method is required to overcome
such difficult and unstable
ground conditions. An alternative
is the MAI Self Drilling Anchors
(MAI SDA), which is specially
designed for use in ground where
the boreholes tend to collapse
during the drilling process if
casings are not used.

Advantages of Self Drilling
Anchors
Since the slow cased borehole drilling
methods were superceded, the speed
of installation has increased consider-
ably, up to 20-30 soil nails/day using
MAI SDA, and the risk of re-drilling
time spent cleaning collapsed bore-
holes has been eliminated.
The selection of the drilling equip-
ment for MAI SDA installation is also
more flexible, especially for working
in confined space.
MAI SDA rods are manufactured
with a continuous ISO standard
Installation of SDA R38 N with ROC D7 at Carriere d’Arvel, Switzerland.
thread, affording the flexibility to
adjust the nail to the actual require-
ments on site, without waste or delay,
as construction proceeds.
Transportation and handling of
MAI SDA to and on site is safe and
economical, because of the commonly
used rod length of 3 m or 4 m. These
can be extended using couplings to
allow installation of soil nails up to 15
m depth, depending on the geology.
There is also the option to use simulta-
neous drilling and grouting installation
techniques.
Method of Installation
Self Drilling Anchors are installed
with air driven or hydraulic rotary
percussion drilling equipment, using
a borehole flush medium suitable for
the specific ground conditions.
There are three types of borehole
flush: water flush for long boreholes in
dense to very dense sand, gravel forma-
tion or rock conditions, for a better
transportation of large cuttings and cool-
ing of the drill bit; air flush for short
boreholes in soft soil such as chalk and

ROCK & SOIL REINFORCEMENT 55

RR3/RT20 23/6/05 10:18 Page 56
TALKING TECHNICALLY
clay, where water spillage is to be avoid-
ed; and simultaneous drilling and grout-
ing (SDG) for all lengths of boreholes in
all unconsolidated soil conditions.
Using SDG, the grout stabilizes the
borehole during installation, providing
Principle of the MAI Self Drilling Anchor.
56
a better grout cover along the nail
shaft. The grout has good penetration
into the surrounding soil, so higher
external friction values are reached,
and the installation is completed in a
single drilling operation, saving time.
By utilizing a sacrificial drillbit, the
MAI SDA is drilled continuously for-
ward without extraction, until the design
depth is reached. To reach a required nail
length of 12-15 m, the 3 to 4 m standard
rod lengths are easily coupled together.
ROC D7 offers excellent reach with a folding boom.
Galvanized MAI-SDA R 25 and R32 anchors
installed into loose and collapsing ground using
simultaneous drill and grout at the Shortlands
Junction, Bromley, Kent, UK.
When using the first two flushing
media for the drilling operation, the
soil/steel interface has to be created by
grouting through the hollow stem of
the anchor. The grout exits through the
flush holes of the drillbit, and backfills
the annulus around the nail that has
been cut by the larger diameter of the
drillbit.
For the third operation, the flushing
medium is already a grout mix, which
has the ability to harden after the
installation process is completed.
A typical application of SDA is
currently being carried out by the open
cast mine Carriere d’Arvel in
Switzerland. Here an Atlas Copco
ROC D7 drillrig equipped with a
Ceminject (integrated rotary injection)
adapter and a rod handling system is
being used for SDA installation.
The ROC D7 feed reaches to a
height of 7 m, allowing installation of
two rows of SDA from one position.
The rod handling system contains
at least two sets of three 3.5 m-long
R 38 N SDA rods, facilitating installa-
tion of two complete 10 m-long Soil
Nails without having to manually feed
ROCK & SOIL REINFORCEMENT
RR3/RT20 23/6/05 10:18 Page 57
extension rods at these extreme work-
ing heights.
The newly developed integrated
injection adapter (Ceminject) can be
used for either simultaneous drilling
and grouting, or as in this case, first
drilling to full depth with an air flush
and then grouting the annulus of the
borehole. The SDA installation
becomes a fast continuous mechanized
process with high grouting quality in a
safe working environment.
Similar methods were used to stabi-
lize the slope at Shortlands Junction,
Bromley, Kent, UK, where loose and
collapsing ground was affecting opera-
tion of the railway.
Installation Using ROC
Drillrigs
The use of self drilling anchors for sta-
bilization and reinforcement work in
soft rock is common both in the under-
ground world of mines and tunnels
and, for a wide variety of applications
on the surface.
On surface, it is generally poor
quality ground and soil that threaten
the stability of installations or land-
scapes. Embankments along roads and
railways, various types of foundations
and hills prone to landslide, and the
sidewalls of cut-and-cover tunnelling
are just a few examples.
Field tests have shown that the
Atlas Copco ROC D-series of drillrigs
can be used to install self-drilling
anchors (SDAs), as well as for blast-
hole drilling. Hence, contractors who
own one of these crawler rigs for quar-
rying operations are perfectly-
equipped to take on stabilization jobs.
ROCK & SOIL REINFORCEMENT
Atlas Copco ROC D7
installing MAI SDA
for soil reinforcement
using MAIm400NT
grout pump.
A simple conversion kit enables
this rig to be converted to an SDA
installation unit, without losing the
advantages of the ROC D7 standard,
high-tech features.
The rock drill is fitted with a kit
consisting of an Ceminject (integrated
rotation injection) adapter, swivel and
brackets to replace the standard shank
adapter. The SDA shank adapter is a
female shank having integrated coupling
sleeve to ease uncoupling. Available for
R32 and R38 anchors, it requires a
flushing head with inner diameter of 53
mm, normally used on surface crawlers,
because of the size of the female front
part of the shank adapter.
Ceminject is a SDA shank adapter
combined with a separate swivel pro-
viding flushing media and grout. The
swivel is mounted on the rock drill with
a bracket and has two separate inlets.
The Shank Connector is a coupling
sleeve locked to the shank adapter. To
provide the locking function a special
male T38 shank is required. This is an
alternative to SDA-shank, when
installing R51 or T76 anchors and when
alternation between bolting and blast
hole drilling is required. A flushing head
with inner diameter of 53 mm is needed.
The Rod Handling System RHS 52
is used for carrying bolts on surface
crawlers. The system is equipped with
SDA bushing halves in the gripping
arms and the star wheels carrying the
rods.
BSH 110 is a hydraulic drill steel
support providing gripping and guid-
ing function. To drill SDA it is
equipped with the rubber bushing and
steel bushing halves to match the
anchor size.
TALKING TECHNICALLY
The grout pump m400NT, available
from Atlas Copco MAI, is also recom-
mended.
Two-man Operation
Only two people are needed – one to
handle the drilling, and one to handle
the pump. The SDAs, with their R
threads and sacrificial bits, are
installed and grouted in one operation.
These easy adjustments will enable
ROC D7 owners to get the best, and
the most, out of their equipment. For
some, it may open up whole new mar-
kets that they have previously not
even considered.
The beauty of being able to adapt
the ROC D7 for such applications is
that the contractor can make full use
of the rig’s powerful and flexible
hydraulic system. The folding boom,
for example, can be positioned up to a
height of 7 m beside a slope, or very
low for horizontal toe-hole drilling. It
can also be positioned at extreme
angles, enabling SDAs to be used in
very inaccessible places.
Connecting Grout Pump
and Ceminject adapter
Most of the time there is a need to
alternate between flushing with water
and grout. In surface SDA installation,
it may be inconvenient to grout during
drilling, as this may contaminate the
feed with the grout, or minimize
spillage during collaring. The alterna-
tive is to flush with water when
drilling-in the anchor, and then grout it
through the Ceminject. This would be
the final step in the installation
sequence, prior to uncoupling the last
rod from the rock drill. To alternate
between water and grout, connect the
grout pump and water hose to a y-cou-
pling equipped with two valves, so
that water or grout may be selected.
The hose from the y-coupling is then
connected to the Ceminject, either
direct or by letting it run on the feed
through the hose tree and over the
hose drum. This type of y-coupling
requires manual switching between
water and grout.
When installing SDAs using a sur-
face drillrig, some contractors have
57
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TALKING TECHNICALLY
COP 1832 rock drill with Ceminject adapter.
Standard rod handling magazine with SDAs and couplings.
The special bushing halves prepared for firm gripping of the SDAs.
chosen to drill and grout simultaneously,
using only grout as the flushing
medium. This has the advantage that,
once the anchor is completely drilled
into the ground, it is fully grouted
and ready to be attached to the face
plate. This makes the connection
between the grout pump and the
Ceminject straightforward, needing
58
only a single hose. It is possible to
replace the hose for air flushing by
the grout hose by attaching it to the
hose tree and letting it run over the
hose drum to the rock drill.
To simplify the system further, and to
reduce number of people needed to do
the installation, two hoses can be con-
nected to the Ceminject, one to the grout
pump and the other to the water flushing
system on the rig. The water supply
hose should be equipped with a non-
return valve at the connection to the
Ceminject, in order to prevent grout
from entering the water system. The
two hoses can be put on the feed over
the hose drum.
This system makes it easier to con-
trol both water and grout flushing,
with the water controlled by a valve
on the rig, and grout flow by starting
and stopping the pump. The grout
pump can be controlled remotely by
the rig operator, or by the pump oper-
ator on demand from the rig.
SDA Installation Cycle
The optimal SDA installation cycle
comprises the following steps:
1. Drill first SDA rod, either with
simultaneous drilling and grouting or
with conventional air or water flush,
guiding with the Drill Steel Support
(DSS) in open position. When the rod
has fully penetrated into the soil/rock,
stop the flush and loosen the rod end
connection to the drifter by clamping
the DSS and unscrewing the female
shank adapter. Uncouple before
retracting the rock drill.
2. Extend with next rod using the rod
handling system, open DSS and com-
mence flushing, then resume drilling.
4. Repeat rod-adding sequence until
final design length of the anchor has
been drilled.
5. If simultaneous drilling and
grouting modus has been used, then
the installation cycle is now complete
and the feed can move to the next
anchor position.
6. In air- or water-flush modus,
switch over to grouting mode and,
while maintaining a slow rotation of
the anchor, commence grouting until
the hole is full. The in-situ rotation
mixing process of the grout guarantees
a homogeneous filling of the annulus,
improving corrosion protection and
external friction values of the
rock–grout interface.
7. The installation cycle is complet-
ed and the feed can move to the next
anchor position.
by Mark Bernthaler
ROCK & SOIL REINFORCEMENT
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TALKING TECHNICALLY

3D Images for the Design of

Rock Support
Reducing Rock Fall
Hazards in Tunnels
Rock blocks falling from the roof
or sliding into the tunnel can be a
hazard for the miners and equip-
ment, besides generating addi-
tional costs. Efficient
identification of potentially
unstable blocks and instant
design of appropriate rock rein-
forcement thus contributes to
safer and more economical
tunnel construction.
A recently developed imaging
system and evaluation software
assists in identifying unstable
blocks and design of rock sup-
port.

Introduction
Currently the assessment of potential
for excessive overbreak and disconti-
nuity controlled block falls or slides
heavily relies on experience.
Measurement of discontinuity pattern
and orientations is done manually, if
at all. The evaluation of the incom-
plete and inaccurate data with respect
to block fall hazard is slow, and usual-
ly does not allow for the determina-
tion of appropriate rock support in
time.
In order to master these shortcom-
ings with respect to efficiency and
accuracy, a 3D imaging system has
been developed consisting of an imag-
ing device and 3D evaluation software
components. Named the
JointMetriX3D® system, it unites sev-
eral features:
• Data (image) recording at the face
• 3D image generation and assessment
• Metric and accurate measurement
of discontinuity orientations, dis-
tances, persistence, and other geo-
metrical properties
• Link to other applications, such as
CAD
Evaluated 3D image generated with JointMetriX3D®. Joints are represented by traces and areas. The
arrows indicate the orientation of an area by its normal vector while the spherical triangles indicate the
orientation of the plane fitted through the trace. The absolute position and orientation of the joints is
directly determined.
A 3D image combines a large
number of three-dimensional surface
measurements with a high-resolution
colour image, thus easing visual
inspection of the rock mass.
Imaging at the Tunnel Site
The major goal is to record the actual
rock mass conditions comprehensively
by producing images that allow repro-
ducible assessments. The stereo-pho-
togrammetric principle of
JointMetriX3D® requires two images
of the same area captured from differ-
ent positions in order to obtain 3D
information. Currently, two options for
imaging are available. The first one
uses conventional calibrated single
lens reflex (SLR) cameras, while the
other uses a panoramic line scanner.
SLR Camera
A conventional SLR camera with a
minimum 6 MPix sensor is used to
take two free positioned images. In
order to allow for measurements, the
camera is calibrated. Scale and local
orientation is introduced by locating a
vertically levelled bar somewhere
within the region of the images.
The whole data acquisition process
requires only about one minute.
Processing the images leads to 6 MPix
3D images with several hundred thou-
sand 3D measurements.
Panoramic Line Scanner
For very high-resolution images, the
panoramic line scanner should be
applied. This scanner is capable of
producing images of more than 100
Mpix, recording very fine details.
During scanning, the device head
rotates, recording the face column by
column. A major advantage of the
panoramic principle is that existing
reflective targets in the tunnel can be
used to establish a reference of the
image to the tunnel. Data acquisition

ROCK & SOIL REINFORCEMENT 59

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TALKING TECHNICALLY
on site typically takes in the region of
ten minutes, leading to 3D images
which are referenced to the tunnel
coordinates.
3D Image Generation and
Measurements
From a stereoscopic image pair a 3D
image is reconstructed by purpose-
built software. This can be carried out
by personnel on-site or off-site, using
secure Internet connections.
Once a 3D image is ready, assess-
ments and measurements are taken
from it using the 3D software JMX
Analyst. This software allows the
inspection of 3D images thoroughly,
giving a realistic impression of the
actual conditions.
Measurements are taken directly on
the 3D image using the software, such
as:
• Joint locations, orientations, spac-
ing, persistence, etc.
• Lithological boundaries
• Areas
• Volume of overbreak
JMX Analyst contains a tool to plot
joint data in stereographic projection
and the variation of orientations of
joint sets (cone of confidence, spheri-
cal aperture, etc).
Rock block support by bolting during tunnel excavation .
Prediction and final design is based on the rock mass structure derived from JointMetriX3D® measurements.
60
All measurements are metric and An imaging system, such as
referenced either to a relative or the JointMetriX3D® can be installed on a
tunnel coordinate system, and can be drilling jumbo, allowing for an instant
exported directly into standard file for- imaging during work. Recorded data
mats. are transferred to the office for evalua-
A free copy of JMX Analyst is tion, and the necessary information for
available for download at www.joint- the rock reinforcement transferred
metrix.com/. back to the drilling equipment within
minutes.
Prediction of Block Failure
by Wulf Schubert, Markus Pötsch
Modes and Support Design and Andreas Gaich
The measurements derived from 3D
images are used to establish a consis- 3D imaging with SLR camera.
tent and accurate ground model. Using
the acquired information on the rock
mass structure, potentially unstable
blocks are identified with respect to
their location, volume, and weight.
Once the failure mode and the
properties of the blocks are identified,
the quantity, location and length of
required bolts to stabilize the blocks is
determined.
Further processing of the existing
data can be used to extrapolate the
rock mass structure in a representa-
tive volume around the tunnel,
allowing an assessment of the condi-
tions ahead of the face. This
enhances the quality of short-term
prediction, thus reducing any sur-
prises during excavation.
ROCK & SOIL REINFORCEMENT
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Introducing Swellex Hybrid
New Versatile
Rock Support
By combining the benefits of
Swellex bolts with those of the
MAI Self Drilling Anchors (SDA)
system, Atlas Copco has devel-
oped a new versatile type of rock
support that can be pre-ten-
sioned, grouted or use as a rock
reinforcement system for seis-
micity.
The new Swellex Hybrid pro-
vides immediate support, long
life expectancy and the level of
safety and productivity character-
izing Atlas Copco Rock
Reinforcement products. By cou-
pling MAI SDA bolt sections, the
system can be installed in very
tight locations to virtually any
hole length.
Competence Centre
The Atlas Copco Competence Centre
team was looking for a type of rock bolt
offering the following features: immedi-
ate and efficient support; immediate
anchorage in any type of rock; adapt-
able to any hole lengths; fast and trou-
ble-free installation; longevity when
required; pre-tensioning capacity when
requested; and the possibility to control
the anchorage capacity and behaviour
of the rock support to maintain the bolt
integrity in case of seismicity.
Shortly after Atlas Copco acquired
the reputable MAI SDA system, it
Hybrid bolt for long anchorage in rock.
ROCK & SOIL REINFORCEMENT
TALKING TECHNICALLY
became apparent that the solution was Components
to combine the two. 1-
1 Retainer
Equipped with a Swellex end, the
new rock bolt offers immediate
anchorage. As only a short segment of
Swellex is required, the product may
be installed in long holes by simply
adding new MAI SDA segments. 2-
2 Swellex Connectable
Good anchorage capacity in any type (blind segment)*
of rock is another advantage of using a
Swellex segment at the end of the bolt.
Furthermore, as a plate and nut are
fastened on the MAI rod side, real pre- 3-
3 Grouting valve*
tensioning is possible.
A special coupling has been devel-
oped to connect the MAI rods and the
Swellex segment for the purpose of
grouting, offering longevity while
4 MAI Anchor Rod R32
4-
adding stiffness in shearing. (hollow bar)
By limiting the length of the Swellex
segment, the anchorage strength can be
controlled. Sliding behaviour at high
tensile load consumes energy without 5-
5 MAI Anchor Coupling
compromising the integrity of the bolt,
with the insurance of a perfect, low-cost
installation every time.
Pre-tensioning and 6-
6 MAI Anchor Rod R32
Grouting
The vast majority of grouted rebars
and cable bolts are not pre-tensioned, 7-
7 Face Plate
mainly because this process is cum-
8
bersome and time consuming. The 8- Nut
need for pre-tensioning is higher if 99- MAI Anchor Adaptors
ground movement is likely to occur for Swellex inflation and
during the cement curing period. grouting
As pre-tensioning creates an active * Notes -
The Grouting valve(3) is included with the
support, larger stress can be absorbed special version of Swellex Connectable(2)
without rock failure. when Hybrid bolt is to be grouted.
- A standard Swellex Connectable blind seg-
The Swellex segment and the ment (2) is used when the hybrid is to be
grouting device are inserted first, fol- used for energy absorbancy.
lowed by as many MAI SDA rods as Installation sequence of Swellex Hybrid for
needed to reach the required length. pre-tensioning and grouting.
The Swellex segment can then be
inflated through the MAI SDA The grout then achieves higher
anchors. A plate and nut are installed strength and resistance.
after inflation to provide immediate
support and real pre-tensioning. Seismicity
Grouting can then be carried out
immediately, or later, once equilibrium Most of the present generation of rock
has been reached with no further bolts, such as cone bolts and durabar,
movement of the rock mass expected. that address the seismicity problem
61
RR3/RT24 19/7/05 8:48 Page 62
TALKING TECHNICALLY
use the same principle of having a part
of the system that can disengage and
absorb energy through friction or defor-
mation. The efficiency of these systems
depends on the quality of the installa-
tion, which varies significantly with the
quality of grout and de-bonding agent,
rock mass condition, and experience
and training. Often, because of poor
quality of installation, these systems
have not achieved the expected success
and efficiency underground.
The advantage with the Hybrid
system is that, once the anchorage
capacity (kN/m) is deduced from on-
site pull test of the short Swellex seg-
ment, it is easy to calculate the length
of the Swellex required to reach the
maximum sliding strength that would
not damage the bolt under dynamic
conditions, and the free sliding length
needed to dissipate the energy. The
installation is easy and, above all,
always perfect, as it is controlled by
the Swellex pump. The installed
system can also be tested at any time
to make sure it is working according
to calculation.
Site Testing
The Hybrid bolt is now being tested at
WASM facility in Australia to deter-
mine the optimal anchorage for maxi-
mal energy absorbancy of the system
under dynamic loading conditions. Both
the Hybrid bolt and its system of con-
trolled energy absorbancy are patented.
If, for example, a 1 m Swellex
Pm24C offering a 150 kN anchorage
is proven to slide (yielding strength =
200 kN) under dynamic conditions
without damaging the bolt, a sliding of
0.15 m would consume as much as
22.5 kJ of energy.
Once sliding behaviour is tested and
the system proven, a sliding pull test
(on a short bolt segment inflated) per-
formed on site will confirm the anchor-
age capacity. The length of the Swellex
will then be chosen to match the maxi-
mum sliding strength, and sliding dis-
tance calculated according to the energy
to be dissipated. This system offers the
facility to be tested at any time.
Recent studies have shown that the
quality of surface support is of para-
mount importance for ensuring the
62
efficiency of rock reinforcement for
seismicity, in order to make the system
absorb the energy and preserve the
rock mass between each bolt.
Life Expectancy
When it comes to protecting the
investment, for long life expectancy
Swellex Hybrid offers solutions to
match the threat.
When used for pre-tensioning and
grouting:
Atlas Copco has developed a spe-
cial grouting device that is coupled
between the Swellex segment and
MAI rods. This allows the Swellex
Hybrid to be inflated, pre-tensioned
when required, and then grouted
through the MAI SDA rods. The
grout then protects the Hybrid bolt,
preserving the MAI rods from contact
with the environment. For full protec-
tion from a corrosive environment, or
for long life expectancy, MAI rods
can be supplied galvanized, and
Swellex in Plasticoated or coated ver-
sions. The grout will then offer the
first protection layer, followed by the
zinc layer, or the plasticoating on the
Swellex. As the MAI bolts are grouted
from inside out, there is no access for
corrosive elements.
Installation sequence of the Atlas Copco Swellex
Hybrid.
When used for seismicity, Swellex
plasticoated and galvanized MAI SDA
anchors are recommended for corrosion
protection. A plug can be used to protect
the inside of the Swellex in the long term.
Installation Sequence
For pre-tensioning and grouting:
1-Drill the hole to the required
length using 48 to 51 mm bit.
2-Insert Swellex (the length can be
determined from pull test – should
be sufficiently long to generate pull
out resistance equal or higher to its
yielding strength into the hole).
3-Thread the SDA rod all the way into
the grouting valve on the Swellex.
Extend with additional SDA rods
and special Hybrid couplings (good
for 300 bar) to match the hole depth.
4- Install plate and nut
5-Attach inflation coupling to the
last SDA rod.
6-Inflate Swellex through the SDA
rods using a standard Swellex pump
having 300 bars in water pressure.
7-Open the grout valve (in the Grouting
device) by rotating the MAI rods by
a 1/2 turn anti-clockwise.
8-Detach the inflation coupling.
9-Pre-tension the bolt.
10-Grout (MAI 400 NT Grout Pump
is recommended).
For seismicity:
1-Drill the hole to the required length
using 48 to 51mm bit.
2-Insert Swellex (the length can be
determined from pull test – should
be sufficiently short to generate pull
out resistance lower to its yielding
strength into the hole).
3-Thread the SDA rod to the Swellex.
4-Install plate and nut.
5-Attach inflation coupling to the last
SDA rod
6-Inflate Swellex through the SDA
rod using a standard Swellex pump
having 300 bars in water pressure.
7-Detach the inflation coupling.
8-Pre-tension the bolt.
By combining the merits of the
Swellex and MAI SDA systems, Atlas
Copco has invented a completely new
approach to rock bolting.
by Mario Bureau
ROCK & SOIL REINFORCEMENT
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MINING WORLDWIDE

Swellex in Mining
Safe and Speedy
Support
Rock support is often a bottleneck in
the business of underground mining,
and an obvious solution is faster
rockbolting. The cost is negligible
when compared to the higher profits
that can be made by keeping equip-
ment fully and economically employed
to increase production.
The mining industry is increasingly
recognizing that Atlas Copco Swellex
rockbolts, which are quickly and
safely installed to give immediate
support, are speeding up operations
and boosting revenues. Over the past
two decades, the Swellex rockbolting
system has become world famous as
schedule. This means that operations must Bieniawski diagram showing stand-up
be synchronized so that one does not fall times for different spans and rock
the simplest, fastest and most reliable
ground reinforcement technology behind, holding up the others and wasting classes.
available. time and money.
The Swellex bolt is a folded steel The development of Atlas Copco’s
tube, which is inserted into a pre-
drilled hole in the rock. Water is
Rocket Boomer and Boltec rigs is
blasted into the tube at high pres- constantly reducing drilling time, making
sure, blowing out the fold and Swellex the perfect partner to provide
expanding the tube into the exact reinforcement quickly, so that the next
shape of the hole, adapting to every operation can start without delay.
irregularity.
Bolt installation takes less than 30
Drilling ahead of the tunnel face to
seconds, and provides full and imme- install bolts or grout as pre-reinforcement,
diate support along the entire hole is a common way of improving the rock
length, in ground conditions ranging quality before excavation takes place.
from the hardest rock to clay and Instead of relying on supporting the ground
even non-cohesive material.
The system speeds up rock rein-
following excavation, pre-reinforcement
forcement considerably and, over the increases rock strength prior to excavation.
years, has built up an enviable repu- There are several benefits to this. First,
tation for saving time and money, as a pre-reinforced rock mass will be less
well as providing a safer under- damaged, both by blasting and by the
ground environment for miners and
tunnellers alike.
elastic and non-elastic stress redistribution
In the tunnelling business, Swellex of the excavation process. Second, the
bolts are already accepted as the key rock mass is never without support, even
to better operational efficiency. Now at the split second following blasting of
they are ensuring higher advance the round. Third, the support can be
rates, productivity and quicker access
to orebodies in mines as well.
more active when installed early, rather
than passive when installed later. Fourth,
pre-reinforced ground will not deteriorate
Forward Stabilization Using or collapse as rapidly as a totally un-
Swellex supported excavation, allowing a safe
working period for installation of regular
In single-face development, high-speed support.
rockbolting obviously cuts the time to The Bieniawski diagram shows the rela-
completion. But in multiple face develop- tionship between the unsupported span and
ment or ore extraction, the objective is to stand-up time of an excavation with refer-
utilize manpower and equipment efficiently, ence to its rock mass quality. Empirical
as well as to advance the faces on observations have shown that, for a given

ROCK & SOIL REINFORCEMENT 63

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MINING WORLDWIDE
excavation size, a linear reduction in Rock
Mass Rating (Bieniawski, 1974) will lead
to a logarithmic reduction in unsupported
stand-up time. Hence, a linear increase in
excavation span results in a logarithmic
increase in instability potential. For large
span drifts, the time period available to
install roof support is significantly lower
than for small drifts. In the case of a 4.3 m-
span tunnel driven through poor to very
poor quality rock, it may be logistically
impossible to support the roof before it
collapses. Obviously, the operational and
safety implications of such cases are
important.
Field observations show that cable bolts
installed in stopes before the first blocks
are blasted are more effective than cable
bolts installed after the slot or cut has been
excavated. For cable bolts installed prior to
stope exploitation, the grout curing period
is generally respected. This is not always
the case for cable bolts installed during
Project: Underground gold mine pre-reinforcement.
Location: Mine Doyon, Rouyn-Noranda, Quebec.
Mining method: Longhole stoping with cemented rock fill.
Rock: Quartz and sulphide veins surrounded by seritic schist.
Rock reinforcement required: Protective umbrella in access
drift.
Rockbolt selected: Super Swellex.
Mine Doyon Experience
A variation of the umbrella method was
attempted at Mine Doyon, located near
Rouyn-Noranda, in northwestern Quebec.
The Mine Doyon property is one of the most
important gold-bearing orebodies in produc-
tion in Canada. At least four major ore zones
are found on the Doyon property. Economic
mineralization is found on a corridor that
extends at least 2 km E-W, and from surface
reaches a depth of over 1,000 m.
The No.1 Ore Zone is defined by a
major quartz and sulphide vein system,
oriented E-W. The orebody is also oriented
E-W, dips steeply south, and has an aver-
age width of 8 m at depth. It is surrounded
by sericitic schist corresponding to the
sub-unit 4b of the Blake River Group
(Savoie et al, 1991). Mining method is
long hole stoping, with cemented rock fill.
Mill production is around 3,500 t/day.
Several tectonic events have been
identified, among them a N-S compression
64
stope exploitation, when production con-
cerns may override ground support design
concerns. The cohesive effect of the cable
is greater when added to undisturbed
ground than when added to weakened and
disturbed ground.
In tunnelling, the umbrella grouting
method of pre-reinforcement is frequently
used. This method pre-supports the
planned roof area with steel rods. Large
holes are drilled in the future roof peri-
meter, and grouted at high pressure with
high strength, fine grained cement grout.
Through each cemented hole, a smaller
hole is then drilled, in which a high-
strength reinforcement bar is grouted.
Although highly effective for shallow tun-
nels driven in very adverse ground condi-
tions, it is easy to see that such a
work-intensive operation would be deemed
neither practical nor economic for mining
applications, although the underlying con-
cept could definitely be useful.
followed by a N-S extension; an inverse
shearing caused by a NW-SE compression;
and a polyphased fracturing caused by an
as-yet undetermined stress gradient.
The footwall of the No. 1 Zone is located
in very poor quality sericitic schist, with
Rock Mass Rating values between 0 and
30. This alteration zone runs for about 100
m up to the ore body, which is located in
very weak chloritic schists. Stope develop-
ment in this ore zone was delayed due to
repetitive caving in access drifts.
The rock mechanics engineer at Mine
Doyon designed a pre-reinforcement
method using cable bolts installed over the
future roof of the access drifts. An array of
nine 50 ft cable bolts was used to pre-
support the roof during drift development.
The method was successful from a rock
mechanics point of view, allowing three to
four rounds to be taken before installing
heavy support consisting of vertical cable
bolts and shotcrete. Primary support could
be installed during the normal cycle with-
out safety problems.
Although stability was achieved, pro-
ductivity was compromised, since the
bolter was tied up in stope preparation and
rehabilitation work. Also, since several
levels were being developed concurrently,
travel time for the equipment and cable
grouting crew was significant. A better
solution was needed.
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MINING WORLDWIDE

Requirements were: easy integration in

the normal development cycle; installation
before the next drift advance; effective
support; and reasonable cost.
In order to increase productivity and
regain some flexibility, it was decided to
try pre-reinforcement using Super Swellex
bolts instead of cables, and to slightly
reduce drifting length to about 3 m. Five to
six Super Swellex, parallel and spaced
60 to 75 cm apart, are installed sub-hori-
zontally over the perimeter holes. Holes are
drilled using the development drillrig. Pre-
reinforcement holes are 50 to 60 cm longer
than drifting length, to accommodate the
3.6 m-long bolts. Inflation pressure is 300
bars. Several variations of the method were
used to secure pillars and cuts in stopes.
With the Super Swellex bolts, produc-
tivity actually increased to the same level
as for ramp and drift development in fair to
good quality rock.
Since the few extra holes required for
the spiling bolts are drilled at the same
time as the blasting holes, and the bolts are
installed in the short period between
drilling and loading, this pre-reinforcement
method does not increase the excavation
cycle time. The experience was a total suc- stope have been developed using this Pre-reinforcement using Super Swellex
cess, and the method became a standard at method. Close cooperation between the at Mine Doyon, Canada.
Mine Doyon for bad ground conditions. engineering and production departments
Presently, around 300 m of access drift and made this success possible.

Detailed Research in Peru Project: Underground gold and silver mine.

Location: North-west of Arequipa, Peru.
The Ares Gold and Silver Mine is located
Excavation method: Drifting.
275 km north-west of Arequipa, Peru,
Rock: Variety of different rocks.
nearly 5,000 m above sea level. It is a new
Rock reinforcement required: Permanent and temporary support.
ore deposit in which the Victoria vein,
Rockbolt selected: Standard, Midi and Super Swellex.
nearly 2,000 m long and up to 200 m deep,
is the main mineralized structure.
The design of drift support in the mine
has been the subject of detailed research by
its soil mechanics team, and different types
of bolts were field-tested.
The final choice, for both permanent
and temporary support in the five different
types of rock at the mine, was Swellex
bolts from Atlas Copco. Super Swellex and
Midi Swellex bolts are being used in areas
where the metal content is high and recov-
ery must be around 95% and, in addition,
some 1,600 Standard Swellex bolts/month
are being installed at the mine.
Thanks to its special features, the
Swellex system has not only increased
safety, but has contributed to an increased
Installing Swellex at Ares mine.
advance rate and improved economy.

ROCK & SOIL REINFORCEMENT 65

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MINING WORLDWIDE
Project: Mine with copper, zinc, silver and gold.
Location: Near Val d’Or, Quebec.
Mining method: Longhole stoping with paste backfilling.
Rock: Volcanogenic massive sulphide deposit.
Rock reinforcement required: Support through fault zones.
Rockbolt selected: Super Swellex.
Louvicourt Solution
The Louvicourt Mine is a polymetallic ore-
body of copper, zinc, silver and gold,
25 km east of Val d’Or in northwestern
Quebec. It is a volcanogenic massive sul-
phide deposit, starting 47.5 m below
ground surface. It is part of the Abitibi
Greenstone Belt, within the Precambrian
Shield of eastern Canada. The orebody
dips 70 degrees north and strikes E-N-E
66
Super Swellex aids safe and cost effective development
at Louvicourt mine in Canada.
with a plunge to the east. Dimensions of
the orebody are 300 m along strike and
500 m along dip. Thickness varies from
20 m to 100 m. The mining method is long
hole stoping with paste backfilling.
Systematic stability problems are
encountered while drifting through fault
zones disseminated in the orebody. The
gouge associated with the faults, the
unfavourable dip of the two main joint
sets, and the intense black chlorite alter-
ation of the joints, contribute to the forma-
tion of high roof and unstable ground
conditions. Gouge thickness can reach up
to 90 cm.
An efficient solution to this problem has
been to use Super Swellex bolts as a pre-
reinforcement method. Three to four rings
of 3.6 m-long Super Swellex, on a 1.5 m x
1.5 m to 2.0 m x 2.0 m pattern, are
installed in the roof of the drift before the
next advance in the fault zone. The holes
are drilled 50 degrees upward, and the
bolts are inflated to 300 bars using a pneu-
matic Swellex pump. Steel straps are
sometimes used to increase support capacity
and cohesion. The immediate support
effect, and simplicity of the operation,
with minimum handling, are definite
advantages to using Swellex instead of
cable bolts.
The method creates a small increase
in normal cycle time, but the drilling
and installation time are more than
justified by the cost, risk and lost time
associated with rehabilitating a caved roof.
The collaboration of the production depart-
ment was crucial to developing the
method.
Such experience shows that Swellex
bolts can be efficiently used as a pre-
reinforcement system in order to improve
productivity and safety while excavating
tunnels in incompetent rock. The method
can be applied to systematically support
roof, or to prevent caving from a nearby
fault zone. The method is fast, improves
safety, and can be easily integrated into
development operations. Cooperation of
the underground department for testing is
paramount to the success of the technique,
as the experience of the miners and super-
visors is a valuable asset in improving
excavation methods.
ROCK & SOIL REINFORCEMENT
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MINING WORLDWIDE

Increased Output in Portugal Project: Underground copper mine.

Location: Southern Portugal.
The Neves Corvo Copper Mine in southern
Mining method: Drift and fill with benching.
Portugal, owned by Somincor, has recently
Rock: Orebody roof and walls.
increased annual production from 2.1 to 2.3
Rock reinforcement required: Faster bolting to increase
million t. Reserves are around 30 million t of
production.
copper and 1.9 million t of copper and tin ore.
Rockbolt selected: Swellex.
Some 95% of the ore is being extracted
using several mining methods: 60% of the
tonnage comes from a modified drift-and- Rockbolting is the bottleneck in the pro-
fill method, 20% from benching, 10% duction cycle, and several bolting units
from mini-benching, and the remaining have to be used because of the long dis-
10% from mining of the sill pillars. tances between the different faces,
Drift-and-fill mining is carried out by The mine blasts 25 faces/day to meet
13 face drilling rigs, of which nine are production targets, which means time is
Atlas Copco Boomer units. Two Atlas precious. Although the unit cost of Swellex
Copco Boltec rigs for mechanized rock- bolts might seem expensive compared to
bolting, equipped with the latest Swellex some other rockbolts, they have proved to
hydraulic pumps, have been put into pro- be the best solution in terms of the total
duction, and the time taken to install a installation costs.
Swellex bolt in a pre-drilled hole at the
mine is now less than 30 seconds.
For benching and mini-benching, the
mine is using three drill rigs, two of which
are Atlas Copco Simba units.
The two fully-mechanized Boltec rigs
are installing 2.4 m-long Standard Swellex
bolts in the roof and walls of the orebodies,
with an average spacing of 1 m. Swellex
bolts have been used at the mine for many At the Neves Corvo copper mine in
years, and more than 60,000 are installed Portugal, Sven Buskqvist, Wirsbo
annually. They are popular because they Stålrör AB, Antonio Rodrigues,
offer instant support with easy and fast Somincor, and Torres Marquez, Atlas
installation. Copco Portugal.

Systematic Support in Turkey Project: Underground coal mine.

Location: Çeltek, Asia Minor, Turkey.
At the Çeltek Coal Mine in Turkey, some
Mining method: Longwall mining.
300 km north-east of the capital Ankara, the
Rock: Seam roof.
support system of a gate road has been
Rock reinforcement required: Replace steel arches with bolts.
changed from the traditional steel arches to
Rockbolt selected: Standard Swellex EXL.
systematic support with Atlas Copco Standard
Swellex EXL bolts. This follows a joint effort
involving Atlas Copco Turkey and a team led After experiencing the speed and ease
by rock support expert Professor Erdal Ünal of the Swellex bolt installation, the mine
of the Middle East Technical University. The management and support crew agreed that
aim was to introduce the high load-carrying the system also offers value for money. ■
capacity and yielding characteristics of
Swellex to the country’s coal industry.
A universal pull-tester developed by
Professor Ünal’s team was used to show the
superiority of the Swellex bolts in terms of
speed, safety and economy.
Time spent on roof support in a cycle At Çeltek mine in Turkey, a Swellex
decreased from two hours to between 20 and bolt is installed to demonstrate its
30 min/m of advance in the gate road, result- unique ability to provide safe and
ing in an increased daily advance rate. immediate support.

ROCK & SOIL REINFORCEMENT 67

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TUNNELS IN AUSTRIA

Removing Bottlenecks in
Austria
Crossroads of Europe Project: Parallel tube for existing bi-directional road tunnel.
Location: Graebern, on A2 Vienna-Klagenfurt highway.
With its position in the heart of Excavation method: Drill/blast and mechanical excavation.
Central Europe, Austria serves as a Contractor: Joint venture of Ostu Stettin, Hinteregger, and Porr
transportation hub for virtually any
business needing to move goods Tunnelbau.
across the continent. Rock: Mix of biotite gneiss and non-glaciated folded, faulted,
For traffic between the Balkan and tectonised strata.
States and the north, or diagonally Rock reinforcement requirement: Spiling followed by
across Europe from east to south, immediate face support.
Austria presents the shortest route.
Indeed, the risk of traffic nuisance is Rockbolts selected: Super Swellex and self drilling anchors.
such that trucks are currently banned
from its highways during the night
hours.
In its efforts to upgrade to full
European standards, Austria is build-
ing more dual carriageways, and
driving parallel tunnels for a number
of existing bi-directional tunnels across
the country. In the tunnels, the latest
in Atlas Copco technology is being
employed, including the Rocket
Boomer L2 C and self drilling anchors.
Two such projects are the parallel
tunnel recently completed at Graebern,
on the Vienna to Klagenfurt section of
the important A2 motorway which
connects Vienna with Carinthia and
Italy, and a twin tube tunnel project at
Steinhaus, located near Semmering, a
favourite skiing destination for the
Viennese.

Second Tube for Graebern

The new 2.148 km-long tube was driven
parallel to the existing Graebern tunnel in
highly variable ground conditions. The
faces at either end were in different strata,
requiring a flexible approach to excavation
and support.
The contractors used some equipment,
such as the Atlas Copco Rocket Boomer
drillrigs, that was released following the
completion of the 9.9 km-long Plabutsch
tunnel, a similar dualling project on the A9
motorway at Graz.
Around 1.5 km of the tunnel was exca-
vated to standard 70 sq m section,
400 m of which was in excavation class 7
and needed a reinforced shotcrete or con-
crete invert, requiring an enlarged section
of 78 sq m.
An oversize safety section in the centre Atlas Copco Rocket Boomer L2 C at
of the alignment provides a third lane over Graebern south face.
a distance of 48 m, where vehicles may
park in an emergency, or possibly turn
around. They may also turn to enter a wide
cross passage leading to the second tube,
which is big enough for trucks.
South Attack
At the south end of the alignment, where
the rock was generally too soft for blast-
ing, an Atlas Copco two-boom Rocket
Boomer L2 C drilled for spiling and bolt-
ing in the top heading, so that the face
could be mechanically excavated.
The area was intensively folded and
faulted, with a mixture of competent and

ROCK & SOIL REINFORCEMENT 69

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TUNNELS IN AUSTRIA
Rock Support at Graebern Tunnel
incompetent rock. As there was no glacial
cover during the past million years,
glacial erosion did not remove the highly
tectonised and incompetent parts present at
the southern portal.
The centre section of the top heading
was generally left in place as a safety
pillar, to support the tunnel face
while sectional lattice arches were installed
at 1.0-1.2 m centres, together with
rockbolts and shotcrete. Part of the exca-
vated face was also temporarily secured
by 12 m-long self drilling anchors,
which were grouted in place. For systemat-
ic bolting, self drilling or cement grouted
anchors with lengths of 4 m or 6 m were
used.
When required, 25 mm-diameter, 4 m-
long pipe spiles were set around the roof
profile in 45 mm-diameter holes drilled by
the Rocket Boomer L2 C. Any blastholes
required were drilled using 45 mm Atlas
Copco Secoroc bits.
The top heading was followed by a 2.7
m-high bench and invert, which were ex-
cavated some 60-80 m back from the face,
but periodically slipped back to 150 m
behind the face.
Steinhaus at Semmering
The Steinhaus tunnel is on the B306
Vienna to Bruck road, which passes
through Semmering, a favourite skiing
resort for the Viennese. The B306 is being
upgraded, and will form part of the new S6
highway. This will connect with the San
Miguel interchange on the section of the
A9 Trans-European Highway between the
main centres of Graz and Linz.
The tunnel is twin-tube and 1.5 km-
long, on a double curving alignment
that takes it into the side of the valley
70
North Face
The north end of Graebern featured biotite
gneiss, a more-competent metamorphic
sedimentary rock with a high amount of
quartz and feldspar. Predominantly, the rock
mass was jointed and faulted, and so mostly
decomposed and friable. Therefore, spiling
with pipes was often an absolute necessity. In
addition, Super Swellex 4 m-long bolts were
set in the roof at the face as immediate support.
Regular support comprised 15 cm of
shotcrete with one layer of wire mesh and
4 m-long rockbolts. If spiling was re-
quired, lattice arches were erected, and
shotcreted in place. A three-boom semi-
automatic Rocket Boomer L3 C performed
the support drilling duties at the north end,
in addition to blasthole drilling.
Drilling of a full round of approximately
130 x 2 m-deep holes in the top heading took
an hour, in addition to a half-hour for charg-
ing and blasting. Blasting agents were dyna-
mite and cartridged slurry, with 19 intervals
of electronic detonators with millisecond
delays at 80 milliseconds per step. The
drilling rounds were set up using an array of
seven lasers to establish a perfect profile.
in which the village of Steinhaus is
located. It has been constructed by
Bilfinger Berger for the Austrian highways
authority.
The rock quality is variable, generally
soft and non-glaciated, comprising chalk,
phyllite, calcite and quartzite, with a maxi-
mum cover of 60 m.
The tunnels accommodate a two-lane
highway in each direction. There are three
cross-passages, with the middle one having
a large cross-section to facilitate the
switching of trucks between tubes in emer-
gency situations.
ROCK & SOIL REINFORCEMENT
RR3/RC2.qxd 23/6/05 10:59 Page 71
The full 80 sq m section of each main
drive was achieved with top heading,
bench and invert excavations. The faces
passed beneath some village houses with
around 50 m cover, and two blast vibration
monitoring stations were set up.
Cautious Advance
Work at Steinhaus commenced at the west
portal with a 47 m-long central pilot
tunnel, within which the pillar between the
two main tubes was cast using self-com-
pacting concrete. The separation over the
first 50 m of alignment was 2 to 4 m,
increasing progressively to 60 m at the
halfway mark. The rock pillar on the
second 50 m of drive was anchored using
pre-stressed bolts, tightened by plates on
both sides.
The drillrig fleet comprised three late-
series Atlas Copco Rocket Boomer 352S,
and one newer Rocket Boomer L2 C. They
spent 80% of their time drilling for rock
reinforcement because, generally speaking,
only 10-20 blast holes were required in the
faces of the top headings.
The faces, which were mechanically
excavated, were secured by up to nine 16
ft-long self drilling anchors with mortar
injection. Roof and side support was
achieved mainly with grouted rebars and
self drilling rockbolts from Atlas Copco
MAI, and five MAI M400 water mixing
pumps were used for grouting.
In order to maintain reasonable under-
foot conditions, a temporary shotcrete invert
reinforced with steel mesh was laid in the
top headings, every 4 or 5 arches on
advance. Drainage holes were drilled in the
face whenever necessary. Usually, three or
four arches were set at 1.5 m intervals in
each face during a 24 h cycle of three shifts.
Umbrella Working
At the 90 m mark on the south drive, a
20 m-high Karst cavity was encountered,
which, fortunately for the tunnellers, proved
to be dry. The drillrig was pulled back to
drill over the face and into the cavity.
Some 30 cu m of 8 mm concrete was
then pumped through the drillholes, using
one of the shotcrete jumbos. Advance over
a 10 m stretch beneath the filled cavity was
protected by arches of 20-30 spiles made
of 51 mm x 8 m-long R32 pipe installed at
2 m increments.
ROCK & SOIL REINFORCEMENT
TUNNELS IN AUSTRIA
Project: Twin tube 1.5 km-long road tunnel.
Location: Steinhaus on the B306 Vienna-Bruck road through
Semmering.
Excavation method: Mechanical excavation with some
drill/blast.
Contractor: Bilfinger Berger.
Rock: Soft, non-glaciated chalk, phyllite, calcite and quartzite.
Rock reinforcement requirement: Forward support and
immediate face support.
Rockbolts selected: Self drilling Atlas Copco MAI rockbolts.
Once into more competent ground, the Rocket Boomer 352S at Steinhaus
drillrigs were able to deliver 80-90 portal.
holes/round in the top headings, drilled to
depths of 1.5-1.7 m. Blasting was by mil-
lisecond and long delay non-electric deto-
nators and encapsulated slurry main
charge. The bench followewd at between
90 m and 220 m behind the face, where the
temporary invert was ripped out by an ex-
cavator with hydraulic hammer. A concrete
pump was stationed at each bench as a
convenient way of pumping shotcrete past
the ramp position, from where a mixer
truck transported it to the face jumbo.
Self drilling rockbolts have become
very popular in recent years, and are now
used in a number of different applications,
for both surface and underground drilling.
In tunnels, their primary use is for advance
support of extremely friable rock, or in
formations where the drill hole will col-
lapse before a normal rockbolt can be put
in place.
The bolt is made up of five essential
parts: a threaded bolt, a single-usage drill
bit, a connection casing, a screw plate and
a nut. The rockbolts are available in stan-
dard lengths, by the metre from 2-6 m-
long, with special customer-designed
lengths of up to 12 m. ■
71
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RR3/RC3.qxd 23/6/05 11:01 Page 73
Swellex in Extreme Temperatures
Hot and Cold Mining
Swellex rockbolts are used success-
fully in hot and cold extremes on
both sides of the world. Not only has
the bolt been found to perform to full
capacity in all temperature condi-
tions, but it has also found favour
with the operators. Because of its
light weight, and speed of installa-
tion, the operators are finding that
Swellex does not overexhaust them
under the rigorous conditions in
which they work. Another bonus is
that grout mixes and resin ampoules
are not required, significantly reduc-
ing the transportation costs to
remote mines, and limiting the fetch-
ing and carrying to be done under
extreme conditions. This is truly a
market sector where Swellex is
unbeatable!
Performing in Permafrost
The Raglan mine is located on the remote
Ungava Peninsula of northern Quebec,
where the mean annual temperature is
minus 10°C, with an ambient temperature
underground of minus 15°C.
It is a conventional shovel-and-truck
open pit, with an underground mine at
Katinniq, where there are two mining
methods in use: long-hole stoping and cut
and fill.
Although large stopes are not typical at
the mine, a stope opened in 2003 measured
160 m-long x 63 m-wide. The orebody is
wide, with limited height and strike length,
and the footwall dips at a bility is important.
45° angle, making most of it unfavourable
for development of longhole stopes. At
any given time, Katinniq has 10-15 stopes
in operation, with only one or two
being the more productive longhole
stopes. The rest are cut-and-fill which,
despite being more labour intensive,
account for over half of the 50,000-
55,000 t/month of ore produced.
Katinniq has reserves of 19.5 million t,
grading 2.85% nickel and 0.79% copper,
as well as significant recoverable cobalt
and platinum-group metals. The mine is
accessible by air, and linked by an all-
weather road to ship-loading facilities at
ROCK & SOIL REINFORCEMENT
CANADA & JAPAN
Project: Raglan Katinniq nickel mine.
Location: Northern Quebec, Canada.
Mining methods: Longhole stoping, cut and fill.
Operator: Falconbridge Nickel.
Rock: Blocky with permanently frozen fissures.
Rock reinforcement required: Long bolts not requiring resin.
Rockbolt selected: Swellex Mn24 and Connectable.
Location of Raglan Mine in Northern
Quebec.
Deception Bay, about 100 km to the east.
The nearest supply town is Rouyn-
Noranda, about 1,600 km south.
With the ground permanently frozen to
a depth of 425 m, rockbolting at Raglan
could be a difficult and time-consuming
procedure, without Swellex. Although the
cold makes working conditions difficult,
the ground is more stable because there is
no water moving through fissures in the
rock. The normal maximum stope size is
30 m-wide and 105 m-long, so ground sta-
The host rock is extremely competent,
with no ground stress problems. With
joint spacing over 2 m, the main rock
support consideration is the risk of
falling blocks. The mine generally uses
2.4 m bolts for stability, but these may
increase to 4 m-long or 5 m-long bolts
when big blocks occur.
Previously, the mine used mechanical
bolts and rebar set in resin for rock sup-
port. However, the mechanical bolts
required periodic re-tensioning to be effec-
tive. This was labour intensive, and the use
of resin posed significant logistical and
transportation problems.
73
RR3/RC3.qxd 23/6/05 11:01 Page 74

CANADA & JAPAN

Easy Installation fastening screens in the 5 m-wide drifts;

After an extensive research and testing
period, Raglan made the switch to Swellex
bolts in 1999. Since then, they have been
using Swellex almost exclusively, in order
to ensure consistent quality of rockbolting
while maximizing productivity.
At Raglan, all drifts are screened and all
stopes are bolted. The mine is budgeted to
use: 6,500 of the 600 mm Swellex bolts for
50,000 of the 1.6 m bolts used largely in
wall rock; 62,000 of the 2.5 m bolts used
for the back; and 2,000 of the 3.8 m Super
Swellex bolts as needed.
Raglan uses brine to expand the Swellex
bolts in order to avoid freezing problems.
This has not resulted in detectable cor-
rosion in the bolts, and recent pull tests
confirm this. Swellex Mn24 has now
replaced Super Swellex at the mine.

rock such as this, and rates the easy and

Project: Toyoha lead/zinc mine.
trouble-free installation system as a big
Location: Hokkaido, Japan.
plus.
Mining method: Sublevel stoping.
Toyoha uses up to 2,000 bolts/month of
Rock: Volcanic host.
the 2 m-long Midi Swellex type, which are
Rock reinforcement required: Easily installed non-grouted
well suited to the large diameter explosives
rockbolts.
now being used. The number of holes
Rockbolt selected: Standard and Midi Swellex.
required at the face has been reduced as a
result.
Hot Work in Hokkaido The operators prefer Swellex bolts
because they can be set in the hot condi-
Drillers at the Toyoha mine in Japan get tions without using a work platform, or
more than a warm welcome when they heavy tools and equipment. Two-thirds
arrive for work each day. Due to the vol- of the bolts currently used in the mine
canic rock in the area, the mine generates are Swellex. They are lightweight, easy,
rock temperatures of 130°C, and a heat- quick and safe to work with, and do not
wave follows the opening of any new require grouting, keeping the work area
areas. Humidity is extremely high, and clean. ■
it is not unusual to see jets of steam
coming from newly drilled rockbolt holes.
These are, indeed, extreme conditions
under which to install effective rock
reinforcement!
Toyoha, which is the world’s largest
producer of the rare metal Indium from its
lead and zinc operations, carries out sub-
level stoping in the steeply inclined ore-
body, where drifts are 3 m-high and
4 m-wide.
In these difficult conditions, and since
neither cement grout nor resins can be
easily handled in such high temperatures,
the mine uses Swellex rockbolts from
Atlas Copco for rock reinforcement.
Drilling and installation of 1.5 m-long
Swellex bolts in the normal pattern used at
the Toyoha mine to stabilize a round is
performed by a single miner in just 32
minutes. This is a very fast production rate,
especially considering the high temperature
and humidity. The key is in the Swellex
system itself, which enables bolt after bolt
to be expanded in just 22 seconds apiece.
The mine management insists that only
Installing Swellex at Toyoha Mine, Hokkaido, Japan.
Swellex can give superior safety in hot

74 ROCK & SOIL REINFORCEMENT

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KVARNTORP, SWEDEN

Coated Swellex Examined

Unique Testing
Opportunity
Not far from Orebro in central
Sweden lies Kvarntorp mine, a dis-
used underground sandstone mine
that has been converted as an
archive store.
The rock is sedimentary, occurring
in horizontal layers, with sandstone
overlain by shale. The sandstone is
porous, but relatively homogeneous,
varying from white to light grey in
colour. It is lightly laminated with
thin clay seams, which are often not
more than 1 mm-thick. The ground-
water is corrosive, so, when Coated
Swellex rockbolts became available,
the mine was quick to realize the
advantages, and began using them in
1987. Recently, tests were conducted
on two of these bolts that had been
installed nine years earlier, and it was making it difficult to establish the exact Cross-section of bolt No 1 shows
found that virtually no corrosion had conditions to which the bolts have been corrosion described as insignificant.
taken place.
exposed.

Support Investigation Rock Reinforcement

A few years ago, owner Yxhult AB experi-
enced a number of small falls of roof at
Kvarntorp mine. It was found that several
point anchor expander bolts installed in
1968 had rusted through 0.8 m inside the
rock, and had fallen out.
The Swedish industrial safety authority
requested Yxhult AB to launch an investi-
gation to determine the extent of the prob-
lem, and to recommend a rock support
programme that would ensure the safety of
people working underground.
The company contacted SvBeFo, the
Swedish scientific organization involved in
studying the behaviour of rock in mining,
construction and building, to solicit their
involvement. The Stockholm-based con-
sulting company Sycon was contracted to
carry out the investigation, and Atlas
Copco agreed to take part in the project.
The ground water in Kvarntorp seeps
through the overlaying shales, which have
relatively high sulphur content, and is
known to be corrosive. There was a con-
siderable amount of water present in the
rock during the excavation of the openings,
but this had disappeared over the years,
Support was exclusively by rockbolts,
installed vertically as the drives and rooms
were excavated. Expander type point
anchor bolts were used initially, then the
mine switched to cement-grouted rebar.
These were used from 1967 to 1969, when
they switched to resin-grouted rebar, and
in 1987 to Atlas Copco Swellex bolts.
The following rock bolts and grouting
agents were used during the production
phase of the mine: cement grouted rebar,
2.2 m-long; resin-grouted rebar, 2.2 m-
long, with two Celtite cartridges; resin-
grouted rebar, 1.8 m-long, with two Celtite
cartridges; and Coated Standard Swellex,
1.8 m-long.
During this development of rock sup-
port, point anchor expander bolts proved
entirely inadequate, and were replaced by
cement-grouted rebar. The disadvantage of
cement-grouted rebar is that it is messy,
time-consuming, and does not provide any
support before the cement hardens.
In 1969, the mine switched to resin
cartridges as the grout medium used to
install rebar dowels. This has the advan-
tage of providing more immediate support.

ROCK & SOIL REINFORCEMENT 75

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KVARNTORP, SWEDEN
Internal surface of bolt No 2 shows it However, it is still arduous and, as with
is practically free from corrosion. cement, there are high wastage factors.
Both resin and cement grouting of rebar
present the operator with a number of
installation quality concerns. These range
from inadequate grout in the hole or, as in
the case of resin, “over-spin” or “under-
spin”, both of which adversely affect the
support capability of the installation.
Coated Swellex
Swellex rockbolts are manufactured from
folded steel tubing that can be inserted in
the drill hole manually or mechanically,
and expanded with high-pressure water.
The installation takes a few seconds, and
the expanded bolt is pressed tightly against
the rock, deforming to the irregular sides
of the drill hole. This provides guaranteed
full column support, as the water pressure
is applied equally throughout the bolt.
Coated Swellex has a rubberized bitu-
men coating on the outside of the bolt. As
the bolt is expanded, this coating, which
is semi-viscous, is pressed into the
microstructure of the rock on the inside of
the drillhole. The coating provides a barri-
er between the rock and the bolt that pre-
vents the ingress of corrosive water. As the
coating completely covers the outside of
the bolt, and the bolt expands over its full
length, the result is a guaranteed quality
installation.
It was decided to perform pull tests on a
number of bolts at Kvarntorp mine to test
their integrity after having been in the
rock for nine years. The Swellex exceeded
76
their minimum specified breaking strength
during these tests.
Overcored Bolts
It was then decided to over-core two
Swellex bolts to establish their condition.
These were forwarded to the Swedish
Corrosion Institute for further examination.
All Swellex rock bolts are stamped with
an alpha-numerical identification. The
recovered bolts were marked 1.8 930125 B
STD Sweden, showing that this was a
1.8 m-long bolt manufactured in Sweden
on January 25, 1993. They were recovered
in mid-May, 2002, so were in the rock for
a little over 9 years.
At the Corrosion Institute, the rock cores
were removed and the bolts visually
inspected, after which cross-sectional pieces
were sawn out for more detailed inspection.
Observations by the investigating engi-
neer were that uniform corrosion on the
outside of the bolts was very small, less
than 0.1 mm-deep. Internal corrosion was
mostly non-existent, with a few small shal-
low patches. One of the bolts had two
small local corrosion penetrations that did
not affect the breaking strength.
Conclusion
The conclusion was that, after more than
nine years in the corrosive environment of
Kvarntorp mine, Coated Swellex bolts had
not lost any of their strength or support
capability. They were not involved in any
of the rock falls that had occurred.
Sycon made the following recommen-
dation: the area where the rock falls had
occurred should be re-bolted using 1.8 m
Coated Swellex bolts fitted with 150 mm x
150 mm bearing plates, installed 5
bolts/row, with 2 m between each row.
The result of this investigation establishes
Coated Swellex rock bolts as long term sup-
port suitable for use in a variety of environ-
ments. Situations differ from mine to mine,
and from tunnel to tunnel, and require care-
ful study by qualified people. However,
there is no doubt that mines and tunnels with
aggressive environments can benefit from
the many advantages of Swellex rockbolts.
The full report from the Swedish
Corrosion Institute is available from Atlas
Copco in English upon request. Contact
Turgay Ozan turgay.ozan@atlascopco.com
and ask for report number 80 103 (rev 1). ■
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NEVADA, USA

Tunnelling with Nuclear Quality

Assurance
Stability for a Project: Nuclear waste repository investigation.
Location: Yucca Mountain, Nevada.
Hundred Years Excavation method: TBM and roadheader.
Contractor: Kiewit/Parsons Brinckerhoff.
The construction of the Exploratory
Studies Facility (ESF) at Yucca Rock: Volcanic tuff.
Mountain has set new quality stan- Rock reinforcement required: Systematic roof support with 100
dards for tunnelling operations. It has year stability.
been proved possible to build a Rockbolt selected: Super Swellex.
tunnel according to nuclear quality
standards, while at the same time
maintaining flexibility for scientific
investigations and acceptable tun-
nelling productivity. The 7.8 km-long
ESF tunnel has been driven by TBM
within the rock formation that is
being evaluated to determine suit-
ability for the final repository, and
may become a part of the repository
itself.
The requirements on long-term
stability for radiological safety of a
future repository, in this case equal
to 100 years, resulted in rejection of
most available ground support prod-
ucts. Instead, Super Swellex rock-
bolts were chosen, together with
welded mesh and a rolled steel
channel, for permanent support in
the ESF tunnel. A similar system
was used to support the more
recent 2.681 km-long East-West
Cross Drift tunnel to investigate
ground conditions over the proposed
repository.
Tunnelling at Yucca Mountain
will probably go on for many more
years, adding invaluable practical
experience to the world’s pool of
knowledge of how to construct an underground laboratory for engineers Curved drive at Yucca Mountain ESF
repositories for nuclear waste. With and scientists to help determine the ability tunnel, close to Las Vegas.
nuclear waste accumulating in many of natural and engineered barriers to safely
other countries, this project is being store spent nuclear fuel and high-level
watched very closely by a number of radioactive waste in a geologic repository.
agencies around the world.
A large percentage of the ESF tunnel
design has been done according to a
Underground Laboratory Nuclear Quality Assurance program
(‘Q’-standard), similar to that used for
Yucca Mountain, located in the Nevada nuclear power plants. Ground support is
desert approximately 160 km from Las ‘Q’ classified.
Vegas, is today the only site that the US This has impact on ground support
Department of Energy (DoE) is studying design, type of ground support chosen,
for the nation’s first permanent high-level procurement of ground support products
nuclear waste repository. (including lifetime documentation and
The Exploratory Studies Facility (ESF), traceability of materials used in manufac-
part of the Yucca Mountain project, will be turing), installation of ground support, and

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The data gathered, together with results

and conclusions from the investigations,
will assist in the final decision on whether
Yucca Mountain is suitable for a nuclear
waste repository.
Yucca Mountain consists of layers of
volcanic tuff, with a total thickness of at
least 1.8 km. Most of the excavation will
be in the uppermost and middle Topopah
Spring formations, located approximately
300 m below the surface. This is the poten-
tial subsurface repository horizon, and is
more than 100 m above the groundwater
table.
The ESF has been geologically mapped
along its total length, using a 55 m-long
gantry built into the TBM trailing gear.

ESF Tunnelling Progress

Part of the ESF main tunnel with
typical ground support installed.
verification of the function of the products
used.
A 7.8 km-long tunnel, which is a part of
the ESF, has been completed. Investigations
to determine the suitability of Yucca
Mountain as a potential repository are well
underway, following which a repository
licence application will be submitted to the
Nuclear Regulatory Commission.
Exploratory Studies Facility
The 7.8 km-long, 7.6 m-diameter ESF
tunnel was excavated by Kiewit/PB using
a CTS TBM to a design by TRW
Environmental Safety Systems Inc. By
examining the surface and the underground
space that will be accessed via the ESF, the
scientists will be able to thoroughly inves-
tigate rock strength and movement,
groundwater, and earthquake and volcanic
activity.
Other factors that will be considered in
the site characterization include: geologic
history; geologic information; public
safety and concerns; local economic and
socio-economic impacts; environmental
concern; ease and cost of constructing and
operating the site; and the effect of high
temperatures on the strata.
The TBM was launched from a 60 m-long
drill/blast starter tunnel. The first part of
the ESF tunnel, the North Ramp, was
driven at a 2% downgrade against rock
beds dipping 2° to 15° to the east. The first
200 m of tunnelling were difficult, and
steel sets were installed on 1.22 m centres.
The Bow Ridge Fault, encountered
approximately 200 m into the mountain,
was filled with a soil-like, weak tuffaceous
material, having an unconfined compres-
sive strength as low as 1.4 MPa. Even
though the fault had slipped approximately
100 m, it was only a few metres wide.
After crossing the fault, the TBM entered
softer material in which steering was diffi-
cult. Ground was lost above the TBM,
necessitating backfilling and grouting of
the void created.
For about 1,000 m, tunnelling was
through the Imbricate Fault Zone, which
proved very difficult. Minor faulting
events had caused through-going joints,
oriented in the same direction, closely
spaced and nearly parallel. This, in combi-
nation with low stressed rock, led to block
fallouts, and steel sets combined with steel
lagging had to be used extensively.
Close to the Ghost Dance Fault, two
testing alcoves were excavated to gain
access to the fault deep inside Yucca
Mountain.
After approximately 2,700 m of tun-
nelling from the entrance at the North
Portal, the TBM reached the Topopah
Spring potential repository host rock at
approximately 300 m depth. In this forma-
tion, 3,000 m of the ESF main tunnel was

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NEVADA, USA

constructed using Swellex bolts, wire mesh

and rolled steel channels for support, and
high advance rates were achieved.

NQA System Applied to

Ground Support
Since the ESF is an underground labora-
tory, where rock characteristics are studied,
the DoE stresses that ground support must
not interfere with the geotechnical and
geological testing. Also, the final ground
support system must be installed as the
tunnel progresses.
The tunnel must be reinforced in such a
way that stored nuclear waste could be
retrieved 100 years after it is put in place.
Hence, the ground support must ensure tion to this, steel reinforced concrete Each steel set and position for the
long-term stability and maintainability. inverts were installed as the TBM Super Swellex bolts has a number, for
Cement grouted rebar bolts cannot be advanced, providing the surface and track the installation report.
used in areas where scientific investiga- to support the TBM trailing gear.
tions will take place, because the grout About 70% of the tunnel has been sup-
may penetrate rock fractures and contami- ported by Super Swellex rockbolts, with
nate test results. Also, due to the curing steel sets used for the remaining 30%.
time of the grout, this type of bolt cannot More than 20,000 Super Swellex bolts
be tested immediately after installation. have been installed in the ESF tunnel.
There is also a ban on the use of epoxy The Super Swellex rockbolt is a friction
resin based rockbolting systems, since the bolt manufactured by Atlas Copco. The
amount of organic material in the tunnel bolt is made from a welded circular steel
has to be minimized in order not to pose tube, then folded on itself into a ‘W’-shape
any threat to nuclear waste packages. to decrease the diameter. Bushings are then Installing Atlas Copco Super Swellex
The use of shotcrete is limited, since it pressed onto the collapsed steel tube, and from the TBM bolting station in
can interfere with geological mapping and the ends sealed by welding, to create a competent ground.
geochemical tests.
For many such reasons, Swellex rock-
bolts, manufactured by Atlas Copco, were
approved for permanent rock reinforce-
ment in the ESF tunnel.
Procurement of ground support materi-
als requires lifetime documentation and
traceability, from materials used in the
manufacturing, to fully inspected installa-
tions. Records are kept in a thorough and
precise way, and internal and external
audits are carried out to certify that every-
thing is done according to specifications
and procedures.

Ground Support System

As main support, 3 m-long Super Swellex
bolts complete with the domed Super
Swellex face plate on a 1.5 to 1 m pattern,
depending on ground conditions, were
used, together with a 250 mm rolled steel
channel and welded wire fabric (WWF).
The steel channel and WWF prevent rocks
falling from the roof of the tunnel. In addi-

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NEVADA, USA

spacing was 1,500 mm, with allowable

maximum of 1,687 mm. Spacing and pres-
surization of the bolts was monitored to
verify that they were properly installed,
with a pressure between 290 and 310 bar.
The Swellex pump unit was checked
with a calibrated gauge at least once a day
by the Shift Engineer to ensure that the
pump was giving the correct pressure.
During tunnelling, five out of every 100
rockbolts installed were tested to check if
the proof load was reached.
If the TBM entered a new geological
formation, five destructive pull-tests were
carried out to verify that the Swellex bolts
met the minimum anchoring requirement.
Complementary to this, 20 non-destruc-
tive pull-test were made. Not a single bolt
failed in the pull-out tests.

Using the drill feed to press the screen
against the rock while installing a
Swellex rockbolt.
confined space inside the bolt. A hole is
then drilled in the lower bushing. When
the bolt has been positioned in the bore-
hole, water is injected through the hole
drilled in the bushing, causing the tube to
unfold. At 30 Mpa the bolt is full expanded
in the hole, and the pump automatically
stops. As the pressure inside the bolt
reaches 30 Mpa, the steel tubing adapts to
the shape of the borehole, and may consol-
idate the surrounding material while it
expands to fit the irregularities of the hole.
The resulting frictional and mechanical
interlocking reinforces and increases the
stability of the rock surrounding the drilled
hole.
When each batch of bolts arrived at site,
the Kiewit/PB Quality Control group car-
ried out thorough tests and inspections to
verify that they had not been contaminated
or damaged, and that the dimensions were
according to the specifications.
Rockbolt drilling and installation was
carried out at two stations on the TBM. At
the first station, four Swellex bolts were
installed, together with the screen and the
channel. At the second station three holes
were drilled, and the remaining three bolts
installed, including the bolt located at the
highest point in the tunnel. The nominal
Future Tunnelling
Further tunnelling since completion of the
ESF tunnel has included the 2.681 km-long
exploratory East-West Cross Drift Tunnel
across the potential repository. This
employed a 5 m-diameter Robbins hard-
rock TBM, which started at an intersection
with the North Ramp of the ESF and, after
an initial curve, followed a tangential
alignment, and crossed over the proposed
repository block west of the main loop of
the ESF tunnel, to terminate in the
Topopah Springs geological formation.
Once again, Super Swellex 1.8 m-long
rockbolts were used for ground support on
a 1.2 m x 1.2 m grid over the full crown,
with welded wire mesh and 1.2 m-long
steel channels. A total of 20 steel sets was
required in only one area of the tunnel,
where the Super Swellex bolts could not
provide long-term support. The TBM aver-
age advance was 25 m/day over 106
mining days, with a best shift of 34.6 m,
best day of 73.2 m, and best week of
266.7 m. The TBM was mining for only
25% of the time, due to the concurrent
scientific and environmental experiments
being carried out.
The design of the repository is not yet
finalized. However, a system of tunnels
totalling more than 200 km is being
discussed in which more than 1 million bolts
will be installed over a period of 20 years.
Following the signing of the Yucca
Mountain Resolution on 23rd July, 2002,
the Nuclear Regulatory Commission is con-
sidering licensing the repository. ■

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Swellex Versatility in Tunnelling

Fast Installation and Project: 1.1 km and 2.3 km twin tube, three-lane road tunnels,
150 sq m section.
Immediate Support Location: Motorway between Germany and Czech Republic.
Excavation method: Drill/blast, top heading and benching.
Since the introduction of the Atlas
Copco COP series of high-performance Contractor: Walter Bau.
rock drills, drilling is no longer neces- Rock: Syenite, fractured and weathered in places.
sarily the bottleneck in tunnelling Rock reinforcement requirement: Immediate support, due to
operations. Mounted on sophisticat- large span.
ed rigs, drilling preset hole patterns Rockbolt selected: Super Swellex, and Boodex close to the
with contour and profile control,
these machines have encouraged portals.
their owners to reappraise every
aspect of the face operation.
Inevitably, focus has been brought
to bear on the rock reinforcement
systems in use, and their impact on
overall productivity. Fast drilling and
slow rockbolting rarely make eco-
nomic sense, not least because
expensive equipment may be under-
utilized, while conditions are made
safe.
In this environment, Swellex bolts
come into their own, as the most
cost-effective solution. They are fast
to install, and give immediate sup-
port, making the face available for
further operations in the shortest
possible time. The following case
studies trace this theme, through dif-
ficult motorway tunnels in Germany
and Spain, fast-advancing railway
tunnels in China and Switzerland,
and in the new road system on the
volcanic Atlantic island of Madeira.

Driving from Dresden to

Prague
The new 200 km-long A17 autobahn under
construction from Prague in the Czech
Republic to Dresden in eastern Germany
will provide the Czech capital with rapid
access to northern Europe and the North
Sea ports, and will also form a vital section
of the Trans-European road network.
The most difficult part of this section is
the 8.85 km-long alignment from Gorbitz
to Sudvorstadt, where contractor Walter
Bau undertook the twin-tube, three-lane
1.1 km-long Doelzschen and the 2.3 km-
long Coschutz tunnels using sequential
excavation techniques.
Both tunnel alignments are predomi-
nantly in syenite, a hard rock with around
Atlas Copco Rocket Boomer 352 umbrella drilling at Dresden.
10% quartz content. They were each

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driven by drill/blast in a single direction
from twin portals.
Top headings of 72 sq m section preced-
ed the benches, advancing mainly in soft,
mixed ground requiring a lot of support.
The full, flattened ovoid section of
150 sq m was achieved with a 41 sq m
following bench, and a 37 sq m invert.
A total of eight Atlas Copco Boomer
352 drillrigs were used for face drilling,
rockbolting, and umbrella drilling. Face
drilling in the top headings was undertaken
by two Atlas Copco 352 Boomers, stand-
ing side by side. The added flexibility of
the two-rig system speeded up the drilling
and charging process, to the extent that the
entire excavation cycle could be completed
in 2.5 h. This facilitated up to four rounds
in each 24 h period, leaving 14 h available
for support work and rock reinforcement,
much of which was scheduled for the night
shift.
Heavy-gauge steel arches were set in
the top headings, with two layers of Q378
steel mesh and two applications of shot-
crete to roof, sides and floor. A row of
4 m-long Swellex rockbolts was set in a
22 m-long radial arch at the face to give
Project: A dozen km-long road tunnels, each around 60 sq m
section.
Location: Madeira Island, a self-governing region of Portugal.
Excavation method: Drill/blast, mostly at full section.
Contractors: Zagope, Tamega, Epos, and Avelino Farinha &
Agrela.
Rock: Volcanic formations with lava streams, fractured basalt,
ashes and tuff.
Rock reinforcement requirement: Versatile system to cope with
extremely irregular geology.
Rockbolt selected: Standard Swellex.
Fast Bolt for Madeira
The chain of mountain peaks that forms
the Madeira Islands, an autonomous
Portuguese region with its own govern-
ment, rises some 5,300 m from the bed of
the Atlantic Ocean. Madeira is the largest
island of the archipelago, and is 57 km-
long and 22 km-wide. It has a population
of around 260,000, of whom 120,000 live
in the capital, Funchal. The islands are
located 545 km from the coast of north
Africa, having been formed by volcanic
eruption. The resulting mountains are
steep, and plunge from elevations of
82
early support, and 5% of these were ran-
domly tested at 10 t pulling pressure, as a
routine stipulated in the contract.
Where immediate support is required,
Swellex rockbolts can be in place and pro-
viding full support up to seven hours
earlier than conventional cement grouted
bolts. This was invaluable in the softer
ground towards the ends of the tunnels,
where pattern rockbolting was used.
Elsewhere, in better rock conditions, the
contractor favoured the system because
Swellex bolts are fast to install and offer
guaranteed support. The consistent use of
top specification rockbolts was reckoned to
improve the overall quality and integrity of
the tunnel.
When the ground got too soft for con-
ventional excavation, two Atlas Copco
Boomer 352 machines equipped with drill-
rod cassettes were available. These drilled
15 m-long holes around the periphery of
the crown, using Odex eccentric bits and
extension drillrods. The holes were then
lined with perforated steel tubes, through
which cement grout was pumped to form a
protective umbrella. Beneath this umbrella,
a 12 m advance could safely be made.
1,800 m into deep valleys. Roads are tortu-
ous and often dangerous, and travelling is
fraught with problems. Inland routes are
slow and winding, and the coastal roads
are fringed by high cliffs, and are prone to
rock falls caused by winter floods from the
mountains.
Tunnels have been employed to carry
the roads beneath the mountains and under
the cliffs, levelling the routes and making
them safer. The picturesque Via Rapida
road from the airport to the capital Funchal
is a typical example, running over bridges
and through 22 tunnels, with a further six
to be constructed.
The new Via Rapida tunnels were built
by three contractors: Zagope; Tamega; and
Avelino Farinha & Agrela. Rocket Boomer
104 and 135 drillrigs were used, two of a
total of eleven Rocket Boomer rigs that are
employed on tunnelling projects in
Madeira. Atlas Copco Swellex rockbolts
are also a favourite reinforcement method
in the typical strata of volcanic basalt and
tuff.
The Porto Moniz project, near São
Vicente, comprised five tunnels up to
1,269 m-long. It was designed to divert
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TUNNELS WORLDWIDE

heavy traffic from the scenic coastal road

that runs under the cliffs by the ocean. This
is a dangerous route, not least because of
rock falls and floods. Portuguese contrac-
tor Tecnorocha used three of their fleet of
nine Atlas Copco Boomer drill rigs
equipped with COP 1238 rock drills to
develop the tunnels. Blastholes were
4.2 m-deep, and advance varied between
3.5 m and 4 m/blast, resulting in an aver-
age advance of 7 m/24 h.
Standard Swellex rockbolts, together
with mesh and shotcrete, provided the per-
manent support, because they proved to be
the most cost-effective solution. The speed
of installation enabled Tecnorocha to finish
the project sooner, and utilize their equip-
ment more efficiently.
The Ecumeada Tunnel, built through the
Serra de Agua mountain in the centre of
the island, is the longest single tunnel at
3.1 km, and has cut driving time from the
north to the south coast by 20 minutes,
making the journey much safer.
Contractor EPOS excavated the tunnel
by drill and blast, using Standard Swellex
rockbolts, together with steel fibre rein-
forced shotcrete when the rock was good
enough, and steel arches, together with
wire mesh and shotcrete, when it was not.
The volcanic rock formations are prone to
change very quickly, and heavy water
inflows were often experienced. The geo-
technical engineer reported that the
Swellex bolts proved very quick and easy
to install, and provided good reinforcement Boomer 352 installed 15 bolts/h with a Porto Moniz, Madeira, where
in the constantly changing rock conditions. pneumatic Swellex pump, and up to 30 topography favours tunnels as a
Ponta do Sol was a project comprising bolts/h using a hydraulic pump. means of shortening distances.
three road tunnels, with a total length of Very large water inflows were experi-
1,900 m, where Avelino Farinha & Agrela enced, and a waterproof plastic membrane
used an Atlas Copco Boomer 352 for was installed prior to the final 25 cm-thick,
drilling the blast holes and bolt holes. cast-in-place concrete lining. The heads of
Rock reinforcement comprised Swellex all bolts were cut away to provide an even
rockbolts, wire mesh and shotcrete. A surface for the membrane.

Hong Kong Cannot Wait Projects: Tai Lam tunnel–West Rail, 5.5 km, 110 sq m. Black Hill
and Pak Shing Kok tunnels, 20.5 km on the MTRC (metro),
Major new tunnelling operations in Hong
80 sq m.
Kong have used Atlas Copco drilling and
Location: Hong Kong, China.
bolting equipment fitted with the very
Excavation method: Drill/blast, full section.
latest computerized capabilities, together
Contractors: Nishimatsu-Dragages joint venture, Dumez.
with Swellex rockbolts and full service
Rock: Mainly hard rock, such as granite.
back-up agreements.
Rock reinforcement requirement: High productivity systems to
The 5.5 km, 110 sq m Tai Lam tunnel
speed up excavation.
on the West Rail development was a
Rockbolt selected: Standard Swellex.
Nishimatsu-Dragages joint venture, with
the two contractors driving the single

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TUNNELS WORLDWIDE
Rocket Boomers WL3 C drilling tunnel from opposite ends. Nishimatsu’s
rockbolt holes at Tai Lam in Hong stretch was 2.6 km-long, and they achieved
Kong. an average advance of 200 m/month with
Rocket Boomer WL3 C rigs. Their best
monthly performance was 230 m, with two
blasts/day, using the fully-automated ABC
mode for 80% of the time.
Atlas Copco agreed a drillmetre con-
tract linked to spare parts and rock drilling
tools supply, as well as an around-the-
clock service arrangement.
The Black Hill and Pak Shing Kok
tunnel projects on the MTRC Tseung
Kwan O Extension are part of a 12.5 km-
Holding Fast on Slipping
Ground
In Spain, the Autovia del Cantabríco
motorway will eventually run some
500 km along the coast of the Bay of
Project: 1.3 km El Fabar, twin tube road tunnel.
Location: Northern Spain
Excavation method: Drill/blast, top heading and bench.
Contractor: Joint venture Dragados and FCC.
Rock: Weak strata of slates and fractured limestone.
Rock reinforcement requirement: Anchorage capacity, even in
clay-bearing formations.
Rockbolt selected: Standard Swellex.
84
long, five-station extension which will
serve a population of 340,000. A major
factor in the progress of both projects was
the performance of six Atlas Copco L2 C
Rocket Boomer rigs.
The Black Hill tunnels total 8 km, with
four tunnels designed to serve the up and
down trains of two MTR lines, and a
centre siding. Here, six junction chambers,
and two crossovers with 80 sq m cross sec-
tions, were excavated by joint venture con-
tractors Dumez of France and Chun Wo of
Hong Kong.
The contractor used three new Rocket
Boomer L2 C rigs for face drilling, and
two second-hand Boomer 281 units for
rockbolting. The rigs drilled 4.6 m rounds,
and some 30 m/day were achieved for all
four tunnels, with a best daily advance for
a single face of more than 12 m.
The Pak Shing Kok tunnels project was
also a complex job, with nine tunnels
totalling 6.4 km built by a jv of Hyundai
and Kier International. Tunnelling was car-
ried out in a mixture of volcanic tuff and
granite, using three Rocket Boomer L2 C
drillrigs with two booms, drilling to a
depth of 4.2 m. Poor rock areas required
around 60,000 cu m of fibre-reinforced
shotcrete, and some 5,000 Atlas Copco
Swellex rockbolts. Swellex was chosen
primarily for its fast installation time of
around one minute, compared to the 10-15
minutes for conventional bolts.
Although the tunnels are amongst the
most complicated on the MTR, the con-
tractor was able to maintain an average
progress of 550 m/month, completing the
job in less than a year, compared to the
forecast of 18 months.
Biscay, from San Sebastian in the east to
La Coruña in the west, linking the cities of
Bilbao, Santander, Oviedo, Gijón and La
Coruña. The project and works promoter is
the Ministry of Public Works. Parts of the
eastern section are already open to traffic.
Other sections, like the 65 km-long stretch
from Ribadesella to Gijón, are under
construction.
The 1.3 km-long El Fabar twin tubes, in
predominantly fractured limestone with slate
and quartzite, were driven by a jv of FCC
and Dragados using Atlas Copco Rocket
Boomer L2 C drillrigs on each face. Three
Atlas Copco Wagner ST 8A Scooptrams
were employed shifting the muck.
ROCK & SOIL REINFORCEMENT
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The 54 sq m top headings were driven
some 700 m from the east end, then the
whole operation moved to the west portals.
The top headings were holed through in
the middle of the tunnel before bench
excavation started. The Scooptrams were
fully effective at this range and section,
enabling the normal number of load/haul
operators to be halved.
The Boomer L2 C units drilled 40-50
blastholes per round, with the fractured
rock limiting depth to 1.5 m, and steel arch
support with mesh and reinforced concrete
was required. For every metre of advance,
ten 3.6 m Swellex rockbolts were installed
for instant support, in holes drilled by the
Boomer rigs.
A 24 h/day, 6 day/week schedule was
operated at the site, with the average daily
advance 4 m on each face.
AlpTransit, Largest European
Tunnelling Project
Lotschberg was being driven from the
south by a 9.38 m-diameter TBM from the
Raron portal and a similar machine from
the Steg lateral adit. Both of these were
gripper TBMs, each equipped with work
platforms with anchor drills immediately
behind the face. Rockbolting and meshing
was undertaken 4.2 m behind the cutter-
head, and this is followed by independently
operated shotcrete robots, which sprayed a
concrete lining over the crown. Yielding
Swellex was installed to counter expected
problems of rockburst, caused by the
increased overburden in competent gneiss.
In rockburst, the pressure builds up in the
rock around the tunnel perimeter, and can
yield explosively, causing dangerous
spalling. If the rockbolt is designed to take
up some of this swelling pressure, then the
bursting effect can be mitigated without
compromising on support.
Experience gained at Raron has been
used to develop the new Swellex
Manganese Line, which offers more load-
ing capacity and enhanced elongation.
COP 1432 rock drills speeded up the
drilling, and the easy and fast installation
of the Swellex bolts provided immediate
support behind the TBM. The TBMs
advanced an average of around 90 m/week.
ROCK & SOIL REINFORCEMENT
TUNNELS WORLDWIDE
Rocket Boomer L2 C in top heading at El Fabar.
Projects: Gotthard base tunnel, 57 km; Lotschberg base tunnel,
34 km.
Location: Switzerland
Excavation method: Drill/blast, full section and top heading;
TBM 9.43 m diameter.
Contractors: Satco jv (Mitholz), MaTrans jv (Raron), Ast-
Holzmann (Amsteg).
Designers: Consortium of best Swiss engineering and
consulting companies.
Rock: Mainly hard rock such as granite, limestone, schist,
gneiss, granodiorite, amphibolite.
Rock reinforcement requirement: Safety; versatility to cope
with geology and load requirements; high productivity with
drill/blast and TBM; some rock bolts have to withstand rock
bursts.
Rockbolts selected: Standard Swellex, Super Swellex, Yielding
Super Swellex.
Operations in the north were concentrat-
ed at the lateral adit at Mitholz, from where
two faces were driven south, and one north,
using Atlas Copco Rocket Boomer XL3 C
three-boom rigs. These are each followed
by a suspended trailing backup carrying
transformers, cable reels, ventilation fans
and ancillary equipment. A full 8 m-wide x
8.5 m-high face was drilled to 4.5 m depth
for each blast. During and after mucking
out, the blasted area was mechanically
scaled, and the roof and sides were shot-
creted. Some 20-30 Swellex 3 m or 4 m
rockbolts were then installed into holes
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TUNNELS WORLDWIDE

At Alptransit Gotthard, contractor Ast

Mountain of Swellex at Mitholz on
AlpTransit Lotschberg.
Atlas Copco Rocket Boomer XL3 C, one
of three delivered to Mitholz.
Holzmann completed the 1.78 km Amsteg
access adit on a 1% downgrade through the
Aar Massiv and Erstfeld gneiss to the main
tunnel horizon, where four faces were
established.
An Atlas Copco Rocket Boomer 353E
drillrig was used on the adit to drill a full
face of 105-110 holes to an average 3.5 m
depth. The face took around 1 h 50 min to
drill out, and the holes were charged with
aluminized slurry with non-electric detona-
tion. Average daily advance was 10 m, or
four rounds.
Swellex rockbolts of lengths 3 m or 4 m
were installed into holes drilled by the
Boomer 353E, using the rig basket for
access. Following each second round of
advance, a 5 cm layer of shotcrete was
applied to the roof. A further 5 cm of fibre-
reinforced shotcrete was then applied to
the walls, and another 2 cm to the roof.
At the base of the adit, a 90 m-long x
13 m-wide x 12.5 m-high transformer
room was excavated, again using the
Rocket Boomer. This was advanced as an
8.5 m-high top heading and 4 m bench to
create a 125 sq m cross-section, reducing
drilled by the Boomer XL3 C. In squeezing
to 108 sq m at the back. Most of the sup-
ground, wire mesh and fibre reinforced
port was by 3 m and 4 m-long Swellex set
shotcrete were used, and, in the extreme
in 38 mm holes.
south of the drive, where crystalline rock
The junction with the running tunnels is
may produce rockbursts, Swellex
hugely impressive, particularly in view of
Manganese and MAI SDA were used.
the 1,000 m of overburden at this point.
The profile of the running tunnels was near
perfect, with average overbreak of
18-22 cm measured by the Bever profiler
on the drillrig.
Two 9.58 m TBMs started on the
11.4 km drives towards Sedrun in mid-
2003, with 40 m-long crosspassages at
320 m intervals.
In the opposite direction, excavation
towards the portals has not yet started.
Meantime, Murer and Strabag have driven
a 1.88 km-long cable tunnel between the
transformer room and the existing Amsteg
power station using a Robbins 3.7 m-diam-
eter hardrock TBM.
Swellex has a prominent role in
AlpTransit, since Swiss designers can rely
on the safety and controllability of its
installation, as well as its versatility, which
is particularly important in long and deep
tunnels. Contractors are happy that
Swellex is a good investment, improving
productivity and helping to keep costs
under control. ■

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Rapid Support Behind the TBM
Improving Utilization
For TBM tunnelling, the Alpine and
Appenninic geology of Italy is both
good and bad. The relatively hard
rock suits TBM tunnelling, but
volcanic and seismic activity over
the millennia has rendered it highly
fractured and disturbed, requiring a
relatively high degree of support.
TBM utilization in Italy can be as low
as 30% to 50%, with rock support
and reinforcement accounting for
50%, or more, of the total production
time.
When rock support is required in
conjunction with a TBM operation,
consideration must be given to
the type of support required, and
how quickly it can be installed. In
highly fractured rock, reinforcement,
principally rockbolts, should be
installed as quickly, and as close
to the face, as possible. However,
for most types of TBM, installing
support close to the face results
in downtime. Given the relatively
high cost/m of TBM tunnelling,
such stoppages are a major concern
for both the contractor and the
client. Developments in the speed
and ease with which support can
be applied to improve TBM utiliza-
tion are of interest to all parties
involved in TBM tunnelling in dis-
turbed rock. The main challenge is to
limit machine downtime and increase
productivity while at all times
respecting safety requirements. At
Alassio, the client specified Swellex
and supplied a stock of bolts to the
contractor, such was the interest in
improving TBM utilization.
ROCK & SOIL REINFORCEMENT
ITALIAN TBM APPLICATIONS
Project: Pilot tunnel for motorway link road.
Location: Alassio, Italy.
Excavation method: Open face TBM.
Contractor: Ilbau srl.
Rock: Soft, dry, non-abrasive calacareous marls, some clay and
blocky rocks.
Rock reinforcement required: Fast, dependable roof support
with five-year life.
Rockbolt selected: Swellex.
Alassio Motorway Link Road
Ilbau, a division of Austrian contractor
Strabag, has excavated a total of over
100 km of TBM tunnels, of which more
than 50 km are in Italy. The company
employed its veteran 3.6 m-diameter Jarva
Mk12 TBM to excavate the pilot for the
2.4 km-long two-lane road tunnel on a new
link road between Alassio and the nearby
Genoa-Firenze motorway. The four-lane
highway was built in the 1960s, and passes
through many tunnels and over many
bridges on its route parallel with the Italian
coast. As with all TBM projects, the aim at
Alassio was to install adequate support
with minimum impact on TBM productivity.
With a stroke of 1.2 m and a cutterhead
body of about 2 m, the Jarva TBM allowed
installation of immediate support within
3 m of the face. However, since this
involved TBM downtime, it was kept to a
minimum, with most support work carried
out concurrent with TBM advance from
the platform on the trailing backup some
16 m back. This also allowed installation
of truly radial rockbolts in the crown.
Ground support by rock classification
behind a TBM.
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RR3/RC7.qxd 23/6/05 11:13 Page 88
ITALIAN TBM APPLICATIONS
Table 1. Comparison of rock classifications methods.
Class Bieniawski 1973 Deere 1969 Barton 1974 O-Norm
RMR RQD Q Class (3.9 m dia. TBM)
I 83 90 33.0 F1-F2
II 67 75-90 12.5 F3
III 52 50-90 8.5 F4
IV 29 25-50 1.5 F5
V 15 less than 25 0.09 F6
As part of its contract, Ilbau was respon-
sible for the design of the pilot tunnel sup-
port. For more reliable estimating, and
easier communication with its client, Ilbau
developed a rock class and support mea-
surement system specifically for TBM tun-
nelling (Table 1). Adapted from established
Austrian practice, the table not only consid-
ers the most appropriate rock support for
given rock conditions, but also specifies
where, and how quickly, the support should
be installed. In better rock conditions
(Classes F1, F2 and F3) bolts, mesh and
shotcrete could be installed from the work-
ing platform without interrupting TBM
progress. In Classes F4, F5 and F6, support
must be installed as close to the face as pos-
sible, and requires a halt in TBM advance.
Class F7 constitutes rock with no self-
supporting capacity. In such conditions,
ground consolidation techniques, or full
lining support with ribs and timber lagging
or bolted liner plates, may be required. In
zones of extremely difficult ground, con-
solidation and support measures ahead of
the TBM should be considered.
At Alassio, because of the potential
impact on TBM utilization, the payment
schedule for rockbolting and other support
requirements varied according to where it
was installed, with higher unit prices for
support installed close to the face, involv-
ing TBM downtime.
The client specified the use of Swellex
for rock reinforcement at Alassio, and sup-
plied the requisite bolts to Ilbau for installa-
tion. Although sometimes perceived as more
expensive than alternative rock support and
reinforcement systems, the unit price of
Swellex becomes substantially less signifi-
cant when compared with the costs saved in
labour and TBM downtime. The easy han-
dling of Swellex is welcomed by tunnelling
crews, and its geomechanical properties and
speed of installation are attractive to consult-
ing engineers, clients and contractors.
Alassio geology comprises mainly soft,
dry, non-abrasive calcareous marls with
88
defined bedding, some clay content, and
zones of fractured and blocky rock. Rock
quality tends to change very rapidly, and
often from stroke to stroke of the TBM.
As a rock reinforcing tool, Swellex is
effective over a particularly wide range of
rock and soil types. In Ilbau’s table of rock
support for instance, Swellex is applicable
in all classes requiring rock bolts, from
class F1 to F6. By specifying Swellex, there
is no need to keep a stock of any other type
of bolt on site. Together with its ease of
application and immediate support poten-
tial, Swellex has the all-round advantage.
In the first 1,918 m of the Alassio pilot
tunnel, required support was mostly that of
types F2 to F4, with 15% in type F5. Swellex
reinforcement over the same length averaged
about four bolts/linear metre, 60% of which
were 1.5 m-long, and the remainder 2.1 m.
Support installed was about 10% more than
originally estimated, with a corresponding
10% reduction in productivity.
Swellex, wire mesh and shotcrete were
used in fault zones where roof falls had
occurred. In other areas, thin layers of shot-
crete spalled off, with small falls of rock
away from bedding planes. These created no
serious safety hazards, and confirmed that
Ilbau was installing adequate support for a
pilot tunnel, neither too much, nor too little.
Rock support accounted for approxi-
mately 50% of TBM downtime on the
Alassio pilot tunnel, with most falling into
support types F2 to F4, and 15% in type F5.
To monitor the quantity and quality of
support installed, the client’s consultant
geologist visited the site about twice a
week. In addition, the consultant monitored
geotechnical instrumentation installed by
Ilbau. Along the tunnel there were 15 con-
vergence measuring stations, and three sta-
tions containing three groups of 1.5 m, 3 m,
and 4.5 m long extensometers in the crown
and into each wall, as well as five tangen-
tial and five radial pressure cells. Data
gathered greatly assisted the main tunnel
final support and lining designs.
The TBM completed the 2,472 m-long
pilot tunnel in eight months, working
127 h/week on a 2 x 11 h shift/day, 5.5
days/week, and broke through on schedule.
Average advance was about 15 m/day, with
a best advance of 53 m/day in class 2 rock,
installing 110 bolts, mainly from the backup
platform. This was close to the optimum
60 m/day achievable in a short tunnel oper-
ating a single track muck hauling system.
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ITALIAN TBM APPLICATIONS

Val d’Arzino Water Diversion Project: Water diversion tunnel.

Location: Arzino River, Pordenone, Italy.
The Val d’Arzino is north of Venice, near
Excavation method: Robbins 4.5 m-diameter TBM.
the border with Slovenia and Austria. A
Contractor: Ilbau, Austria.
scheme to divert water from Arzino River
Rock: Limestone and marl, interspersed with mudstone,
to the city of Pordenone included a tunnel,
claystone and weathered formations.
5.7 km long, 4.5 m diameter, with a slope
Rock reinforcement required: Rapid support behind TBM in
inclination of 1.5% to 2%, mostly through
variable strata.
stable limestone and marl strata. The older
Rockbolt selected: Swellex.
formations overthrust the younger strata,
and the tunnel crosses the main fault zone.
The area is highly seismic, and, in 1976, a
major earthquake with epicentre near the
Val d’Arzino was apparently linked to the
faults crossed by the tunnel. The rock
encountered along the tunnel alignment
demonstrated a large variation in stability.
A large section of the tunnel (63%) was
driven through good, fair or fairly unstable
rock (Class Fl to F3), but the remainder was
through difficult, unstable ground (Class F4
to F6). The weak formations include rocks
such as marl, mudstone and claystone, with
faults, overthrusts, and weathered rock close
to the surface or affected by underground
water. The challenge was to select a
machine with high productivity in good
rock, but which would still be able to over-
Effect of rock conditions on the 4.5 m TBM at Val d’Arzino.
come difficulties in weak and unstable rock.
The contractor, Ilbau, used a brand new
Robbins TBM, with Swellex rockbolts as
support. Average advance rate was
20.9 m/day and 453 m/month, and highest
advance rate was 90 m/day and
808 m/month. TBM utilization varied from
a maximum of 45% in Class Fl to a mini-
mum of 8.5% in Class F6, averaging
25.6%. The penetration rate was between Rock class distribution at Alassio.
5.5 m/h in Class Fl and 3.5 in Class F5.
Rock reinforcement took 44.4% of the
total time. The contractor worked 2
shifts/day, 11 hours/shift.
Best performance was 54 m/day in
Class Fl, but a significant achievement was
7.4 m/day in Class F6, where heavy rock
reinforcement was required, and only 2 m
to 4 m/day would be expected. It is inter-
esting to note that the good overall perfor-
mance was achieved in spite of two poor
months of around 50 m/month.
A delay was caused by an unexpected
methane gas inflow emanating from a
black marl formation, which accumulated
close to the machine and caused an explo-
sion. Luckily nobody was injured, but tun-
nelling stopped for three weeks to upgrade
gas detection, install safety devices, and
improve ventilation systems.

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ITALIAN TBM APPLICATIONS

Alto Adige was a pilot project for Italy

Project: Underground sewage treatment plant and tunnels.
as a whole, with a view to building other
Location: Media Pusteria valley, Alto Adige, Italy.
facilities such as reservoirs, storage depots,
Excavation methods: 3.9 m-diameter TBM, drill/blast.
car parks and sport and recreational facili-
Contractor: Ilbau srl.
ties underground.
Rock: Alpine schist.
The plant consists of a 950 m-long,
Rock reinforcement required: 3 m and 4.5 m bolts for pilot
3.9 m-diameter headrace tunnel, which
tunnel and cavern support.
conveys the sewage into large caverns
Rockbolts selected: Standard Swellex, Super Swellex.
where screening, desanding, degreasing,
preliminary sedimentation, biological and
chemical treatment, are carried out.
Alto Adige Treatment Plant Some of the resulting sludge is pro-
cessed for agricultural applications, and
The Alto Adige area of the Italian Alps is a some is converted into biological gas to
paradise of mountains, valleys and rivers, feed a built-in heating plant, achieving a
where protection of the environment is of 50% saving in energy costs.
paramount importance, especially as the The headrace tunnel and 326 m-long
local economy relies heavily on tourism. pilot tunnel for the central cavern were
This was uppermost in the minds of plan- driven by an Atlas Copco Jarva Mk12
ners when a sewage treatment plant TBM. Standard Swellex bolts were
became an urgent necessity in the Media used for reinforcement in the pilot tunnel,
Pusteria valley, near the Austrian border. and more than 4,000 Super Swellex in
Rather than upset the environmentalists, 3 m and 4.5 m lengths were used for
they opted to place the 25,000 sq m plant reinforcement of the central and side
underground. This plant is the first of its caverns.
kind in central Europe, and will serve Blasthole drilling was carried out by an
95,000 people, cleaning 95% of phospho- Atlas Copco Boomer H 188 two-boom rig,
rus, nitrogen and other oxygen-depleting equipped with service platform. In the
pollution out of the waste water. The plant drilling and bolting operations, Atlas
will occupy the smallest possible surface Copco Secoroc rock tools were used
area at the bottom of the valley, eliminat- throughout, drilling 51 mm and 64 mm
ing odour and noise, and will also be safer holes. Bolting, using both Super Swellex
in the event of earthquakes. The design and cable bolts, was carried out with an
and size are in accordance with the latest Atlas Copco rig equipped with a BUT 35
European regulations, and will achieve boom and automatic rod adding system. A
strict purification limits. service contract provided for regular
maintenance of the COP rockdrills,
TBM usage statistics for different rock types. which were dispatched to the Atlas
Copco workshop in Milan after every
Relation between Classification, ROP and TBM Utilization 5,000 drillmetres.
Above ground, an Atlas Copco ROC
Rock ROP Utilization Daily Thrust Cutter load Torque 612HC with folding boom was used for
(m/h) % average (bar) (t/cutter) (amps) benching on the construction site where
(m/day) the administration and service buildings
J1 4.61 35.2 35.7 99.5 14.3 125
were erected.
The site manager found it a great bene-
J2 5.88 38.0 49.2 82.7 11.9 138 fit to have a single supplier covering the
J3 3.96 47.1 41.0 93.1 13.4 137 job, for drillrigs, rock drilling tools, and
T1 4.71 46.6 48.3 86.9 12.5 133 rock reinforcement. In addition, where
R 7.70 25.6 43.3 73.7 10.6 144
drilling long holes for bolting in a narrow
space is normally difficult, the rod
LT 5.27 19.9 23.1 56.1 8.1 114 adding system on the BUT 35 boom made
F 5.22 21.4 24.5 62.4 9.0 130 it easy.
CF 5.28 38.4 44.6 76.2 10.9 128 The geologist found that the Swellex
bolts fulfilled their safety function
J1 to LT are volcanic rocks-pyroclastites. excellently in the schist rock. They were
F and CF are Brixen quartz-phyllites. fast to install and gave immediate rock
support. ■

90 ROCK & SOIL REINFORCEMENT

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WORLDWIDE HYDRO

Swellex in Large Hydroelectric

Projects
Construction Reliability Project: San Roque on Agno River, 345 MW.
Location: Philippines.
International consultants are increas- Excavation method: Drill/blast.
ingly specifying Swellex in their Contractor: Raytheon Ebasco Overseas Limited.
designs for hydro projects, because
of the need for absolute controllabil- Designer: Golder Associates.
ity of installation. Unlike railway and Rock: Mainly volcanic tuff.
highway tunnels, hydro tunnels are Rock reinforcement requirement: Quality control, capacity to
not easy to inspect, so there has to work in soft and weak rock.
be a greater emphasis on reliability Rockbolt selected: Super Swellex.
of construction methods and materi-
als. The fact that projects can be
designed in one country for construc-
tion in another, using materials from
a variety of sources, can be a cause
of great concern to both the hydro
tunnel designer and his client. Using
Swellex as the specified support
system reassures both parties that
the quality, flexibility and reliability
factors are fully covered.

Removing the Bottleneck at

San Roque
US contractor Raytheon Ebasco Overseas
Ltd. (REOL) was responsible for the San
Roque dam project on the River Agno in
the Cordillera Mountains of Pangasinan
province, about 250 km north of Manila,
the Philippines capital. The 1,100 m-long,
188 m-high dam embankment is believed
to be the biggest in Asia, and is the twelfth
largest in the world. It will create a vast
14 sq km reservoir for recreation, provide
downstream irrigation to 87 sq km of farm-
land, and supply power to the national grid
from the dam’s integral 345MW hydro-
electric power station.
Three diversion tunnels were designed to
accommodate a flood flow of 4,600 cu m/sec.
The two largest high-level tunnels are
16.5 m-high, 11 m-wide and horseshoe-
shaped. They will each cater to flows up to
2,100 cu m/sec. The remaining 400 cu m/sec
of flood water will go through the smallest
low-level tunnel, which is 817 m-long, 6 m
x 6 m, and also horseshoe-shaped. It will
normally have a flow of about 120 cu m/sec.
The underground fleet at San Roque
comprised 22 Atlas Copco Wagner
Scooptram loaders and Mine Trucks, the
first such equipment to be used in the Three diversion tunnel portals at San
Philippines. Six ST-7.5Z loaders worked Roque.
on the main tunnels, matched by the same
number of MT-436B mine trucks. These
were supported by a further ten of the
smaller Wagner ST-2D units for use in the
dam’s grout gallery tunnels. When the size
of the tunnels was increased, six of the
Wagner ST-2D loaders were replaced with
the larger Wagner ST-3.5 units.
Exceptional availability of between
92% and 96% was achieved, exceeding the
85% guaranteed by Atlas Copco. Atlas
Copco Wagner’s comprehensive preventa-
tive maintenance programme, combined
with operative training, which is part of the
company’s on-site full service package,
was the key to the equipment’s success.

ROCK & SOIL REINFORCEMENT 91

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WORLDWIDE HYDRO

of 7 m/day was achieved on each face,

Installing Super Swellex at San Roque. Super Swellex was specified by the
designer, Golder Associates of Georgia,
US, as the regular pattern bolt. This
hydraulically-expanded bolt gives immedi-
ate rock support and full column bond, and
has an excellent quality control procedure
during its installation. An average advance
generally from two 4 m rounds. After
drilling, blasting and mucking out, the
exposed rock was sprayed with 50-75 mm
of fibre-reinforced shotcrete before instal-
lation of the 4 m-long Super Swellex bolts.
A second application of shotcrete was then
applied to produce a smooth 350 mm-thick
tunnel lining.
Immediate rock support was especially
important when facing the soft and un-
stable rock at San Roque. Moreover, in
such rock conditions, reinforcement is a
bottleneck in the excavation cycle, so the
contractor was pleased with the oppor-
tunity to use a fast and trouble-free bolt
like Swellex to speed up production.
The 11 m-wide, 8 m-high benches
remaining in the two large tunnels were
duly excavated on schedule before the start
of the typhoon season. The Atlas Copco
Wagner fleet then moved on to muck out
two 1,500 m-long tunnels at the site, a
7 m-diameter irrigation tunnel and a 9 m-
diameter tunnel to the main powerhouse.
San Roque Power Corporation will sell
and supply electricity to the national grid
from 2002 for 25 years, before transferring
ownership to the Philippines National
Power Corporation.

Atlas Copco Boomer H178 face drilling
at Uri hydro scheme.
Economical Support Solution
at Uri
The Uri project is located in the foothills
of the Himalayas, in the Kashmir Valley of
northern India. The new hydropower plant
will harness the flow of the Jhelum river,
and its 480 MW turbines will supply
much-needed electricity to the region.
Urico contractors, a design/construct
joint venture led by Skanska and NCC,
employed six Atlas Copco Boomer H178
drillrigs on the development of 22 km of
tunnels at Uri. The Boomer H178, with its
three booms, was selected as the most flex-
ible machine available to excavate faces of
cross-sections between 25 and 100 sq m,
together with the 22 m-wide machine hall
cavern. Average progress in the tunnels
was 250 m/week, with a best week of
278 m. Atlas Copco assisted the contrac-
tors with an extensive training programme
to teach the local employees how to
operate the rigs.
Rock reinforcement at Uri consisted of
shotcreting and bolting, with Swellex com-
prising 75% of the bolts used. The drillrigs
were used for all rockbolting work,
installing 700 x 3 m-long bolts/week.
Swellex was chosen wherever possible,
because they are quicker to install, and
more economical overall, than grouted

92 ROCK & SOIL REINFORCEMENT

RR3/RC8 23/6/05 11:16 Page 93
rebar bolts. Indeed, in places where water
was flowing, Swellex was the only realistic
option. The rock encountered varied from
quartz schist to shale, with some of more
recent volcanic origin.
Construction at Uri involved the exca-
vation of 1.2 million cu m of rock under-
ground, and the placement of 375,000 cu m
of concrete lining along the 15 km of water
tunnels.
Right Combination at Alto
Lindoso
Atlas Copco was the main supplier to
Italian contractor Torno for the Alto
Lindoso 600 MW underground hydroelec-
tric plant located in northern Portugal,
close to the border with Spain. The com-
pany provided all of the drilling equipment
needed for 12 km of headrace, tailrace and
access tunnels. The power generating plant
was installed in a chamber 70 m south of a
110 m-high arched dam with a span of
296 m near the confluence of the Castro
Laboreiro and Lima rivers, which provides
a maximum head of 338 m.
Atlas Copco helped train the drillrig
operators and maintenance personnel, and
provided a manned workshop container for
hydraulic service operations at site.
The five Boomer rigs employed drilled
mainly in hard granite with a compressive
strength of between 1,800 and 2,000 bar.
Around the tailrace tunnel exits, the
ROCK & SOIL REINFORCEMENT
WORLDWIDE HYDRO
Project: Uri hydroelectric power station.
Location: Northern India, Jammu and Kashmir.
Excavation method: Drill/blast, top heading and bench.
Contractor: Joint venture Skanska and NCC.
Designer: Skanska/NCC.
Rock: Variable, from weak to hard rock.
Rock reinforcement requirement: To cut bottleneck in
production cycle.
Rockbolt selected: Standard Swellex.
Project: Alto Lindoso hydropower.
Location: Northern Portugal, close to Spanish border.
Excavation method: Drill/blast.
Contractor: Torno Construction.
Client: EDP – Portugal National Power Board.
Rock: Hard granite, weathered granite, schists, and shales.
Rock reinforcement requirement: To provide temporary
support for access ramps, tunnel and chambers.
Rockbolt selected: Standard Swellex.
drillers faced weathered granite, as well as
some schists and shales.
Torno operated a two-shift system of
12 h/shift, gaining advances of 3.5 m/round.
Swellex rockbolts were used exclusively
for rock reinforcement, complemented
where necessary by shotcreting, wire mesh
and steel arches. The combination of Torno
skills with Atlas Copco service succeeded
in completion of what had previously been
a very troublesome project, and Alto
Lindoso is now contributing power to the
Portuguese national grid.
View of dam site at Alto Lindoso.
93
RR3/RC8 23/6/05 11:16 Page 94

WORLDWIDE HYDRO

six turbines installed. By the early 1990s,

Project: 40 m-deep open pit at Ybbs-Persenbeug power station.
more capacity was required, and it was
Location: River Danube, Austria.
decided to install an additional 48 MW
Excavation method: Hydraulic breakers and excavators.
turbine.
Contractor: JV of Mayreder-Kraus, Porr, Universale, Hofmann
The project involved the excavation of a
Maculan, Stuag, Ilbau, Strabag.
180 m-long x 40 m-deep x 20 m-wide
Rock: Faulted bedrock.
open pit alongside the existing station,
Rock reinforcement required: To secure vertical faces of open
without interrupting its operation. Trials
pit.
with drill/blast indicated an unacceptable
Rockbolt selected: Super Swellex up to 12 m-long.
high level of vibration which, combined
with faulting in the bedrock in the vicinity
Super Bolts on the Danube of the station, threatened the existing tur-
bine installations.
The River Danube drives turbines in no It was decided to use hydraulic breakers
less than nine power stations as it wends and excavators, together with additional
its way through Austria. The oldest, at rock reinforcement of the vertical walls of
Ybbs-Persenbeug, was built in 1959 with the pit. The design consultants advised the
client that cement-grouted rockbolts,
General view of open pit at Ybbs-
which take up to a week to set, would
Persenbeug power station.
cause excessive delays to the project.
Accordingly, it was decided to use Atlas
Copco Super Swellex bolts which, even in
the long lengths required in this unusual
installation, take only 15-20 minutes to
install, including the time spent drilling.
Bolts of lengths 8 m, 10 m, and 12 m
were guided into the 48 mm-diameter drill-
holes by hand, and then pushed home by one
of the two Atlas Copco drillrigs employed at
site. Some 2,000 Super Swellex bolts were
used, 900 of which were 12 m-long.
The bolts gave instant support to the
walls of the pit, helping keep the project on
time and within budget. The chief engineer
of the joint venture constructing the power
station observed that it would have been
impossible to stick to the construction sched-
ule without the rapid and secure installation
offered by the Swellex bolting system.

Inserting 12 m-long Swellex rockbolt

to support the cut beside the Danube.

94 ROCK & SOIL REINFORCEMENT

RR3/RC8 23/6/05 11:16 Page 95
Rock Mass Stabilization at
Tala Hydro
Tala Hydro scheme has been constructed
in the remote Himalayan kingdom of
Bhutan, using more than 40 items of capi-
tal equipment supplied by Atlas Copco.
The dam site is about 85 km by road from
the border with India, and is located near
the village of Wangkha, on the Wangchu
river, some 3km downstream of the exist-
ing Chukha tailrace outfall.
Hindustan Construction found MAI
anchors were crucial for stabilization of
the walls of the desilting chambers at Tala,
and as primary support during excavation
of the Head Race Tunnel (HRT). The same
anchors have also been found to be very
useful in reducing pore water pressure
behind the support system.
Major features of Tala are: three desilting
chambers sized at 250 m x 13.9 m x 18.5 m;
a 22.97 km-long, 6.8 m finished diameter,
50 sq m modified horseshoeshaped, con-
crete-lined headrace tunnel (HRT); and an
underground powerhouse 206 m-long by 19
m-wide and 45.5 mhigh, with transformer
cavern 191 m-long by 16 m-wide and 27 m-
high. The HRT, which has been excavated
at 7.5 m-diameter with rock cover of 60 m
to 1 km, utilized five construction adits. In
the tunnels, Atlas Copco Boomer 352s were
used in rock classes 1, 2 and 3, where the
average advance was 120 m/month, and in
class 4 rock up to 70 m/month. Class 5
rock, which had to be fully ribbed at 60-75
cm intervals, strutted, bolted, meshed and
shotcreted, slowed advances to 30 m/month.
The Atlas Copco Secoroc button bits were
reported by the contractors to have
S.D. Jeur, Project manager, Hindustan Construction
Company, C4 Package used Atlas Copco Odex for
piperoofing, in combination with MAI SDAs, to make
tunnelling possible through soil.
ROCK & SOIL REINFORCEMENT
WORLDWIDE HYDRO
Project: Tala Hydro on Wangchu river, 1,020 MW.
Client: Tala Hydro Power Authority (THPA).
Location: Wangka, Kingdom of Bhutan.
Excavation method: Drill/blast.
Contractors: Jaiprakash; Hindustan Construction; Larsen &
Toubro.
Rock: Gneiss with quartzite bands and biotite schists.
Rock reinforcement requirement: Roof support.
Rockbolt selected: MAI SDA.
achieved up to 30% longer life than
expected.
Hindustan Construction used MAI self
drilling anchors (SDA) for stabilizing the
reinforced concrete wall of desilting
Chamber No 3. The wall of the chamber
was anchored to the deeper competent rock
using one row of 114 MAI SDA with 20 m
length and 38 mm-diameter at 3 m centres,
and another row of 36 MAI SDA with 24
m length and 51 mm-diameter at 3 m cen-
tres. 32 t pull out tests conducted on the 38
mm-diameter and 20 m-long MAI SDA
resulted in displacements of 11 mm and 17
mm respectively, well within specification.
Hindustan Construction used the
Drainage, Reinforcement, Excavation,
Support Solution (DRESS) in the 330m-
long section of HRT affected by adverse
geology in Package C4. Here, MAI SDAs
were used both as radial bolts and as
drainage elements, in combination with
Odex Piperoofs. For anchoring steel arches,
SDA of 8-12 m lengths were installed in a
systematic pattern. If no water seepage
resulted, they were grouted. Two 38 t pull
out tests were conducted on 38 mm-diame-
ter, 8 m-long MAI anchors to check the
efficacy of grouted anchors in the poor
strata in the HRT. These passed, with dis- Atlas Copco Boltec 435H at work in
placements of 16 mm and 22.8 mm.■ Tala headrace tunnel.
95
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MAINLAND JAPAN

Top Combinations in Japan

Speed with Safety Project: High Speed Railway, Daini Shibishan.
Location: Kyushu Island, Southern Japan.
Tunnelling operations in Japan are to Excavation method: Drill/blast.
the highest standards of quality and Contractor: Kajima-Zenitaka-Shita joint venture.
safety, and Swellex was originally
introduced as a problem solver in spe- Project Owner: JR – Japan Railways.
cific rock conditions such as high Rock: Weak formation of shale, sandstone and clay strata.
water inflow and squeezing ground. Rock reinforcement requirement: Versatility to cope with
Since then, Swellex has been used to geology, immediate rock support, non sensitive to water inflow.
replace steel arches on a number of Rockbolts selected: Super Swellex, Midi Swellex.
projects, to good effect. Experience
obtained on the more difficult projects
has led to Swellex being specified as a
pattern bolt in current projects,
mainly where grouted rebars are con-
sidered too slow to install and take
load. Wherever there is rapid defor-
mation of the strata, Swellex is the
bolt of first choice because of its fast
installation and immediate load bear-
ing characteristics. In Japan, it is a
popular combination of speed with
safety, controllability and reliability.

Bullet Train Secured on

Kyushu
Daini Shibisan is a twin-track railway
tunnel, part of the high-speed railway system
under construction between Kagoshima and
Kumamoto on the large island of Kyushu, business of having to re-excavate rock Portal at the Daini Shibisan high speed
south of the Japanese mainland. when it had been deformed by less- railway tunnel.
The 3,394 m-long tunnel, one of thir- effective reinforcement methods.
teen in the section, was excavated by the The site manager described the Swellex
Kajima-Zenitaka-Shita joint venture, who contribution to the operation as highly
had to overcome major problems with the valuable, and an extremely efficient and
amount of groundwater present in the reliable method of dealing with the porous Installing Swellex rockbolts at the
sandstone, shale and clay strata. and highly-fractured rock formation. Daini Shibisan face.
Drilling and reinforcement was compli-
cated, with some holes collapsing as soon
as they were drilled, making it virtually
impossible to inject the cement required to
grout rockbolts. The solution was Atlas
Copco Swellex rockbolts, which expand to
fill the hole, need no cement, and have the
advantage of providing immediate rein-
forcement to the surrounding rock. Atlas
Copco Boomer drifting rigs installed the
bolts, which were expanded using an ESP-
A51 electric Swellex pump.
In this type of environment, Swellex
bolts are known to perform much better
than conventional bolts, and are also more
cost-effective. Their introduction into
Daini Shibisan tunnel ended the expensive

ROCK & SOIL REINFORCEMENT 97

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MAINLAND JAPAN
Project: Chou Highway,
Shin-Iwatono tunnel.
Location: Honshu
Island, Central Japan.
Designers: JH, Japan
Highways.
Excavation method:
Roadheader, drill/blast.
Contractor:
Tobishima/Aisawa
joint venture.
Rock: Variable
volcanic formation
including andesite,
tuff and breccias.
Rock reinforcement
requirement: Safety,
versatility to cope with
geology, even in soft
layers.
Rockbolt selected:
Super Swellex, Midi
Swellex.
Project: Sobu road
tunnel.
Location: Honshu
Island, Central Japan.
Excavation method:
Drill/blast,
microbenching.
Rock: Mixture of
sedimentary and
volcanic rock
formations.
Rock reinforcement
requirement: Safety,
versatility to cope with
geology, even in soft
layers.
Rockbolt selected:
Super Swellex, Midi
Swellex.
98
Easily Through Difficulties on rates of 2.5 m/min in the tuff-brecchia, and
3.0 m/min in the harder andesite.
Honshu Swellex rockbolts were selected because
The Chuo Highway connects Tokyo and of their versatility and effectiveness in the
Nagoya in central Japan, and work is under varying ground conditions, and the speed
way to widen the road from two to three with which they could be installed. These
lanes. Shin-Iwatono is one of the tunnels properties were particularly important in the
excavated along the alignment, and is softer strata mined by the roadheader.
located 100 km north west of the capital.
Work on the 1,591 m-long tunnel, with its
cross-section of 130 sq m, was carried out
by the Tobishima/Aisawa joint venture for
Japan’s Public Highway Corporation.
Rock at the site is andesite lava and tuff-
breccia. The first 126 m of tunnel excavation
was by roadheader in soft tuff-breccia. Drill-
and-blast operations then commenced in
andesite lava using an Atlas Copco Rocket
Boomer 352-2B, the first in Japan, and
leased by local distributor Drill Machine.
The Rocket Boomer 352-2B is equipped
with two BUT 35 booms, with COP 1838
Rocket Boomer 352-2B rockbolting at Shin-Iwatono
rock drills mounted on BMH 6812 feeds. Ad-
highway tunnel.
vance per round was 1.2 m, with penetration
Solving a Geological Puzzle Swellex bolts have been employed in pat-
tern bolting on a number of projects in
with Swellex heavy and fast deforming ground, where
At the 3,692 m-long Sobu tunnel located in grouted rebars are considered too slow to
mountainous terrain on the road between take load. There is also increasing accep-
Kyoto and Yonago Tottori prefecture, top tance of Atlas Copco MAI SDA self
performance was achieved by COP 1838 drilling rockbolts. ■
rock drills fitted to a Rocket Boomer H
195. The cross-section at Sobu is between
90 and 100 sq m, and excavation was by
micro-benching, a common method in
Japan.
The rock is sandstone, shale, tuff and
porphyrite, with a compressive strength
of 400-500 bar. The drillrig achieved 100
holes in 40-50 minutes, with a penetration
rate of 3 m/min, and total advance was
6 m/day.
Site management reported low con-
sumption of shank adapters and other
accessories.
Japanese tunnels require the highest
standards in safety and support, and the
quality of rockbolts, and their standard of
installation, are paramount.
Initially, in Japan, Swellex bolts were
employed as a problem solver for specific
rock conditions, such as squeezing ground
and high water inflow. They have also
Rocket Boomer H 195 micro-benching at Sobu road
been used in difficult situations to replace tunnel.
steel arches. Lately, large quantities of
ROCK & SOIL REINFORCEMENT
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SDA WORLDWIDE

Front Stabilization Using MAI

Anchors
Improving Rock Project: Mineral conveyor tunnel 9.36 km-long with
4.5 m-diameter.
Quality Location: Pontida Valley, Italy.
Excavation method: Open gripper TBM.
Drilling ahead of the tunnel face and
Contractor: Strabag Del Favero.
installing bolts or grout is a com-
mon way of improving rock quality Rock: Flysch and micaceous sandstones with silts and clay
before actual excavation takes place. layers.
Atlas Copco has, as a supplier, Rock reinforcement required: Umbrella of 24 x 9 m-long bolts.
been involved in a number of such Rockbolt selected: Atlas Copco MAI Self Drilling Anchors.
projects, both in mining and
construction.
Pre-reinforcement is a different
way of approaching ground control.
Instead of relying on supporting the
ground following excavation, pre-
reinforcement increases rock
strength prior to excavation. There
are several benefits to this. First, a
pre-reinforced rock mass will be less
damaged by blasting, and less dis-
turbed by elastic and non-elastic
stress redistribution around the exca-
vation. Second, the rock mass is
never without support, even at the
split second following blasting of the
round. Third, the support can be
more active when installed early,
rather than passive when installed
later. Fourth, pre-reinforced ground
will not deteriorate or collapse as
rapidly as a totally unsupported exca-
vation, allowing a safe working
period for installation of regular
support.
In tunnelling, the umbrella grout- Umbrella System at Umbrella of 24 MAI SDA type R51L at
Montegiglio.
ing method of pre-reinforcement is Montegiglio
frequently used. This method pre-
supports the planned roof area with Montegiglio tunnel, in Italy, is a 9.36 km-
steel rods. Large holes are drilled in long, 4.5 m-diameter connection intended
the future roof perimeter, and grout-
to support the mineral extraction activity
ed at high pressure with high
strength, fine grained cement grout. of Colle Pedrino and Montegiglio quarries.
Through each cemented hole, a A conveyor belt for the movement of min-
smaller hole is then drilled, in which eral to the Calusco d’Adda cement plant is
a high-strength reinforcement bar is installed in the tunnel.
grouted. Although highly effective for From the south entrance of Montegiglio
shallow tunnels driven in very quarry, a cableway to Pontida valley links
adverse ground conditions, it is easy the two quarries. The tunnel was driven by
to see that such a work-intensive TBM on a different alignment, westward
operation would be deemed neither
and more northerly. For the first 800 m, the
practical nor economic for mining
applications, although the underlying tunnel proceeded straight on a SW-NE
concept could definitely be useful. heading beneath Carvico village at a
downward slope of 11.4%. The TBM was

ROCK & SOIL REINFORCEMENT 99

RR3/RC10.qxd 23/6/05 11:20 Page 100
SDA WORLDWIDE
BSH 110-SDA for handling MAI operated 5 days/week in three 8 h
anchor. shifts/day, with maintenance carried out
during the morning shift.
Every 200 m of advance, the TBM had to
be stopped for a shift to extend the conveyor
belt. The conveyor belt storage was located
in the area in front of the south entrance.
The stabilization and support interven-
tions for the Montegiglio tunnel depended
upon the observed geological and geotech-
nical conditions of the rock. Six types were
defined, ranging from non-systematic
intervention, to bolts with increasing thick-
ness of shotcrete, up to bolts with net, ribs
and reinforced shotcrete.
During the initial excavation in the
Flysch di Bergamo geology, contractor
Strabag Del Favero suspected weak ground
conditions ahead, and performed a horizontal
Project: Twin-tube 5 km-long highway tunnel.
Location: Hanbau-Tsaotwen Expressway, Taiwan.
Excavation method: NATM with top heading, bench and invert.
Consultant: China Engineering Consultants Inc.
Rock: Gravel with mudstone and clay alternations.
Rock reinforcement required: Presupport around arch and
sidewalls, roof support.
Rockbolt selected: Atlas Copco cement grouted SDA.
Presupport at Pakuashan
The 5 km-long Pakuashan tunnel is being
constructed over a seven-year period in
Central Taiwan, as part of the Hanbau-
Tsaotwen Expressway, one of 12 planned
east-west connections. NATM is being
used, despite the poor geological condi-
tions, which do not fit any of the com-
monly used rock classifications.
100
investigation along the axis of the tunnel.
The results showed that further advance
with the TBM would achieve only limited
results. In fact, at that point, the excavation
met micaceous sandstones, with silts and
clay layers with the consistency of damp
sand. These exhibited very low cohesion,
or no cohesion at all, due to the weak grain
bond. In these conditions, excavation
became difficult, with some collapse of
material from the crown. The support
design for this particular type of section
specified an umbrella of steel pipes with
diameter 104 mm, with a length of
12 m and 3 m overlap. Due to the small
tunnel diameter of 4.5 m, only limited
space was available for positioning and
working the drilling equipment, so an
alternative solution was needed.
Atlas Copco proposed the use of a
Boomer H145 equipped with two booms
and COP 1440 rock drills. The feed length
was adapted to 4.4 m to suit the tunnel
diameter, to enable Strabag Del Favero to
install radial anchors. More importantly, an
umbrella could be installed consisting of
24 Atlas Copco MAI SDA of type R51L,
with a length of 9 m and a overlap of 3 m.
This allowed the contractor to excavate a
total of 6 m, in steps of 1 m, before placing
the next umbrella.
After some initial mechanical adjust-
ments on the Boomer, it was found that the
umbrella could be installed within a period
of 15 h, facilitating faster excavation of the
tunnel.
The Pakuashan ridge is an anticlinal
structure of rocks, which may be subdivided
into two main geological groups. Firstly,
1 m-thick alternations of mudstone or
clay of hard to very hard consistency
and low degree of cementation, and sand-
stone, appearing as loose to medium dense
sand. Secondly, silty-sandy gravel with
cobbles and occasional boulders of maxi-
mum diameter 50 cm. The matrix is
frequently slightly weathered, and cemen-
tation generally poor. Groundwater is a key
factor governing rock mass behaviour.
Twin tubes with 120 sq m section are
being excavated from all four portals, in
loose to heavily compacted gravels. The
65 sq m top headings are maintained
60-70 m ahead of the benches, and invert
closure follows 6-10 m behind each bench.
20 m-long x 4 in-diameter drainage holes
ROCK & SOIL REINFORCEMENT
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SDA WORLDWIDE

are drilled ahead of the face, using casing. Installing 6 m-long SDA at Pakuashan.
Excavation is by backhoe, with a ripper for
profiling.
Presupport consists of 3 m-long fore-
poling using SDA around the arch and
sidewalls at 0.5 m spacing. Lattice arches
are then set at 1 m centres, and 4 m and
6 m SDA cement grouted rockbolts
installed, along with two layers of wire
mesh and 300 mm of shotcrete. A layer of
wire mesh and 200 mm of shotcrete are
laid on the floor of the top heading as
temporary support.
This is the first use of SDA in Taiwan.
One in 50 of the installed bolts is subjected
to a 17.6 t pullout test.
Maximum advance on a top heading has
been 3.3 m/day of 24 h, and the site works
7 days/week. Around 800 m from the por-
tals, the faces moved from compacted
gravel into sand with very little cohesion, in the centre of the alignment using NATM
slowing advance rates considerably. techniques, allowing four more faces to be
Effectiveness of the support regime is opened, and facilitating dewatering.
measured using arrays of convergence A 400 mm-thick cast concrete lining
bolts installed at 20 m intervals. There is with waterproofing membrane and drainage
also a cross section of extensometers at system will be installed as final support.
200 m intervals which measure at depths The mechanical behaviour and engi-
of 3 m, 6 m, and 9 m into the profile rock. neering characteristics of the gravel forma-
Every 500 m, radial pressure cells and tion are related to the degree of
strain gauges are installed in the shotcrete, cementation of the matrix and the percent-
together with measuring anchors to record age gravel content.
stress and strain in the ground. Results Based on the monitoring data, maximum
from all three sets of stations are analyzed crown settlements of about 400 mm have
and compared to theoretical behaviour. been observed in areas of fine sediments
In addition to the main tunnels, there with ground water, while in sections with
are nine pedestrian cross passages, three dense gravel, 50 mm is typical. Maximum
vehicle cross passages, and ten emergency shotcrete stresses of 150-200 kg/sq cm
parking bays. A 240 m-deep x 10 m-diam- have been measured, within the design
eter ventilation shaft has been constructed shotcrete strength of 210 kg/sq cm.

Reinforcing Feuerletten Clay Project: Nuremberg-Ingolstadt high speed railway.

In Autumn 1998, work started on a new
high speed railway line between the cities
of Nuremberg and Ingolstadt, forming the
northern part of the proposed high speed
connection between the two major
Bavarian cities, Munich and Nuremberg.
The Göggelsbuch tunnel, which has a
total length of 2,287 m and an excavated
cross-section of 150 sq m, is the only nat-
ural tunnel in the north section of this
alignment. It is equipped with an emer-
gency shaft that is connected to the surface
by two 150 m-long galleries.
Although smaller than the two 7 km-
long tunnelling projects in the middle
Location: Ingolstadt, Germany.
Excavation method: Mechanical excavator.
Contractor: Bilfinger Berger and Max Bögl joint venture.
Rock: Hard, solid Feuerletten clay.
Rock reinforcement requirement: Forward face support,
systematic roof support.
Rockbolts selected: Atlas Copco MAI SDA, SN anchors.
section of the railway, the Göggelsbuch is
unique, as its alignment runs through a
layer of Feuerletten, a hard, solid clay
which is subject to shrinkage cracking
when dry. Once in contact with water,
Feuerletten softens and becomes imperme-
able due to a swelling of its clay minerals.

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SDA WORLDWIDE
Aerial view of Göggelsbuch tunnel.
The 35 km-long northern section of the
railway line, including the Göggelsbuch
tunnel, is under construction by a joint
venture of Bilfinger Berger and Max Bögl.
It has a reinforced concrete lining vary-
ing between 75 and 125 cm in thickness at
the invert, and which is a constant 35 cm-
thick in the arch. A single 3 mm layer of
polyethylene membrane helps to seal the
tunnel lining against a water head of 30 m.
The anchorage systems used in the con-
struction of the tunnel comprised 4 m-long
SN anchors and Hollow Bolt Type MAI
anchors with varying lengths. Dywidag
Systems International (DSI) supplied both
systems. The DSI hollow bolt anchor type
MAI is optimally used wherever geologi-
cal conditions would normally require
cased drilling to place anchoring or nailing
elements. Its advantage lies in the simplic-
Supporting the face at Göggelsbuch. ity of the system, the flexibility in its
102
length achieved by coupling sections
together, and the quick and economical
installation method.
Swelling Clay
The Göggelsbuch tunnel runs exclusively
in the Feuerletten layer, with between 4
and 20 m of Feuerletten overhead. The
clay comprises a clay stone with fine to
medium sand, which is locally interrupted
by up to 5 m-thick sequences of pure sand-
stone, and by up to 10 m-thick sequences
with alternating sandstone and clay stone.
The layers of Feuerletten are usually
orientated horizontally.
The swelling of the clay, and the pres-
sure exerted, have been examined and ana-
lyzed precisely. All the tests demonstrated
that the pressure due to swelling, in con-
nection with the hydrostatic load, was not
decisive in calculating the internal lining.
Groundwater-filled layers of sandstone,
and impermeable layers of clay with
groundwater flowing on them, were pre-
sent during the complete advance works.
After the whole tunnel had been excavated,
an underground water flow of 5 l/s was
measured.
Construction was from May, 1999 until
September, 2000, advancing simultaneous-
ly from both north and south portals. The
top heading forming the crown was holed
through before the bench and invert were
started.
Concrete lining, from south to north,
took some five months from December,
2000 with one wagon for the invert form-
work, carrying two forms. Two separately
running forms were used for the crown
lining, which took another 4-5 months.
Supporting Production
The rock was excavated using a tunnel
excavator along its entire length, with a
hydraulic breaker in sections with thick
layers of sandstone. The advance per sec-
tion was limited to 1.3 m. The tunnel was
secured with a 20-35 cm-thick layer of
site-mixed shotcrete, and 4 m-long x
25 mm-diameter SN anchors were installed
for systematic rockbolting.
The crown invert was supported with a
temporary shotcrete layer to minimize
movement. Trials without the temporary
support showed unpredictable results, and
the roof above the crown had to be
ROCK & SOIL REINFORCEMENT
RR3/RC10.qxd 23/6/05 11:20 Page 103
strengthened over a length of 50 m, due to
excessive movement.
While advance from the south pro-
gressed with hardly any problems, the
north drive suffered poor face stability.
Despite continuously increasing the dens-
ity of support, a face collapse occurred in
July, 1999. The supports that were
installed at that time were: 30 cm of shot-
crete in the arch; 20 cm of shotcrete on the
arch invert; system anchorage with 4 m-
long SN anchors, at 7 units/m; 10 cm of
reinforced shotcrete on the working face;
8 m-long MAI R32 face anchors, at 9 units
per section; and 6 m-long MAI R32 rods,
at 35 units/m.
It was decided to keep the same types of
support, but those guaranteeing the stability
of the working face were intensified. The
length of the MAI face anchors was
increased to 12 m, and the number doubled
to 18 per round. The length of the MAI
R32 steel rods was also increased from
6 m to a maximum 8 m. This intensified
system of face support was installed over a
length of 500 m, once the collapsed face
had been cleared. No further collapses
occurred on the remaining crown drive,
which was completed without further delay.
Self Drilling Anchors at North
Downs
The Channel Tunnel Rail Link (CTRL) is
the link between King’s Cross Station in
North London and the tunnel terminal on
the coast. This link is being built in two
phases. The first comprises the 3.2 km-
long North Downs tunnel along with three
other major civil engineering contracts,
and was begun in 1998/99. The second
phase will comprise four separate contracts
and utilize a total of eight TBMs. Phase
Two started in 2001.
The contract to construct the North
Downs tunnel was awarded to Eurolink, a
joint venture between Beton und
Monierbau of Austria, Miller of the UK
and Dumez/GTM of France. The tunnel
was constructed through chalk strata
common to the region, using NATM
techniques.
The likelihood of poor ground condi-
tions is increased at the tunnel portal,
where the weaker rock has been exposed to
weathering. Also, geotechnical engineering
calculations show that there are increased
ROCK & SOIL REINFORCEMENT
SDA WORLDWIDE
The excavation of the bench and the
invert of the tunnel were subsequently
completed in about the half the scheduled
time, catching up on the contract.
Acknowledgements
Thanks are due to Thomas Müller of
Bilfinger Berger, and Frank Schmidt of
DSI, for describing the construction
process. Excavating the bench at Göggelsbuch.
Project: High speed railway tunnel.
Location: North Downs, Kent, England.
Excavation method: NATM.
Contractor: Eurolink jv of Beton & Monierbau, Miller, and
Dumez/GTM.
Rock: Chalk with possible flint bands.
Rock reinforcement required: Secure portal area for NATM
advance.
Rockbolt selected: Atlas Copco MAI SDA.
stresses where the tunnel barrel is discon-
tinued at the portal.
At the London portal, some form of
additional ground support was required
to allow NATM tunnelling to progress. It
was decided to drill a total of 24 holes at
0.5 m centres around the crown of the
tunnel. These were installed 15 m deep at
115 mm diameter, using the Atlas Copco
Boodex system. The holes were lined with
easy-to-handle 1.5 m lengths of attached
casing.
A false portal was built at the entrance,
and the spacing of the steel arches was
continued at 1.5 m as the tunnel advanced
under the crown umbrella. ■
103
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KEMI, FINLAND

Rock Reinforcement at Kemi

Chrome Mine
Intelligent Mining
The large chromite deposit being
mined by Outokumpu at Kemi,
Finland has a lower than average
Cr2O3 content of about 26%, so
chromite and ferrochrome production
technology has had to be continuous-
ly upgraded to remain competitive.
The Intelligent Mine Implementation
Technology Programme of 14 projects
achieved real time control of mine
production in precise coordination
with the needs of the mineral pro-
cessing plant and the ferrochrome
smelter. The system utilizes a fast, Ore reserves at Kemi chrome mine are Aerial view of Kemi mine, located
mine-wide information system that abundant, and the efficiency of the Tornio close to Finland’s border with Sweden.
can help optimize financial results for smelter is enhanced by its proximity to both
the whole operation. Computerized
the mine and harbour facilities. Mining pro-
drilling with Atlas Copco Rocket
duction has been progressively switched
Boomers and Simbas, accurate coring
with Craelius rigs, reliable rock rein- from surface to underground, where inten-
forcement with Cabletec and Boltec sive use is being made of information tech-
rigs with Swellex bolts and pumps, nology to optimize the overall mining and
and the dependability and longevity processing operation. Underground mining
of Secoroc drilling consumables sup- started in 2003 at 150,000 t/y, and produc-
port this unique mine strategy. The tion will increase to the planned level of 1.2
result is cost-efficient, integrated pro- million t/y by 2007. Open pit mining will
duction, on a model which may form cease in 2006.
the basis of the next generation of
mining techniques.
Reserves
The Kemi deposit is hosted by a 2.4 billion
Introduction year old mafic-ultramafic layered intrusion Kemi underground mine simplified
extending for some 15 km north-east of the long section.
Outokumpu is one of the world’s largest
stainless steel producers, accounting for
about 8% of global stainless slab output, and
a similar share of cold rolled production.
140 m3/s Backfilling station 70 m3/s
These are hugely significant proportions of a 190 m3/s

market that has risen by an average of 5.5% EAR4 115 Repair shop FAR2
EAR3

per annum over the last 20 years, and is cur-

Final pit bottom
rently enjoying 7% growth. Backfill raise

Trial Stoping area

Mainstay of the Outokumpu strategy is 277 Backfill raise 275
300

its highly cost-efficient fully integrated 350 Pump station

350 Repair shop

mine-to-mill production chain in the Kemi- 450 Expl.

storage
Tornio area of northern Finland. An ongoing 450
475
500
investment programme of EUR1.1 billion 500 Pump station
550 and Repair shop
will expand total slab capacity from 1.75
600 Crusher
million t to 2.75 million t, and coil rolling 580 Pump station

capacity from 1.2 million t to 1.9 million t.

104 ROCK & SOIL REINFORCEMENT

RR3/RC12 19/7/05 10:14 Page 105

KEMI, FINLAND

town itself. The chromite-rich horizon

appears 50-200 m above the bottom of the
intrusion, and has an average dip of 70
degrees northwest. The main immediate
host rock is weak talc-carbonate, in which
the hanging wall contact is clearly defined.
At the footwall, the chromite and host rock
are inter-layered, and must be mined selec-
tively. However, there is strong granite
some 80 m below the footwall.
The Kemi chrome deposit comprises 11
mineralisations within a 4.5 km-long zone
varying from 5-105 m in width, with aver-
age thickness of 40 m, a mineral resource
of 150 million t of 28.6% Cr2O3. Of this
there are 50 million t proven reserves
underground between the 500-m level and
the bottom of the open pit. The ore body
continues at depth, probably to 1,000 m,
with 750 m having been reached by the
deepest exploratory hole. The 1.5 km-long concentrate contains about 45% Cr2O3 of Atlas Copco Rocket Boomer L2 C is
x 500 m-wide main pit has a final planned 0.2 mm grain size, while upgraded lumpy used for sublevel development.
depth of 220 m. ore is about 35% Cr2O3 with 12-100 mm
A two shift/day, five day/week pattern is size. The former is pelletized at Tornio, and
worked in the mine, from which about 1.2 then mixed with upgraded lumpy ore before
million t/y of ore grading 24-26% Cr2O3 is smelting to produce ferrochrome.
processed continuously by the concentrator. Concentrator operation is optimized by
The yield is 220,000 t/y of 12-100 mm accurate calibration of the feed slurry ana-
lumpy concentrate with 35% Cr2O3, and lyzers, and control of product quality from
420,000 t/y metallurgical grade concentrate each unit process, both by compensating
at 45% Cr2O3. Over the years, some 30 for changes in feed type, and measuring
million t of ore have been produced from product quality on-line. Manual input can
open pits, resulting in 130 million t in be used, as well as on-line information.
waste heaps. A Craelius Diamec 264 APC drill rig car-
ries out 10 km of coring each year. Drill sec-
Ore Grade Control tions are established every 10 m and
downhole survey is standard procedure, using
Ore grade control in both the open pit and a Maxibore system. Based on the drill hole
the underground mine involves intensive data, a 3D model of the orebody is created Atlas Copco Simba M6 C at work in
wire line diamond core drilling, to deter- and used as a basis for production planning. the sublevels at Kemi mine.
mine boundaries and qualities of specific
ore types. In addition, all blast holes in the
open pit are sampled. Technical innova-
tions for ore characterization and quantifi-
cation include OMS-logg down hole
logging, and automated image analysis for
establishing grain size distribution.
Basic production data about mineralogi-
cal and process histories are logged for each
ore stope on a daily basis, and this is merged
and compared with daily and blast-specific
production histories from the database.
Each ore blast is treated selectively at
the concentrator, in order to minimize feed
variation and maximize process stability.
In the concentrator, total chromite recov-
ery is around 80%, depending on the pro-
portion of lumpy ore. Metallurgical grade

ROCK & SOIL REINFORCEMENT 105

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KEMI, FINLAND

equipped with a 10 t travelling gantry and

Atlas Copco Craelius Diamec 264 APC
at work underground.
Atlas Copco Boltec LC installing
Swellex Mn12 rockbolts.
Tying all these streams of collected data
and planning outputs together requires an
extremely fast communications network,
interfacing with a single master database.
Underground Infrastructure
The main decline starts at a portal in the
footwall side of the pit, at about 100 m
below the rim. The decline is mostly 8 m
wide x 5.5 m high, to accommodate pass-
ing vehicles. It descends at 1:7 to a depth
of 600 m at the base of the hoisting shaft,
and connects with several intermediate
sublevels. The decline is asphalted
throughout most of its length.
There is also a 5,000 cu m repair shop
for open pit equipment at the 115 m level,
and a larger 14,000 cu m workshop at the
350 m level for the underground mobile
equipment fleet. The final 23,000 cu m
main workshop is under construction at the
500-m level. The 350-m level workshops
are enclosed by megadoors, which keep in
the heat so that an ambient 18 degrees C
can be maintained. The service bay is
16 m-long inspection pit. The washing bay
is equipped with two Wallman hydraulical-
ly controlled washing cages, so there is no
need for operatives to climb onto the
mobile equipment.
The main pumping station is located at the
350 m level, and has pumping capacity of 2 x
250 cu m/h. The slurry-type pumps, with
mechanical seals, pump the unsettled mine
water to the surface with a total head of 360
m. Two other dewatering pumping stations
are located at the 500 m and 580 m levels.
The crusher station at the 560 m level is
equipped with a 1,000 t/h Metso gyratory
crusher. This is fed from two sides by
vibrating feeders from separate 8 m-diame-
ter main ore passes from the 500 m level,
and from one side by a plate feeder, to
which the ore can be dumped from the 550
m level. A 40 t travelling gantry crane ser-
vices the entire crusher house. Crushed ore
gravitates onto a conveyor in a tunnel
below the crusher for transport to the shaft
loading pockets 500 m away.
Underground Production
Trial stopes in three areas accessed from
the 275 m and 300 m levels were mined to
determine the parameters of the bench cut-
and-fill technique to be used. These had a
width of 15 m, and were 30-40 m-long,
with 25,000-30,000 t of ore apiece. Both
uphole and downhole drilling methods
were tested, and 51 mm-diameter down-
holes selected as being the safest.
For production purposes, 25 m-high
transverse stopes are laid out, with cable
bolt and mesh support to minimize dilu-
tion. Primary stopes are 15 m wide, and
secondary stopes 20 m wide. Cemented
fill, using cement, furnace slag from an
iron ore smelter and fly ash from local
power stations, is placed in the primary
stopes, while the secondary stopes will be
backfilled with mine waste rock. The pri-
mary stopes are being extracted one or two
levels above the secondary stopes.
Mining sublevels with 5 m x 5 m cross
sections are being established at 25 m ver-
tical intervals, using one Atlas Copco
Rocket Boomer L2 C drillrig equipped
with 1838 ME rock drills and 5 m-long
Secoroc steel and bits. Rounds of 60-80
holes take about 2 hours to drill, charge
and prime. An emulsion charging truck
with elevating platform and Atlas Copco

106 ROCK & SOIL REINFORCEMENT

RR3/RC12 19/7/05 10:14 Page 107
GA15 compressor provides fast and effi-
cient explosives delivery. The footwall
granite is very competent, but lots of rock
reinforcement is required in the weaker
host rock, where all drives are systemati-
cally rock bolted and secured with steel
fibre reinforced shotcrete.
The planned nominal capacity is 2.7 mil-
lion t/y of ore, which allows for increased
ferro-chrome production at Tornio when
Outokumpu decides to expand the smelting
operation. The total cost for mine develop-
ment is EUR70 million.
Rock Reinforcement
Swellex Mn12 2.4 m-long bolts are used for
support in ore contact formations. These are
being installed at a rate of 80-120 bolts/shift
using an Atlas Copco Boltec LC rig, which
is returning drilling penetration rates of 3.2
to 4 m/min. The CAN-bus controlled LC rig
mounts the latest Swellex HC1 pump, for
bolt inflation at 300 bar pressure, and
reports progress on the operator’s screen.
The HC1 hydraulic pump is robust,
simple, and with low maintenance cost.
Coupled to an intelligent system, it reaches
the 300 bar pressure level quickly, and
maintains it for the minimum time for per-
fect installation. Combined with the rig’s
CAN-bus system, the pump can confirm
the number of bolts successfully installed
and warn of any problems with inflation.
Over 50,000 bolts have been installed to
date without problems.
A series of slip-pull tests carried out
throughout the mine proved the strong
anchorage capacity of Swellex Mn12, both
in the orebody and for the softer talc-
carbonate and mylonite zone.
Cable Bolting
Kemi installs some 80 km of cable bolt each
year using its Atlas Copco Cabletec L unit,
which is based on the longhole production
drilling rig Simba M7, with an added second
boom for grouting and cable insertion. The
Rig Control System (RCS), enables the oper-
ator to pay full attention to grouting and
cable insertion, while drilling of the next hole
after collaring is performed automatically,
including pulling the rods out of the hole.
The main benefit of the two-boom concept is
to drastically reduce the entire drilling and
bolting cycle time. Also, separating the
drilling and bolting functions prevents the
ROCK & SOIL REINFORCEMENT
KEMI, FINLAND
risk of cement entering the rock drill, thereby Atlas Copco Cabletec L installing cable
reducing service and maintenance costs. bolts at Kemi.
Kemi tested the prototype Cabletec L
and eventually purchased the unit after
minor modification proposals. During the
testing period, where most holes were in
the 6 to 11 m range, the rig grouted and
installed cables at rates of more than 40
m/hour. The capacity of the unit, which is
governed by the rate of drilling, provided
around 50 per cent extra productivity com-
pared with alternative support methods.
The Cabletec L is equipped with a COP
1838 ME hydraulic rock drill using
reduced impact pressure with the R32 drill
string system for 51 mm hole diameter.
The machine’s cable cassette has a capac-
ity of 1,700 kg and is easy to refill, thanks
to the fold-out cassette arm. It features
automatic cement mixing and a silo with a
capacity of 1,200 kg of dry cement, which
is mixed according to a pre-programmed
formula, resulting in unique quality assur-
ance for the grouting process.
Bench Cut and Fill
The current mining method is bench cut and
fill, a type of sub-level stoping with down-
hole production drilling, in which primary
stopes are 25 m high, 15 m wide and
between 30 and 40 m long. Using a Rocket
Boomer L2 C rig, the drifts for the primary
stopes are developed laterally from the
footwall through the ore zone. Then a Simba
M6 C production rig drills down 51 mm
diameter blastholes in fans 2 m apart. Each
stope yields between 25,000 and 35,000 t of
ore.
107
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KEMI, FINLAND

work that eventually will cover the whole

Inside the 350 m level workshop at
Kemi.
Tests showed that drilling upwards
would be about 30 per cent more efficient,
but because of safety issues related to the
poor rock conditions, it was decided to
start with downhole drilling while getting
experience with the rock and the mining
method. Meantime, Kemi has ordered a
Simba L7 C rig with a long boom to be
delivered in August, 2005. With the M6 C
and L7 C, operators will be able to cover
all kinds of drilling patterns.
Mining of the 20 m wide secondary
stopes will start in 2005, while sub-level
caving with uphole drilling will be tested
at one end of the main pit in 2006.
Secoroc rock drilling tools are used for
production drilling. The previous 64 mm
holes over-fragmented the ore, but a switch
to 51 mm resulted in lower specific
charges and better fragmentation, while
retaining the same number of holes. When
developing the secondary stopes, the mine
may well go back to 64 mm drilling if
there are problems keeping the holes open
due to the stresses and rock movements.
Kemi is carrying out slot hole drilling
with a Simba M4 C rig mounted on a
Scania truck. The front part of the rig has
been redesigned to accommodate the
Secoroc COP 84L low volume DTH
slothammer, which is used to drill the 305
mm-diameter opening hole for the longhole
raises. The blasting holes are drilled off
using a COP 54 with 165 mm bit with the
same tubes. The 20-m raises are blasted in
two 10-m lifts.
Rig Remote Access
The drill rigs at Kemi are integrated into
the Ethernet WLAN communications net-
mine. Currently, this 1 GB network,
which is based on commercially available
equipment, covers the declines, the work-
shops and parts of the production area.
This network infrastructure not only
allows effective underground commu-
nication but also means that all the
Atlas Copco drill rigs equipped with
the Rig Remote Access (RRA) option
are logically integrated into the informa-
tion systems in Outokumpu’s administra-
tive organization. The RRA is installed
on the Rocket Boomer and Simba rigs.
The RRA, which consists of a communi-
cation server on-board the rig and a net-
work adapter, integrates with the mine’s
network to allow data transfer and remote
monitoring and troubleshooting. It works as
a two-way communication system, since
data can be sent and received in real-time
between Atlas Copco and the mine. For
instance, should one of the drillrigs
encounter a problem, the warning seen by
the operator will also be shown in the mine
office, which can then contact Atlas Copco
immediately, enabling them to enter the
rig’s electronic system and diagnose the
fault.
The RRA’s main benefits are: the
administrative system can be updated
automatically with the latest information
with no manual handling; the rig operator
always has access to the latest production
planning; no need to write work reports
after each shift, since all log files are
automatically saved to the planning
department; instead of forcing work
orders to be written before each shift,
they can be issued during the shift and
directed onto the specific drillrig; and
fault diagnostics can be conducted
remotely, which allows the service tech-
nician to diagnose the problem and
choose the correct spare parts before
travelling to the drillrig.■
Acknowledgements
Atlas Copco is grateful to Juha Riikonen,
manager of the underground mine for his
assistance in arranging the site visit and
reading draft. Contributions by Esa
Lindeman, open pit manager, Heikki
Pekkarinen, concentrator manager, and
Jukka Pitkajarvi, chief geologist (all
name.surname@outokumpu.com).

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LOTSCHBERG, SWITZERLAND

Repairing Squeezing Ground

at Mitholz
Flexibility of Purpose
The Satco joint venture, under techni-
cal sponsorship of Strabag, installed
a complete purpose-designed excava-
tion system at their Mitholz contract
on the Lotschberg base tunnel in
Switzerland.
Speed and efficiency were the key
elements of a successful project, for
which Satco chose Atlas Copco
Rocket Boomer XL3 C drillrigs with
ABC Regular semi-automatic boom
control for production drilling, and
Rocket Boomer L2 C twin-boom
machines for the smaller-section
work. The rigs were equipped with
Secoroc rock drilling tools, and
Swellex rockbolts were used for
immediate support. This combination
of job-matched Atlas Copco equip-
ment, together with first-class on-site
maintenance support, helped Satco main running tunnels are contracted to Satco reached Frutigen portal
to get six months ahead of contract Satco, a joint venture led by Strabag with 8 months ahead of schedule.
schedule over a period of three years. Vinci, Skanska, Rothpletz & Lienhard, and
However, close to the boundary of Walo Bertschinger.
the contracted distance south, the The east and west tubes have been
faces unexpectedly hit soft carbonif- driven by drill/blast some 8.7 km south-
erous banded deposits, some 1,400 m wards, to meet faces coming north from
beneath the Lotschen summit. Huge
Ferden. At the same time, the east tube has
ground pressure was transmitted to
the tunnel lining, causing compres-
been advanced some 7.5 km northwards to
sion and distortion of the steel arch- break out at the Frutigen portal. The west
es. Satco used its Rocket Boomer XL3 tube from Frutigen portal has also been
Cs to install 16 m-long MAI SDA self driven 800 m to junction with the east tube.
drilling anchors to stabilize the strata The nominal cross-section of excavation
for replacement of the steel arches, of the main running tunnel faces is approx-
overcoming a difficult support prob- imately 65 sq m, depending upon the Wolfgang Lehner, project manager for
lem. required support, with a maximum of 280 Satco at Mitholz.
sq m at junction caverns.
These have been advanced using
sophisticated three-boom and basket Atlas
Lotschberg Alignment Copco Rocket Boomer XL3 C drillrigs
equipped with ABC Regular semi-auto-
The 34.6 km-long Lotschberg base tunnel, matic boom control with two control sys-
which has been developed from a number tems, operated by two drillers working
of access points, is in an advanced stage of from separate panels. Drillplan data is
construction, and will be ready for use in transferred from the planning office to the
2007. machines on PC cards.
From the base of the 1.5 km-long, 67 sq The big Rocket Boomer XL3 Cs were
m Mitholz access adit, located about 8 km backed up by a pair of twin-boom Atlas
from the north portal site at Frutigen, three Copco L2 C drillrigs, which handled work

ROCK & SOIL REINFORCEMENT 109

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LOTSCHBERG, SWITZERLAND

This arrangement afforded maximum

manoeuvring room for the large numbers
of mobile equipment in operation.
When in good rock, each full, 8 m-wide
x 8.5 m-high arched face was drilled out
by a Rocket Boomer XL3 C to 4.5 m depth
using Secoroc model–37 48 mm, 9-button
ballistic bits with R35 thread.
Between 105 and 120 holes were nor-
mally required, together with two 102 mm
breaker holes in the centre. Average
drilling rate was 3 m/min, and face and
rockbolt drilling took around 3 hours in
normal ground. The rock generally com-
prised good, hard limestone, which could
be screened and crushed for aggregate.
Total volume of excavated rock was
around 1.8 million cu m, of which some
700,000 cu m is being reused.

Excavation and Mucking

Atlas Copco Boomer XL3 C drilling MAI
SDA to repair squeezing at Mitholz.
such as bolting, cross passage develop-
ment, and extraneous excavation.
Standard Swellex rockbolts, in 3 m and
4 m lengths, were installed as immediate
support, normally at 1.5 m spacing in the
roof and shoulders of each drive. All of the
ancillary face equipment such as trans-
formers, ventilation extensions, and cable
reels were carried on backup platforms
suspended on rails slung from the roof.
Torqueing up a 16 m-long grouted MAI SDA.
All blasting at Mitholz utilized site sensi-
tized emulsion (SSE) explosives supplied
by Dyno Nobel Sweden. The profile holes
were charged at 50% density to control
overbreak, and the blasted faces were
safened using an excavator-mounted rock
scaler. Overexcavation of 45 cm width on
horseshoe section and 60 cm width on cir-
cular section was required to accommodate
squeezing under normal circumstances. An
LHD equipped with 5.4 cu m side-tipping
bucket carried the spoil back to a 1,000 t/h
mobile crusher located some 50-100 m
behind each face. From here, the crushed
rock was delivered by a 330 m overlap
stage conveyor to a 300 t/h trunk convey-
ing system, and thence to a handling plant
close to the adit bottom where the rock
was further crushed to –200 mm, with
oversize scalped by a grizzly. Vertical
pocket elevators carried the spoil 20 m up
to the adit conveyor loading points, from
where two 400 t/h tubed belt systems took
it to the surface for transport to the nomi-
nated stockpiles.
The south section is serviced by two
2,700 kW air conditioning units which are
cooled by 150 lit/sec of recycled ground-
water, and fresh air is supplied by a pair of
2.4 m ventilation ducts. The air is con-
tained by automatic roller shutter doors,
and driven around the faces by auxiliary
fans. The Frutigen TBM tunnel is the main
fresh air intake and, by the time that the air
reaches the south faces, most of it has trav-
elled more than 15 km. All told, there are

110 ROCK & SOIL REINFORCEMENT

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LOTSCHBERG, SWITZERLAND

in excess of 120 km of pipelines installed

underground for various purposes.

Support and Lining

The roof and sides of each excavated
round were shotcreted and 20-30 Swellex
rockbolts installed, using a Rocket Boomer
XL3 C to drill the 38 mm holes. Rock
cover varies from 1,000 m to a maximum
of 2,000 m beneath the Mitholz peaks. In
squeezing ground, wire mesh and steel
fibre reinforced shotcrete were used.
Rockbursting was a hazard at the far south
end of the alignment, especially where
crystalline rock was encountered.
Permanent lining comprises 250 mm-
thick cast in-situ concrete formed over a
drainage membrane, with the crown of the
tunnel positioned 7.2 m above the top of profile, they introduced R32 MAI SDA in MAI SDA under installation alongside
the rail track. The main tunnels are being 8 m and 12 m lengths at a density of ten replacement steel arch.
finished to a standard 62 sq m cross-sec- per metre of advance to replace the grouted
tion. rebar. By the end of June, 2004 the ground
The site worked a 7 day/3 shift opera- conditions had deteriorated to the extent
tion, with four crews of 9 or 10 men rotat- that fifteen 8 m-long R32 MAI SDA, eight
ing on each face. Tunnelling progress was 12 m-long MAI SDA, and seven 4.5 m-
well ahead of schedule when the south long Swellex were necessary for each
faces reached the predicted water-bearing metre of advance.
karstic limestone, the drillrigs having Stronger rock reinforcement was
advanced 250-300 m/month on each face, required, and it was decided to upgrade
with a maximum achieved of 343 m/month. from R32 to R38 MAI SDA, in a mix of 8
A complex probe drilling system using m and 12 m lengths. This unprecedented
250-300 m-long cored holes was employed density of support sometimes reached 350
to investigate conditions ahead of the face, m of rockbolting for each metre advance.
and average water inflows up to nearly 100 Nevertheless, squeezing caused defor-
lit/sec were experienced, with a maximum mation over a 100 m-long section close to
pressure of 54 bar. Hydraulic testing and the face of each drive, causing a pause in
ground probing radar were also used, and a advance while the situation was assessed.
grouting regime established. Each face was secured using 12-15 off 4
m-long fibreglass bolts, and a 470 m-long
Carboniferous Encounter cored exploratory hole drilled to probe Shotcreting a repaired section in the
the ground ahead. This indicated that the south drives.
In April, 2004, some 1.5 km before the
south faces reached the boundary of the
Satco contract, a section of softer rock was
encountered. This was accompanied by
water over a 400 m length, following
which the faces progressed through first
granite, then limestone, sandstone and
shale, before entering an unexpected 600
m-long carboniferous section, in which
thin seams of anthracite appeared in the
shale. At this point, Satco modified the
excavated section from arched profile to
circular profile.
They had been setting six 6 m-long
grouted rebars and four or five 4 m-long
Swellex bolts for each metre of advance
using the arched profile. For the circular

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LOTSCHBERG, SWITZERLAND

circular steel compression arches at 1 m

intervals. For each arch, 16 off 16 m-long
grouted R38 MAI SDA were installed
radially in 4 m-long coupled lengths in 76
mm holes, both to stabilize the strata
around the tunnel and to pin the arches in
place. These were grouted in place at 20-
40 bar pressure.
Once the relining was completed, tun-
nelling operations resumed, and were
soon into good rock. Satco is carrying on
beyond the original contract southern
boundary for more than an extra 1 linear
km of drive awarded as a bonus for early
completion.

Buckled arch with emergency
retaining bolts.
Section of Lotschberg tunnel from
Frutigen to Raron. The unexpected
area of soft sedimentary rock is
delineated by red dotted lines.
Tungsten carbide bit used along with EYY type with
MAI SDA at Mitholz.
carboniferous section would run out after
another 50 m in the west face and 10 m in
the east face, following which there would be
a transition to comparatively good sandstone.
It was decided to reline the deformed
tunnel in sections 50 m-long, installing
North Completion
In the north, probeholes were maintained
40 m ahead of the face, drilled in the
crown by one of the Rocket Boomer XL3
Cs equipped with a RAS rod adding
system. Detection of methane would trig-
ger a warning system on the drillrigs, and
the monitoring system on the suspended
backup would switch off HT electrics if a
dangerous concentration were encoun-
tered.
Tunnelling at the north face was com-
pleted in May 2003, some 8 months ahead
of programme, as a result of which Satco
was awarded a further contract to excavate
some 800 m of the west tube from the
Frutigen portal. All cross passage excava-
tion between the east tube and the TBM
tunnel is now complete.
The main concrete lining operation
went well in the north drive, where pair of
12.5 m formworks returned 25 m/day of
completed lining. Concrete lining is pro-
ceeding apace in the south drives.■
Acknowledgements
Atlas Copco is indebted to Satco and
Alptransit Lotschberg for permission to
publish this article and, in particular, to
Wolfgang Lehner of Strabag, project man-
ager at Mitholz, for his assistance with
interviews and site visit.

North Mithollz Ferden Steg South

Frutigen portal lateral adit lateral adit lateral adit Raron portal
m.s.l. m.s.l.
ELSIGHOR LÖTSCHBERG
2500 LÖTSCHENTAL
2000 ADELRAIN SE-GRAT EGGESCHWAND ST.GERMAN 2500
2000
1500
1500
1000 1000
500 500
0 0

112 ROCK & SOIL REINFORCEMENT

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ZINKGRUVAN, SWEDEN

Mechanized Bolting at
Zinkgruvan
Partners in Production
Zinkgruvan Mining AB, Sweden’s
third largest mining company, is a
part of Lundin Mining Corporation.
Zinkgruvan Mining produces zinc and
lead concentrates for shipment to
smelters in northern Europe.
The mine has been continuously in
production since 1857, and ore output
now stands at about 835,000 t/year,
together with 185,000 t of waste
from development.
Production is obtained from open
stopes where, following difficulties
with seepage from hydraulic fill
when rock quality diminished, the
mine now uses paste fill. Rather than on a 2 x 7 h shift basis. The mine has an Atlas Copco Rocket Boomer L2 C
deepen the main hoisting shaft, the option to purchase a second twin-boom developing the sublevels.
main ramp access was developed Rocket Boomer, this time an M2 C, which
below the 800 m level, and will
bottom out at 1,100 m under present
is the mining version of their existing L2 C.
plans. Key to Zinkgruvan production
efforts is equipment supplied by Rock Reinforcement
Atlas Copco, which includes four
Simba production drillrigs, three The mine installs up to 20,000 resin
Rocket Boomers and two Boltec rigs,
together with maintenance and con-
anchored rockbolts each year, and, having
sumable supply contracts. upgraded its production process, found that
bolting became the new bottleneck. After
prolonged testing of the latest Atlas Copco
Lower Development Boltec LC, they ordered two units.
Using these machines, the working
In order to mine below the 800 m level, the environment for the bolting operatives has
mine uses three Kiruna Electric trucks for improved immeasurably, since the continu-
ore and waste haulage to the main crusher. ous manual handling of resin cartridges
A Simba M4 C longhole drilling rig is has been eliminated. The Boltec LC is a
used on production, drilling up to 40 m- fully mechanized rockbolting rig with
long x 76 mm or 89 mm-diameter blast- computer-based control system for high
holes. The machine produces some 50,000 productivity and precision. The Zinkgruvan
drillmetres/year, while an older Simba models feature a new type of magazine
1357 drills a similar number of metres in holding 80 resin cartridges, sufficient for
the 51-64 mm range. The mine is so installation of 16 rockbolts before refill. It
impressed with the stability of the Simba is equipped with a stinger, which applies
M4 C rotation unit that it has had an old constant pressure to keep it stable at the
Simba 1354 rebuilt to incorporate the same hole during the entire installation process.
unit. A Simba M7 C is being delivered for The operator can select the number of resin
cable bolt drilling. The drilling consum- cartridges to be shot into the hole, for
ables are supplied by Atlas Copco Secoroc which the rig air capacity is excellent.
under contract. The ramp will be driven
from the current 980 m to the 1,100 m level. Vital Combination
An Atlas Copco Rocket Boomer L2 C is
used on ramp and sublevel development, The Rig Control System (RCS) features an
where the requirement is for 18 rounds/week interactive operator control panel with

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ZINKGRUVAN, SWEDEN

hydraulic system with fewer and shorter

Atlas Copco Boltec LC installing
rockbolts in a development drive.
Grinding Secoroc bits on a Grind Matic
BQ2 machine.
full-colour display of the computer-based
drilling system. Automatic functions in the
drilling process, such as auto-collaring and
anti-jamming protection, as well as
improved regulation of the rock drill, pro-
vide high performance and outstanding drill
steel economy. There is integrated diagnos-
tic and fault location, and a distributed
hoses for increased availability. Data trans-
fer is by PC-card, which also allows service
engineers to store optimal drill settings.
The MBU bolting unit on the Boltec LC
features a single feed system, utilizing a
cradle indexer at the rear end, and a robust
drill steel support, plus indexer for grout-
ing, at the top end. It is equipped with a
low-mounted magazine for 10 bolts,
designed for maximum flexibility during
drilling and bolting.
The COP 1532 rock drill is the shortest
in its class, with modern hydraulic reflex
dampening for high-speed drilling and
excellent drill steel economy. It has sepa-
rately variable frequency and impact
power, which can be adapted to certain
drill steel/rock combinations.
The BUT 35HBE heavy-duty bolting
boom is perfect for direct, fast and accu-
rate positioning between holes. Large
capacity working lights, and a joystick-
operated spotlight, ensure that the operator
has outstanding visibility from his working
position.
Profitable Collaboration
The Rig Control System (RCS), originally
developed for Boomer rigs, is now also
installed on Simba and Boltec rigs, so the
mine benefits from the common concept.
Atlas Copco has total responsibility for
all service and maintenance operations on
its equipment at Zinkgruvan, and has three
service engineers stationed permanently at
site. The company is also under contract
for the supply, maintenance and grinding
of Secoroc rock drilling tools, overseen by
a Secoroc specialist.
From the mine point of view, they
believe they have profited by their collabo-
ration with Atlas Copco, particularly in the
field testing of the new generation rigs.
Early exposure to the capabilities of these
machines has allowed them to adapt their
mining and rockbolting methods to the
new technology, giving them a head start
on the savings to be achieved. ■

Acknowledgements
This article is based on a paper written by
Gunnar Nystrom. The editor also grate-
fully acknowledges the inputs of Jonas
Sodergren, Hans Sjoberg and Conny
Ohman, all of Zinkgruvan Mining.

114 ROCK & SOIL REINFORCEMENT

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BOLU, TURKEY

Seismic Tunnelling at Bolu

Overcoming Natural
Disaster
The attempt in the mid-nineties at
tunnelling through the Bakacak Fault
near the Turkish town of Bolu was
aborted following the massive earth-
quake in November, 1999. This
caused the collapse of a section of
mined tunnel, which had been exca-
vated with preliminary primary sup-
port of soil nails and shotcrete.
The overall design has been
rethought, and the tunnel is now
again under construction. Seismic
principles have been applied to this
project, which is crucial to comple-
tion of the Gumusova-Gerede section
of the important North Anatolian
Motorway linking Ankara and Istan-
bul. The design criteria have defined
the fault crossing strategy, and the
practical solutions involve the exten-
sive use of Atlas Copco MAI Self
damage was done to the lining and invert Atlas Copco Boomer drilling over the
Drilling Anchors (SDA) as primary
of both tunnels. Consultants Lombardi SA face for forepoling.
support.
were brought in to analyze the seismic
loads induced by the earthquake, which
History originated at the North Anatolian Fault.
These analyses examined the depth, direc-
The Bolu Mountain Crossing is midway tional effects, soil amplifications and dis-
between Ankara and Istanbul, and repre- tance from the seismic source, and a panel
sents the most challenging section of the of experts was set up to study the results.
motorway construction. Along this 20 km-
long stretch, four important viaducts and a Active Faults
long tunnel are under construction.
The Bolu tunnel is a twin-tube motor- Two active faults were recognized
way tunnel of about 3 km length, accom- along the tunnel alignment: the Zekidagi
modating three lanes per tube, linking the and Bakacak faults (Barka-W Lettis &
western Asarsuyu valley to the eastern Associates).
Elmalik village, on the Ankara side. The The Zekidagi fault dips at almost 90
original design featured five support class- degrees, is approximately 6 to 8 km-long,
es in the tunnel, and two at the portals, and possibly intersects with the tunnel
with an excavation area ranging between alignment at nearly right angles, around Plan of Astaldi section of the Istanbul-
190 sq m and 260 sq m. The original static chainage 62+430 in the left tube and Ankara highway.
design was by Geoconsult GmbH of
Saltzburg, Austria, and, for the worst rock
condition, involved preliminary excavation
and backfill of bench pilot tunnels, a three-
layer lining, and a deep monolithic invert.
Excavation of the tunnel started in
1993, and, almost immediately, problems
were encountered with clays. When the
Duzce earthquake occurred in 1999, a
stretch of about 350 m of tunnel collapsed
behind the eastern faces, and major

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BOLU, TURKEY

Two likely traces of the Bakacak fault,

which dips at 40 degrees, were identified
crossing the Bolu Tunnel between
chainage 62+800 and 62+900 at the left
tube, and 52+730 to 52+800 at the right
tube, over a distance of about 100 m. This
is precisely the zone where excavation was
proceeding at the time of the earthquake.

Crossing Active Faults

Standard cross-section of Bolu tunnel
showing massive support.
Shotcrete operations underway in the
top heading.
52+350 in the right tube, over a length of
25 m to 30 m. It has a potential for small
future displacement in the range of 0.15-
0.25 in an earthquake of magnitude 6 to
6.25. This section of tunnel was lined
according to the original design, and no
particular problems were experienced
crossing the fault, although high deforma-
tions were recorded.
The Bakacak Fault has been identified
as a secondary fault in the step-over region
between the two major North Anatolian
Fault (NAF) branches in the Bolu region.
This clay fault exhibits low potential for
right lateral strike-slip displacements. It is
some 10-45 km-long, composed of several
segments ranging from 3 to 5 km-long, and
rupture displacements of up to 50 cm can
be expected in an earthquake of magnitude
6.25 to 6.5.
Basically, two strategies are feasible to
mitigate the seismic risk induced to tunnels
by ruptures of active faults across the
alignment. These are commonly referred to
as over-excavation, and articulated design.
In the first case, the tunnel is driven
through the fault with an enlarged cross
section. A double lining is installed, and
filled by a porous material, such as foam
concrete. If there is a fault rupture, the
clearance profile is guaranteed by the gap
between the outer and inner linings. This
manner of protection, commonly used for
metro projects, is limited by the width of
the cross section that must be excavated,
and will be most effective when a fault
rupture is concentrated within a few
metres.
The articulated design strategy, on the
other hand, reduces the width of the lining
segments, leaving independent sections
across the fault, and for a distance
beside the fault. In a fault rupture, the
movement is concentrated at the joints
linking the segments, containing any
damage in a few elements, without uncon-
trolled propagation.
The maximum length of any single ele-
ment depends on several factors, such as
width of the cross section, expected move-
ment of the fault, compressibility of the
surrounding soil, and element kinematics.
Articulated design was selected as the
most appropriate for the large cross section
of the Bolu tunnel, and for the excavation
geometry that had already been defined.

Design Philosophy
When the Bakacak fault was recognized as
active, almost one year after the Duzce
event, the restoration of the original tunnel
was almost complete, and the shape and
type of the cross section adopted was
already defined. The bench pilot tunnels of
the original excavation had already been
backfilled.

116 ROCK & SOIL REINFORCEMENT

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The segments geometry was defined by
considering a ratio between length and
width of the tunnel segment equal to one
third, resulting in an element length of
about 5 m. This geometry kept the load on
the single crown segment below an accept-
able threshold value.
For practical reasons, the length of the
segments was reduced to 4.4 m, with a
50 cm joint gap at invert. This facilitated
retention of the original modular reinforce-
ment cage.
Following a fault rupture, the tunnel
will act longitudinally as an embedded
beam, whose extremities are displaced by
the lateral offset of the fault. The assump-
tion made, justified by the geologists, is
that a rupture will be uniformly distributed
across the fault boundaries, with horizontal
displacement. Therefore the shear strain in
the fault soil can be reasonably assumed as
the ratio between expected offset and
width of the fault at tunnel level.
Up to rupture of the joints, the tunnel
will be sheared and bent by the soil as an
embedded beam. Once the joint’s shear
resistance is attained, each segment will be
free to move independently, according to
external loads.
The maximum acceptable shear resis-
tance of the joint has been defined on an
equivalent elastic model, with soil mod-
elled as springs acting in compression. A
displacement is gradually applied to the
extremities, and the shear stiffness of the
joints is designed so as to reach the shear
failure of the joint before lateral overload
of the element cross section, or bending
failure at extremities.
Reinforcement and Joints
Across the fault zone, different support
measures have been adopted. Of these, the
most important is an 80 cm-thick concrete
40 N/sq mm prefabricated concrete slab
intermediate lining to be installed between
the primary lining and the inner lining. The
reinforcement bars have been placed only
in the inner (final) lining and at invert,
while the shotcrete and intermediate lin-
ings have been fibre-reinforced.
The primary aim of the reinforcement
design is to provide a high ductility to the
lining. The allowable rotation has been
estimated, and compared to the estimated
rotation for the load conditions. This was
achieved by introducing stirrups at shear,
ROCK & SOIL REINFORCEMENT
BOLU, TURKEY
keeping the spacing below 30 cm, and also Installing prefabricated concrete slab
by introducing a light dosage of steel fibres intermediate lining.
in the concrete mix, or applying an equiva-
lent double mesh layer. These measures
were installed within the fault, and up to a
distance of 30-40 m from the fault borders.
The joints, at 4.2 m spacing, have been
detailed to prevent soil squeezing between
the segments, and to bridge the static soil
pressure to the surrounding elements, but
opposing a sufficiently low shear resis-
tance in the event of fault rupture.
To provide ring closure of the joint at
the invert, a 0.4 m-thick fibre reinforced
shotcrete beam is applied to bridge the
gap. At the crown, the regular 40 cm-thick
shotcrete preliminary lining has been
assessed as sufficient.
The 50 cm-wide joint is filled by two
layers of concrete blocks, with a 10 cm
low density PS layer in between. A water-
proofing membrane is installed below the
concrete block slabs and the invert.
In general, at the crown, three levels of
linings are installed: a shotcrete lining, an
intermediary lining of poured concrete,
and a reinforced final lining. The water-
proofing membrane bridges the seismic
joint gap between intermediary and final
lining. The joint opening in the final lining
has been enlarged to 70 cm, and the gap
will be covered by a steel plate, for the
purposes of ventilation and fire resistance.
The backfilled bench pilot tunnels were
heavily reinforced to provide sufficient
abutment to the crown loads during the
excavation. These beams cannot be inter-
rupted while excavating, so the cutting of
117
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BOLU, TURKEY

5-piece steel arches are set at 1.1 m

General view of the Bolu tunnel face
with invert pouring underway.
the joint in the section can only be executed
once the invert is in place.
Excavation and Support
The Bolu tunnel has been advanced on a
new alignment, which diverts around the
collapsed section. It is being driven from
newly established faces within the aban-
doned tunnel on the Istanbul side. A
150 m-long cut-and-cover section was
completed at the Ankara portals before
excavation work could commence from
this end.
The weathered, faulted amphibolite
rock, with up to 140 m cover, is broken up
by a Krupp hydraulic hammer mounted on
a Cat 235 excavator, then loaded into road
tipper trucks. The 7 m-high top heading is
opened using 30 x 6 m-long forepoles over
the crown, under which three pieces of the
Heavy steel reinforcement of the 5 m-deep concrete
invert.
intervals. Then 20 off, 12 m-long anchors,
each comprising 3 x 4 m lengths of Atlas
Copco MAI SDA, are drilled in and grouted
using an Atlas Copco Boomer drillrig. The
roof and sides are given a 40 cm-thick
application of steel fibre reinforced shot-
crete, and a 50 cm-thick steel bar reinforced
shotcrete temporary invert is installed.
The bench is then advanced 2.2 m at
each side, and the legs of the steel arches
are installed, together with bolts and shot-
crete. Two incremental advances of 4.4 m
allow the invert to be excavated 5 m-deep
over the full width of the heading, and this
is filled with mass concrete with two pre-
fabricated steel reinforcement cages. A pur-
pose-built, self-propelled stage conveyor is
used to transfer the concrete from the fleet
of 8 cu m mixer trucks. The invert concret-
ing is maintained within 25 m of the face.
The total excavated area of the tunnel is
160-200 sq m. Where the rock is particu-
larly poor, a 60 cm-thick concrete slab
intermediate lining is installed, and the
annulus backfilled with concrete. This is
followed by a mass concrete in-situ lining,
using 150 sq m x 13.5 m-long self pro-
pelled formworks. The final lining opera-
tion is kept within 75-85 m of the face, to
ensure permanent support as early as pos-
sible. Concrete is supplied from two plants
on site with 80 cu m/h output capacity,
backed by a 350 t cement storage silo.
Where necessary, very-heavy lattice
girders are placed as temporary support,
and these are cut away as soon as suffi-
cient permanent support is in place.
The first tube breakthrough is scheduled
for August, 2005, with the second follow-
ing before the end of the year.
The finished twin-tube tunnel will
accommodate three lanes of traffic in each
direction, with vehicle cross passages at
500 m intervals. ■

Acknowledgements
Atlas Copco is grateful to the management
of the Bolu project for permission to visit
the site, and to Olivio Angelini, Gaetano
Germani and Aziz Õzdemir of Astaldi for
their help and assistance in preparation of
this article. Reference is made to Design
and Construction of Large Tunnel Through
Active Faults: a Recent Application by
M Russo and W Amberg (Lombardi
Engineering), and G Germani (Astaldi).

118 ROCK & SOIL REINFORCEMENT

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BALTIC STATES, NORTHERN EUROPE

Stabilizing Foundations
in Baltic Cities
Ancient and Modern
The Baltic States of Northern Europe
have done well to preserve most of
their historic buildings, some dating
from the Middle Ages. However, subsi-
dence is now the main enemy in Riga,
Latvia and Tartu, Estonia, where the
race is on to underpin the buildings
most affected. This is being accom-
plished with minimum intrusion using
micropiling techniques, in which MAI
SDA and grout pumps are the key ele-
ments. Similar techniques are also
being used to great effect in Riga coal
docks, where the sheet piling of the
dock wall is being secured using long
grouted SDA while the harbour is
deepened. The diversity of these jobs
highlights the flexibility of MAI SDA as
an essential construction tool.
concrete cladding and the steel sheet Barge-mounted drillrig installing
pile. Then 47 m-long, 130 mm-diameter 48 m-long MAI SDA anchors at
Riga docks.
Riga Coal Dock holes were drilled 40 degrees below hor-
izontal through the surface sand to pene-
Riga coal dock handles a million t/y of trate the sandstone bedrock below. Each
coal from the Kuzbas region of Russia, and drillstring comprised a cross bit with 16
is looking to expand its business by using x 3 m-long threaded MAI T76 bars and
larger ships, for which the harbour has to 15 couplings. Continuous grout injection
be deepened. was carried out at 40-60 bar pressure in
It was necessary to anchor the existing the 4 h-long drilling operation, during
dock walls to solid ground prior to the which retarders were used to keep the
dredging operation, following which a cement workable.
new, deeper wall is being installed. Atlas A week later, a plate and nut were
Copco MAI anchors are being used as both screwed onto the protruding end of each
temporary and permanent support for the anchor, and stressed up to 60 t. Some 120
sheet piling operation. anchors were required for the first stage,
Their installation is being carried out by and these were installed in a horizontal line
the marine construction division of BMGS, above the high water mark at 3 m intervals.
a Latvian specialist contractor. This allowed dredging of the dock from its
The first stage involved anchoring the previous depth of 10 m to 13.5 m. Each
upper section of the existing steel sheet anchor was pull tested at 90 t.
piles by drilling from a purpose-built barge Sheet piling operations then took place
floating in the dock, an operation which during the winter 2004/2005, along the line
carried on 24 h/day, 7 days/week whenever of the new dock wall, which is around a
the dock was free. The barge had to be metre seawards from the previous position.
towed out of the way every time a coal The annulus between the two walls is
ship tied up. being concreted.
At each anchor position, a 150 mm- The second stage of anchoring is being
diameter cored hole was drilled 1.5-2.0 undertaken in 2005, using the same princi-
m into the dock wall to penetrate the ples as for the first stage. In this case, the

ROCK & SOIL REINFORCEMENT 119

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BALTIC STATES, NORTHERN EUROPE

15 m. The anchors have been designed for

a 40-year life expectancy.
Inlet grouting

Micropiling For Support

Anchored rod
T76, 3 m - long
Cutter
Adapter Sheet pile
H55-MAI T76 Coupling T76
Concrete
Soil
Pre drilled at ø 150 mm
FLOATING PLATFORM Grouting
The 47 metre-long Atlas Copco MAI Self-Drilling
Anchors are drilled through concrete, sheet piles
and into the bedrock, strengthening the dock
walls prior to deepening the harbour.
Drillbit ø 130 mm
Schematic of drillrig mounted on new row of anchors will be drilled between
floating platform to drill downward into the earlier anchors on the same line,
the harbour wall. spaced at 3 m apart. This will result in 240
permanent 47 m-long ground anchors at
1.5 m intervals along the dock wall.
Dredging work can then be carried out
without fear of the dock wall moving, and
the dock will be deepened from 13.5 m to
MAI 400 grout pump at work in Riga basement.
The Old City of Riga, much of which
was constructed in the Middle Ages, is
built upon riverine deposits of the
Daugava flood plain, using wooden piles
as foundations. When installed in a water-
saturated environment, wooden piles will
last indefinitely because oxidation is
inhibited.
For six hundred years, the water table in
Riga Old City was stable. Then, in the
1960s, a hydro dam was built across the
Daugava River some 20 km upstream of
Riga. Since then, the water table has fluctu-
ated, revealing the tops of the wooden
piles, and allowing oxidation. The oxida-
tion has promoted rot, and the affected
buildings have started to sink. The sinking
has not been uniform, resulting in tilting
accompanied by severe structural cracking,
and differential subsidence along the
facades.
Halting subsidence of old buildings is
not easy, because access is usually diffi-
cult, streets are narrow, and working places
restricted. This is the precise scenario for
which micropiles were developed, and a
situation in which MAI anchors and grout
pumps prove their value.
The theory behind micropiling for sup-
port is very simple, seeking to create a
higher friction in the existing foundations
of the building. This is accomplished by
drilling and high pressure grouting
through, or in the vicinity, of the base of
the structure, to produce crosspiles to sup-
port the base of the building.
The micropiles are formed by the intro-
duction of grout during the drilling opera-
tion. The grout pressure is designed to
create piles of the required diameter,
while the grout itself stabilizes the hole
during the drilling process. Addition of
accelerators or retarders allows the
installer to vary the set of the grout
according to the specific ground condi-
tions, and to ensure that the penetration is
sufficient to produce a good pile without
wastage.
The micropiles are generally drilled
tight to the building and as vertical as pos-
sible, with a lookout angle of 15 degrees
or less. A small crawler rig is generally
used, and the grout pump can be remotely

120 ROCK & SOIL REINFORCEMENT

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BALTIC STATES, NORTHERN EUROPE

disposable bit are simply left in the hole,

reinforcing the finished pile.
Grout is mixed in an MAI M400 pump
on which the pressure and quantity can be
varied to suit the job. The machine’s gal-
vanized frame and stainless steel charging
hopper guarantee corrosion protection and
withstand the toughest treatment, and the
pump itself is easy to dismantle for clean-
ing and maintenance. The self drilling
aspects of the MAI SDA system allow
drilling in unconsolidated or non-cohesive
soil which would otherwise require
casing, and the hollow rod permits simul-
taneous drilling and grouting through an
adapter, speeding up pile installation. The
left-handed standard rope thread accepts
standard drill tooling, and can be supplied
in a variety of diameters and threads.
Generally, if the designer has done his
job correctly, and the right diameter of
anchor and drillbit are used, the grouting
effectiveness can be gauged visually by the
appearance of grout at the collar of the
hole.

Saving Riga
FORE, a leading Baltic micropiling con-
Installing MAI SDA using a handheld pneumatic tractor, has underpinned a number of
jackhammer. ancient buildings and office blocks in Riga
Old City.
situated, possibly conveniently close to the To support the new Hotel Man-Tess,
cement storage. FORE installed 200 micropiles to 8-9 m
The pullout force for a micropile is less using MAI R38. The 200 year-old adjacent Atlas Copco ROC 712HC used by FORE
than its load bearing capacity, so a building was supported by 114 mm steel to install MAI SDA.
hydraulic testing jack can be used to check
that any pile has achieved its design
capacity, without influencing its function.
Overall, micropiling offers a dependable,
fast, low-technology, and low intrusion
method of underpinning buildings, and
the drilling techniques used penetrate
both wood and masonry without prob-
lems.

MAI Self Drilling Anchors

The MAI SDA self drilling anchor,
although designed primarily to operate in
tension, is ideally suited to the require-
ments of micropiling.
For drilling purposes, MAI fully-thread-
ed pipe can be cut into any suitable length,
using couplings for extension. This allows
the system to be installed in even the tight-
est situations. Once a hole has reached the
required depth, the pipe, couplings and

ROCK & SOIL REINFORCEMENT 121

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BALTIC STATES, NORTHERN EUROPE

L above: Ancient warehouse in Old Riga
was saved by underpinning.
R above: Subsidence was arrested on
the six-storey Pikadilja Cafe.
pipes installed to 8 m depth at half-metre
spacing using an Atlas Copco 712HC drill-
rig, and filled with concrete. These were
then secured using 15 m-long MAI
anchors drilled at 7 degrees from horizon-
tal, each providing 30 t of anchoring force.
At Pikadilija Café on Valnu Iela, close
to the Opera House, the six-storey struc-
ture has been subsiding into the very soft
deltaic riverine deposit, and needed stabi-
lization before refurbishment. The
ground is non-supporting, and the
micropiles are designed to take the whole
weight of the building at around 20-25
t/unit.
Located on the same street as Pikadilija
Café, the Terranova building has been
underpinned by FORE using 350
micropiles formed from MAI R38 self
drilling anchors to 9 m depth grouted using
an MAI M400 grout pump at 25 bar pres-
sure. Work was undertaken from both the
street and basement of the building to pro-
duce crosspile support.
In Valnu Street, FORE installed 350
micropiles in the basement of the existing
block, which is being converted to offices
and flats. The piles are 15 m deep and 15
degrees from vertical, and designed to pass
through the mud layer and penetrate 1 m
into the sand layer beneath. MAI R38 SDA
grouted by an MAI M400 grout pump pro-
duced high friction piles.
A 14th Century grain warehouse in
Aldaru Iela was underpinned by FORE in
2002 using MAI R38 SDA to produce
crosspiles. The subsidence was arrested,
and the building, situated close to
Parliament House, was refurbished.
In a totally different application, FORE
is installing MAI R38 8 m-depth grouted
anchors to provide stable foundations for
new high-voltage electricity pylons cross-
ing Riga docklands.
Preserving Tartu
Tartu City Hall has been successfully
underpinned using micropiling techniques
developed by local contractor Mikrovai,
and installed using Atlas Copco MAI SDA
self drilling anchors.

122 ROCK & SOIL REINFORCEMENT

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BALTIC STATES, NORTHERN EUROPE

Mikrovai commonly installs 10-12 m-

long piles using a 210 mm conical bit and
square section pipe, and uses MAI SDA
T76 hollow threaded bar for longer
micropiles up to 18 m, with bit diameter up
to 130 mm.
The City Hall was underpinned in 10
weeks using a crew of 8 men. Some 514
holes were drilled and grouted at 20 bar
pressure, using a total of 3,100 m of R32
and R38 MAI SDA hollow threaded bar
with 76 mm bits.
Generally, the R32 micropiles were
credited with 15 t bearing weight, and
the R38 with 30 t. The subsidence at
the City Hall has been successfully
arrested, and minor refurbishment
works are now being undertaken with
confidence.
Also in Tartu, an old student dormitory
block is being refurbished as a science
department for the University. Mikrovai
underpinned the basement foundations by
installing 230 off 6 m-long R32
micropiles using MAI SDA. These were
drilled at 15 degrees from vertical both
inside and outside the building. If and the sheet piles withdrawn for Imposing City Hall at Tartu was
micropiling were not available as a reuse. underpinned in 10 weeks using 3.1 km
proven foundation underpinning tech- Mikrovai has found that the drillbit of MAI SDA.
nique, this building would probably have is critical to a good job, and poor
been knocked down rather than refur- choice can adversely affect the cost
bished. equation. A too-small diameter drillbit
At the crossroads in Tartu city centre, a will result in a smaller grout column
large shopping mall is being constructed than required, and a too-large diameter
by the local Skanska company, for which may cause the hole to collapse. Also,
temporary works include a steel sheet piled they find that the drilling operation
retaining wall to the high side of the slop- must not be carried out too quickly,
ing site. because the grout column has to form
Here Mikrovai has installed 42 off, properly, and this takes a certain time
14-18 m-long R32 MAI SDA and 20 according to the ground characteristics
off, 16-18 m-long R38 MAI SDA to of each job. A rule of thumb when
anchor the wall to the sandstone sub- installing 15 m-long anchors is 15-25
strata. By drilling at 10 degrees below holes/day/rig, if access is not a prob-
horizontal, the anchors, spaced hori- lem. MAI produces a full range of dis-
zontally at 4 m intervals along the posable bits in diameters for every
upper wall section, can penetrate 4 m condition. ■
into the sandstone. The MAI hollow
threaded bar has been used in 4 m Acknowledgements
lengths, with 76 mm EX bits. The R32
anchors have been tested at 20 t and Atlas Copco is grateful to Valery Zagulin,
the R38 at 40 t. chief of BMGS geotechnical department in
Because the more traditional wire Riga, Dainis Musins, managing director of
rope anchors require a casing system of FORE, and Urjo Eskel of Mikrovai for
drilling, they take longer to install and their help and assistance in the formula-
are more expensive for this type of job. tion of this article. Thanks also to Nils
Once the permanent retaining wall is Hellgren, managing director of Geomek,
built, the temporary wall will become representative agent for MAI products in
redundant and the anchors will be cut the Baltic States.

ROCK & SOIL REINFORCEMENT 123

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DAVENTRY, UNITED KINGDOM

MAI SDAs Increase Land Use

for English Housing
Support for New
Housing
In the UK soil nailing represents the
vast majority of the market for self-
drilling anchors and housing develop-
ment forms a large part of market
growth.
At the Admirals Way housing devel-
opment in the English Midlands town
of Daventry, Atlas Copco’s UK MAI
distributor, Dywidag Systems
International, has been supplying
geotechnical specialist contractor
Keller Ground Engineering with hol-
low-bar MAI anchors for clay sub-soil
stabilization.
Keller also recently carried out sim-
ilar work at Snodland, Kent to stabi-
lize chalk and clay

covered up to form the gardens of some of Setting out the embankments in the
central part of the housing
Daventry Development the new properties.
development. In the background soil
Most UK inland soil nailing applica-
tions are classified by geotechnical engi- nailing is progressing on the section
The main development contractor at
already marked out.
Daventry is a joint venture of Thomas neers as low-risk, lightly loaded, passive
Vale Construction (Site Manager Dave installations with a design life of 60 or
Casey) and Westpoint Construction, 120 years. Exceptions are coastal areas
tasked with building 26 houses, five pairs where the effect of saline water is signifi- Installing soil nails in one of the
of flats and two bungalows on the site. cant, or in other aggressive ground condi- development service road
The housing development is on a wedge- tions. embankments.
shaped, sloping site comprising a relative-
ly soft clay mix which, if developed by
conventional means, would probably
necessitate the excavation and construc-
tion of expensive deep foundations for the
houses and service roads. As facilitated by
the MAI Anchor soil nailing method, the
site has been terraced with embankments
supporting the service roads at the end of
the gardens of adjacent new properties.
The soil nails are installed by drilling into
these embankments at 15-20 degrees. A
substantial development cost saving will
result.
At the lower end of the site local condi-
tions over a short length did not permit the
creation of an embankment, so here the
MAI SDAs were inserted directly into a
level surface which would eventually be

124 ROCK & SOIL REINFORCEMENT

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DAVENTRY, UNITED KINGDOM

MAI SDAs
The self-drilling anchors used by Keller at
Daventry were of the R32N hollow rope-
threaded bar design with 100 mm-diame-
ter, open-face, retroflush sacrificial drill
bits suitable for clay. The left-hand thread
allows connection to standard drill tooling.
The bar, measuring 32 mm diameter over
the threads or effectively 29.1 mm has an
ultimate strength in this size of bar of 280
kN and yield strength 230 kN.
MAI SDAs can be installed in unstable
ground without the need for temporary hole
casing by simultaneous drilling and grout-
ing. Depending on the type of bit used, they
are suitable for a wide range of ground
materials including soft clay (as at inclined 15-20 deg and at right angles to the Keller Ground Engineering’s Site
Daventry), sand, gravel, inconsistent fill, tracks, permitting the rig to be driven along Agent, John MacGregor Jr., views the
boulders, rubble, and weathered and frac- the row of soil-nails to be installed. The installation of some of the last soil
tured rock. drill bit and rotation speed are chosen to nails to be installed in the lower part
of the site.
ensure that the borehole is cut rather than
Installation
At Daventry, the consulting engineer’s
ground reinforcement pattern called for
soil-nail lengths of 5-13m depending on
their position on the site. This is achieved
by using coupling sleeves to connect the
standard lengths of threaded bar. In all
750-760 soil nails are being installed at
Admirals Way.
A surveyor first lays out each portion of
the site to be reinforced using red-painted
markers to indicate the planned entry
point for each soil nail according to the
design of the consulting geotechnical
engineer.
Keller used two of their own crawler-
track, hydraulic, rotary drilling rigs to
install the SDAs, generally with the boom
Reinforcement is complete with a
layer of geomat secured by SDA nuts
and plates holding fine wire mesh.

Building from foundations commences

with the completed embankment
reinforcement in the background.

ROCK & SOIL REINFORCEMENT 125

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DAVENTRY, UNITED KINGDOM
Installing the top row of soil nails at
Woodlands Farm, Snodland, prior to
excavating the low part of the slope.
The completed slope stabilization
showing the heads of the soil nails
and the geogrid later
126
displacing the soil through percussive
action or a high feed pressure. This ensures
better permeation of the grout and thus a
better bond.
Each rod section of the soil nail, three or
four metres long, takes only about four
minutes to insert using rotary percussive
drill action and a 3-man crew. There is a
drill-rig operator, another to act as ‘spotter’
and to insert the MAI SDAs and extensions
as drilling progresses, and a grout mixer
and pump operator. Simultaneous with
drilling a cementitious grout is pumped at
2.1-4.1 bar (30-60 lbf/sq.in.) through a special
injection adaptor and thence through the
hollow bar of the SDA. The use of large,
100-mm bits enables a sufficiently large
grout column to be created to meet the
specification.
Once the soil-nails are inserted correct-
ly into the ground, sheets of welded
heavy wire mesh are attached to the pro-
truding SDAs, followed by a layer of
geomat, non-woven, geosynthetic materi-
al incorporating a layer of lighter wire
mesh. The facing components are held in
place by the galvanized plates and
threaded nuts of the SDAs. This all acts
mainly as erosion control of the stabi-
lized surface, but also aids the stability of
the whole installation.
Keller’s John MacGregor reported that,
on the Admirals Way site, the geotechnical
design called for ten ‘test’ soil nails across
the site to which tension was applied once
the grout had cured. Dywidag’s own
Stressing and Testing Services Department
carried out all the testing work. A tempo-
rary bearing platform is installed since the
test load would otherwise be pulling
against a soft (clay) face, albeit overlain
with geogrid etc. The test establishes the
true capacity of the soil nail bond in the sta-
ble zone rather than including the effect of
the wedge zone.
Prestige Housing
Keller Ground Engineering carried out
work on another housing development in
2004. The Woodlands Farm luxury hous-
ing development at Snodland in Kent,
south-east England, represents an impor-
tant application for embankment soil nail-
ing to make the best use of landscaping.
Keller Ground Engineering, working for
Berkeley Homes, used 473 R32N MAI
SDAs to create an embankment between
the building area and a lake in an old chalk
pit. The soil nails were 10 or 12 metres
total length.
Keller employed a drill boom and feed
mounted on the long backhoe boom of a
hydraulic excavator to install five rows of
soil nails in chalk and clay from the top of
the embankment. This allowed free access
for a bulldozer to shape the bottom of the
slope. After installing the soil nails the
head plates and nuts were used to retain a
geogrid layer of mesh and geosynthetic
material to allow restoration with
topsoil.■
ROCK & SOIL REINFORCEMENT
RR3/RC19A 23/6/05 11:39 Page 127
Soil Nailing Infrastructure along
England’s Routes
A Major Force in
Transport Slope
Stabilization
The UK distributor for MAI
International, Dywidag-Systems
International, has been leading the
way in slope stabilization using MAI
self-drilling anchors, in conjunction
with Atlas Copco Construction &
Mining (UK). Some of the most pres-
tigious recent transport construction
and renovation projects in the UK
have benefited from the use of the
MAI SRN hollow-bar anchor system
(Self-Drilling Anchors - SDAs), chiefly
for soil nailing, whether for stabiliza-
tion of cuttings walls or embank-
ments.
First Toll Motorway
One of the leading projects is the UK’s
first toll motorway, the Birmingham
Northern Relief Road; now known as the
M6 Toll. The engineer working for the
Client, Midland Expressway (M6),
designed a steep wall in a cutting, protect-
ing some existing trees. The use of slope
stabilization with soil nails allowed the
‘footprint’ of the cutting to be reduced (see
picture), hence reducing the necessary land
‘take’ from the neighbouring landowner,
saving project expenditure. On behalf of
the main contractor consortium CAMBBA
(made up of Carillion, Alfred McAlpine,
Balfour Beatty and Amec), a specialist
sub-contractor installed 1000 soil nails
using MAI SDAs in a grid pattern across
the face of the cutting wall.
The ground drilled is sandy clay with
occasional boulders, necessitating the use
of sacrificial drop-centre button bits with
tungsten carbide peripheral blades to form
a clean hole. The fully galvanized, R32N
hollow-bar, MAI SDAs varied in total
length from 7 to 12m with couplers.
ROCK & SOIL REINFORCEMENT
UNITED KINGDOM
Since this cutting construction was Cutting during construction of the M6
Birmingham Northern Relief Road
made in February 2003, the M6 Toll now
forms a valuable and busy alternative to showing the (right) wall stabilized by
the previous congested routes of the old MAI SDA soil nails compared with
(left) a more conventional low-angle
M6 and A5 linking the south-west
cutting slope requiring more surface
Midlands of England to the North West,
area and volume of excavation.
by-passing the Birmingham/Black Country
conurbation.
Stabilizing Freight Route
Britain’s transport infrastructure also
includes many kilometres of rail routes, the
structures of which often require attention,
since many are over a century old. One
recent rail project involving MAI SDAs,
678 in all, was the stabilization of a failing
embankment on the Crewe-Salop
Independent Line in the centre of the
Midlands town of Crewe in October 2004.
Network Rail (North West) and its
Engineer considered the more convention-
al solution of sheet-piling the lower part of
the embankment, but this may have
required lengthy closures of a busy rail
route, a deeper structure requiring more
site investigation, and some other environ-
mental disturbance such as from noise.
Using the alternative of soil nailing only
limited access from the top of the embank-
ment was required.
127
RR3/RC19A 23/6/05 11:39 Page 128

UNITED KINGDOM

TSV Line near Henley-in-Arden had been

On the Crewe embankment slope
installing soil nails with excavator-
mounted drills. Note protruding heads
of installed SDAs
The restored embankment on the
London-Brighton line at Earlswood
showing the soil-nailed gabions just
below the rail level
The soil-nail reinforcement was designed
in accordance with the new European soil-
nailing Standard EN 14490, and employed
R32N MAI hollow-bar of 16-m length. Only
the top-bar (down to the coupler) needed to
be galvanized against atmospheric corrosion
in order to preserve the structural integrity
for the design life of the installation.
Two drill booms were used, mounted on
hydraulic excavators with long-reach (22-
m) ‘sticks’. This enabled the soil nails to be
installed in the embankment in an ‘under-
arm’ action, leaving the rail lines below to
be operated as normal and without distur-
bance to neighbouring structures. The
drilling equipment included a shank inte-
grated into the injection adaptor enabling
simultaneous drilling and grouting.
Badger Bother
Other Midlands rail projects have been car-
ried out in Railtrack’s (now Network Rail)
Midland Zone. Two embankments on the
suffering gradual subsidence due to both the
type of fill material used and the activities of
badgers burrowing in the embankments. The
effects of this on the track necessitated the
imposition of a 20-mile/h (32-km/h) speed
restriction on train movements.
Using a series of one-way gates, the
badger population was ‘rehoused’ nearby
before other rectification work began. Trial
soil nails were first tested by Dywidag’s
Stressing and Testing Department to establish
the bond stress of the nail within the stable
zone of the slope, behind the slip plane.
Following successful trials a specialist
contractor installed the SDAs in both
embankments. The method, including
simultaneous drilling and grouting,
enabled the reinforcement to be installed in
the unconsolidated sand and gravel without
resort to hole casing, whilst also reducing
overall installation time. Following com-
pletion of the soil-nail grid, the slope sur-
face was reprofiled, and rail speed
restrictions could be lifted.
Also in the Midlands, there was a major
slip in the Beehive Embankment on the
West Coast Main Line in Leicestershire
that needed to be rectified in February
2004. The slip had been caused by the
presence of a perched water table. The
solution involved drainage of the perched
water table and the installation of three
rows, with 100 soil nails in each, using
R32S galvanized MAI SDA hollow bar.
The head plates of the SDAs also serve to
hold a layer of geosynthetic material in
place to deter surface erosion.
Nailed Gabions
In March 2003 the Earlswood Embankment,
on the main London-to-Brighton railway
line, required major stabilization work for
the Southern Zone of Network Rail. The
Client’s engineers chose a solution combin-
ing a layer of gabions immediately under the
track with embankment slope soil nailing.
Gabions are cuboid steel-wire-mesh baskets
filled with rocks to form, with neighbouring
units, a self-draining wall.
The contractors used MAI SDAs to fix
the gabions in position to form a platform
under the track, and also inserted the series
of soil nails in the underlying embankment.
The embankment works were extensive,
requiring a total of 1500 soil nails formed
by R32N MAI hollow bar. ■

128 ROCK & SOIL REINFORCEMENT

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PORTE-TURIN, ITALY

Portal Stabilization Using

Swellex
Olympic Deadline
Improvements are being made to the
state road EN23 near the town of
Porte, Turin in Italy ahead of the 2006
Winter Olympic Games. The project is
designed to relieve traffic congestion
in the town centre.
Tunnel alignment is in gneiss-
greenstone, mica-schist and glacial-
lake loose ground, so rock
reinforcement is critical to the suc-
cess of the project, particularly at the
portals. Based on its proven quality
and consistent performance, Atlas
Copco Swellex Mn 16 was selected as
the rockbolt for use in stabilizing the
rock around the portal.

Mixed Ground
The project designer for the underground
work is Geodata SpA of Turin, for the
client, a consortium known as Agency of
XX Winter Olympic Games of Turin 2006.
The contractor, Baldassini and Tognozzi
SpA Costruzioni Generali of Firenze, Italy,
is using drill/blast techniques in the rock
sections of the alignment, and a hydraulic
hammer in the loose ground.
Rock reinforcement is required to improve
the quality of the rock, for which Swellex Mn
16 rockbolts in lengths of 4 m and 6 m have
been used for supporting the portal area.
in rock comprising gneiss-greenstone and
gneiss mica-schist belonging to the meta-
morphic substratum of the Cristallino
Massif of the Dora Maira.
Swellex rockbolts were used both
underground for primary support, and to
reinforce the rock walls above the eastern
portals of the tunnels.
Slope Stabilization
The geo-structural survey carried out on the
slopes housing the portals showed that the
Reinforcement of the slope by the
eastern portal of the La Turina tunnel
with 4 m-long Swellex Mn 16
rockbolts.
Reinforcement of the slope at the
eastern entrance of the Craviale tunnel
using 6 m-long Swellex Mn16
rockbolts.

Project Description
The project for the diversion of the Colle
del Sestriere state road N23 is taking place
near the town of Porte, approximately 40
km from Turin, in the upper Chisone
Valley of the Piedmont Region.
In addition to embankments and dry
bridges along the river Chisone, two
single-tube, bi-directional natural tunnels
are being built, La Turina with a length of
601 m, and Craviale with length of 991 m.
La Turina tunnel is being driven partly
in rock and partly in softer ground, where-
as the Craviale tunnel was driven entirely

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PORTE-TURIN, ITALY

bolts based on the number of joints (Jv)

Swellex rockbolts stocked by the
eastern entrance of the Craviale
tunnel.
rock was very altered and fractured. These
slopes, analyzed using the empirical
approach of Romana (1991), were classified
as partially stable, and assessed as class III-
SMR-Slope Mass Rating. They required
immediate support using rockbolts and
mesh with shotcrete to avoid the potential
slide generated by a combined influence of
the joints and inclination of the slope.
The formula of Palmstrom (1982) was
used to calculate the required number of
per cubic metre of rock.
The bolt requirements indicated by this
method were: length 3-6 m; distance between
bolts 1-3 m; bolt strength 120-150kN; and
resulting force applied a 120-150 kN/sq m.
To support the walls around the portals,
Atlas Copco Swellex Mn16/Mn24 were
installed, being the rockbolts with the
specified features. Some 450 bolts of 6 m
length were used to stabilize the slope at
the eastern entrance of the Craviale tunnel,
and around 200 bolts of lengths 4 m and 6
m were installed to support the eastern
portal of Turina tunnel.
Since the sides were reinforced in this fash-
ion, no blocks have moved and the entrances
have been stabilized and safely supported.■
References:
Palmstron, A., 1982. The volumetric joint
count – a useful and simple measure of the
degree of rock jointing. Proc. 4th Cong.
Int. Assn Engng Geol., Delhi.
Romana, M., 1991. SMR classification.
Proc. 7th Congr. On rock mech SRM,
Aachen, Germany.

130 ROCK & SOIL REINFORCEMENT

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SLOVAKIA AND CZECH REPUBLIC

Driving From Budapest to

Nürnberg
Saving the Best Until
Last
Completion of missing links in the
European Motorway system is rapid-
ly producing fast connections
between the most unlikely places.
Key elements of the D2/D5 (E65/E50)
motorway from Hungary to Germany
are the 1.4 km-long twin-tube Sitina
tunnel in Bratislava, Slovakia and the
380 m-long Valik tunnel at Plzen in
the Czech Republic. These are difficult
tunnels, which is perhaps why they
have been left until nearly last to be
completed. Both are using advanced
rock reinforcement techniques to
drive through incompetent rock with
low overburden. Swellex, Symmetrix,
Boodex and MAI SDA are all
employed to keep these jobs moving bench, and is carried out using drill/blast. Grouting rockbolts from the basket of
in the right direction, together with In classes 4 and 5 an invert arch is added, the Rocket Boomer 352.
Atlas Copco drillrigs and Secoroc and excavation is by mechanical means.
drillsteel and bits. Often, a combination of drill/blast and
mechanical excavation is employed.
Mucking out is by wheel loader into 25 t
Sitina, Bratislava dumpers.
The crystalline rock at Sitina is inten-
Contractor Banske Stavby is tunnelling sively tectonically disrupted, with systems Atlas Copco Rocket Boomer L2 C face
under low overburden in heavy, broken of 1 mm-3 cm cracks and breaks which drilling at Sitina south.
granitoid rock using two Atlas Copco
Rocket Boomers equipped with Secoroc
T32 Speedrods and 45 – 51 mm bits.
Injection grouting is carried out using an
MAI m400NT grout pump.
The client for the construction is
Slovenska sprava ciest, and the designer is
Dopravoprojekt a.s, Bratislava.
Sitina tunnel comprises east and west
tubes, each requiring 251 m of cut and
cover at each end and 1,189 m of natural
tunnel in between. The natural tunnel is
being driven at an excavated section of 79-
98 sq m in crystalline rock comprising
biotite and double-mica granodiorites with
sporadic granites, often with veins or peg-
matites up to 1.5 m-thick.
NATM techniques are used, with five
basic rock classes. In classes 1-3, the exca-
vation is divided into a top heading and

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SLOVAKIA AND CZECH REPUBLIC

radially, using one of the Rocket Boomer

North portals of Sitina with east false
tunnel nearing completion.
Symmetrix system umbrella drilling at
Sitina portal.
can be up to several metres wide, and filled
with clay material or breccia or mylonite.
Locally, coarse blocks of schist-biotite
paragneiss of several tens of metres in
thickness occur, locked tectonically into
the granitodiorites. These discontinuities
result in rock splitting to produce large
blocks which can fall from the roof and
sides of the excavation.
The primary lining uses wet shotcrete
with a non-alkaline accelerator, lattice
girders, mesh and 4-6 m-long grouted
rebar rockbolts.
The main faces are advanced as top
headings, with benches trailing at 50-120
m behind. The 51.7 sq m top heading is
micropiled through lattice girders to pre-
vent falling ground, and shotcreted prior to
installation of 4 m-long grouted rebar bolts
drillrigs. The bench is advanced to produce
a full excavated section of 105 sq m. The
lattice girders comprise three pieces in the
top heading, to which legs are bolted as the
bench advances.
The ground conditions may demand any-
thing from 80 x 1.5 m-deep blastholes using
plastic explosives with millisecond delay
detonation in the harder sections, to excava-
tor-mounted hydraulic hammer or scaling
bucket in the softer sections. There is a seri-
ous blasting vibration restriction, due to the
proximity of the Slovak Academic Institute
with its sensitive technical laboratory equip-
ment. Therefore continuous monitoring is
necessary, and parameters are modified to
counter undesirable effects.
Symmetrix Complements
Boodex
Umbrella drilling has been needed
throughout the alignment to date, due to
the shallow overburden and soft, blocky
mylonite. Initially, 12 m-long pipes, com-
prising 4 x 3 m lengths of perforated
Boodex, were drilled in with a pilot bit and
disposable crown. These were grouted for
10 minutes at 20 bar pressure to produce a
concrete column around each pipe. With
25-33 pipes in each top heading, the grout-
ed columns formed complete umbrellas
beneath which it was possible to excavate
in 0.8 m increments. Usually eight incre-
ments were advanced, and eight arches set
and shotcreted, beneath each umbrella,
leaving a 5.4 m overlap beneath which the
next umbrella could be safely drilled.
Lately, Symmetrix has proved cheaper,
more reliable, and faster than Boodex
where rock conditions have been particu-
larly poor, and some 20 Symmetrix 12 m-
long umbrellas have been installed, each
comprising 15–20 boreholes.
Whereas Boodex employs a pilot bit
with a following reamer, which enlarges
the hole to allow the casing to be pushed
in, the Symmetrix system uses a rotating
casing with rock cutting crown behind the
pilot bit. Hence Symmetrix provides
immediate support for the hole, making it
better in very poor ground conditions.
Forepoling with up to 40 x 4 m-long, 25
mm-diameter rebar rods is used in the
worst ground conditions.
In the areas of the main tunnels where
the five crosspassages are being excavated

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SLOVAKIA AND CZECH REPUBLIC

between the tubes, the invert is concreted

to a depth of 1.5 m, and for 10 m on either
side. A similar depth of concrete has also
been laid at the ends of each of the tubes.

Valik, Plzen
Valik tunnel is situated about 30 km from
the German border on the Czech Republic
section of the Prague-Nürnberg motorway.
Overall length of the tunnel is 380 m, com-
prising 330 m of natural tunnel, with 20 m
of cut-and-cover at the west end and 30 m of
cut-and-cover at the east end. There is also a
900 m-long surface cutting at the east end to
connect with the advancing motorway.
The natural tunnel is complicated by
shallow cover and a very narrow corridor with reinforced concrete before the main Atlas Copco Rocket Boomer L2 C
of surface rights beneath which it has to be tunnel drives could commence. starting south tube at Valik tunnel.
excavated. The twin tubes have to be The central pilot tunnel, within which the
extremely close together, requiring buttress reinforced concrete buttress for the main
to be excavated and replaced in entirety tunnel was constructed, was excavated from
the west end within a 4.5-month timespan.
It was driven as a 4 m-high top heading and
Symmetrix or Odex?
2 m bench, using an Atlas Copco Rocket
Boomer L2 C, one of two at site. Main con-
Both Symmetrix and Odex can be used
tractor Metrostav also has one Atlas Copco
for drilling holes up to 273 mm diameter,
Rocket Boomer 352 at Valik, together with
when the choice of bit will depend upon
four GIA DC16 service platforms based on
the specific ground conditions, the pres-
Atlas Copco carriers.
ence of rock and boulders, and the rig to
Excavation was in increments of 0.8 m,
be used.
1.0 m, and 1.2 m, depending upon the spe-
For shallow holes in soft ground, Odex cific ground conditions, and lattice girders
is cheaper to use, a little slower, will were set at similar intervals. In very soft
require more torque, and may deviate if ground, an excavator with scaling bucket
hard boulders are encountered. or hydraulic hammer was used instead of Valik tunnel west end showing south,
However, a skilled driller will overcome the drillrig. pilot and north tube excavations.
these conditions.

Symmetrix is generally used with DTH

hammers, but can also be used with top
hammers such as the COP 1838 for
small diameter holes for applications
such as umbrella drilling where the
lower torque requirement can be crucial.

Both Symmetrix and Odex can be used

with all standard casings, and also with
HPDE, PVC and fibreglass casings.
Drilled casings are becoming increasing-
ly popular in underground construction,
especially in urban areas, where they are
tending to replace pile driving and pipe
jacking in ground containing boulders.
In these conditions, Symmetrix is often
the only method that can penetrate suc-
cessfully, and is sometimes called upon
to drill down to 100 m.

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SLOVAKIA AND CZECH REPUBLIC

holes in the floor of the pilot tunnel, and

installed two heavy rebars into each hole
before pouring concrete to complete the
piles in-situ. The revealed ends of the
rebars were hooked, in order to provide a
secure connection for the main buttress
concrete reinforcement.
Likewise, the crown of the pilot drive
was reinforced by installation of 4 x 6 m-
long grouted rebars per metre of advance
to key into the buttress reinforcement.
In order to establish the east portals, an
18 m-deep pipe umbrella was installed,
together with 6 m-long face anchors. A
beam support was also necessary immedi-
ately above the east portals, secured by 17
x 20 m-long grouted cable anchors.

Buttress formworks inside Valik pilot
tunnel.
Section of Valik tunnel showing
concrete buttress between main
tubes.
Immediate support was provided by 4
m-long Atlas Copco Swellex Mn12 rock-
bolts, with shorter 3 m versions being used
in the stronger rock sections. Some 3,000
of the longer units were installed, along
with some 2,000 of the 3 m version. Up to
25 Swellex bolts were installed for each
metre of advance, with shotcrete being
applied systematically to roof and side-
walls, and to the face when necessary.
Concrete Buttress
The construction of the concrete support
buttress between the two tubes of the main
tunnel required foundation works through
four separate soft ground sections, com-
prising a total of 90 linear metres. To
improve the footing in these areas, 6 m-
deep micropiles were installed in rows of
four and three at 1 m spacing.
This work was undertaken by a specialist
subcontractor, who drilled 123 mm vertical
Main Tunnels
Main tunnel excavations are being under-
taken sequentially using NATM tech-
niques. This involves top heading and
bench excavation of the outside shoulders
of each tube using lattice girders, MAI self
drilling anchors SDA R 25 150kN in 3 m
and 4 m lengths, and shotcrete.
The north tube is being developed in
advance of the south tube. Depending on
the geology, up to 27 SDA are being
installed into each fan or profile, with a 1
m distance between fans.
This is followed by two-phase excava-
tion of the upper sections of each tube to
form the main tunnel roofs, and then the
remaining bench can be removed to con-
struct a curved invert. During the process,
the area above the concrete buttress is
being grouted for consolidation, to promote
transfer of the ground pressure away from
the main tunnel lining. The remaining ele-
ments of the pilot tunnel lining are being
removed on advance. The final lining of the
tunnel will comprise reinforced concrete of
varying thickness from 0.3 m to 0.5 m.
Sitina tunnel is on schedule to open for
traffic in August, 2006.■

Acknowledgements
Atlas Copco is grateful to Banske Stavby
engineers Vladimir Kotrik, Anton Sumerak
jr and Anton Petko for permission to
extract from their paper Technological
Procedure of Construction for the Sitina
Tunnel, and to Metrostav engineer
Miloslav Zelenka, manager at Valik tunnel,
for his assistance at site.

134 ROCK & SOIL REINFORCEMENT

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OSLO, NORWAY

Systematic Grouting at
Oslo Subway
Half Century Progress
The T-Baneringen project is the
biggest enlargement of the Oslo
Subway since the system got under-
way in the 1960s. It comprises sever-
al new subprojects, of which the first
to be undertaken is the section from
Ullevål Stadium to Storo. The align-
ment of the 1.24 km-long tunnel, with
a cross-sectional area of 65 sq m,
passes through a very difficult zone
between sections 700 and 750, which
called for an intense grouting opera-
tion.
Contractor Veidekke chose the lat-
est grouting technology from Atlas
Copco Craelius to handle this chal-
lenge, where absolute control over
the efficiency of the grouting opera-
tion was key to its success. The
Unigrout EH 400-100-90 WBC
described in this report proved to be guide the grouting operation. Leakage Ramp entrance to Oslo Subway tunnel
must be measured and recorded, and leak- development.
the right machine for the job in every
respect. age per drill hole must not exceed 10
lit/min. The grouting stop pressure is set at
35-45 bar.
Grouting Contract Leakage<100 l/min drillhole. Stop pres-
sure 40-50 bar and be standing for 5 min.
The contract differentiated between sys- There is a difference between leakage
tematic and sporadic grouting, with pay- per/min/100 m tunnel and leakage/min/
ment according to work and material drill hole.
quantities. The main components were: In Sweden, the leakage/min/100 m of
drilled metres for investigation; grouting tunnel the most important, while in
and check holes; quantities of cement; Norway leakage/min/drill hole is more
numbers of packers; and the working hours popular.
for the grouting operation. The total inflow of water in the tunnel
The systematic grouting procedure as was measured at 14.9 l/min/100 m. The
laid out in the contract included following: specification was set at 7 lit/min/100 m.
31 holes of 18 m-long; bottom of the hole Pore pressure measurements showed
has to be 5-6 m outside the tunnel contour; that, with the grouting undertaken and
and distance between two covers is set at with some infiltration, the groundwater
10 m, or two blasting rounds. level could be maintained at the same
In Scandinavian tunneling, leakage fig- level as before tunnel construction com-
ures are most important and are used to menced.

W:C ratio starts at 1.0

Leakage figures < 500 lit/min/drillhole gives a W:C ratio = 0.8
Leakage figures < 1000 lit/min/drillhole gives a W:C ratio = 0.7
Leakage figures <1500 lit/min/drillhole gives a W:C ratio = 0.6/0.5

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OSLO, NORWAY
Atlas Copco Craelius Unigrout EH400- The grouting operation in this difficult
100-90 WBC. section 700-750 was accomplished in 21
rounds compared with the 4-5 rounds
required for the rest of the tunnel.
The corresponding figures for the
cement consumption were 425,860 kg
compared with 50,000-70,000 kg for the
standard systematic method.
Craelius Unigrout EH-400
The Unigrout EH 400-100 -90 WBC used
in Oslo features two silos at the back of the
unit, the small silo for bagged cement and
the large silo for 1,000 kg big sacks, or, as
in this case, delivered by separate cement
silo trucks. Both onboard silos are
equipped with vibrators, and the larger of
the two also has an agitator level monitor,
which sends a signal to the operator when
Working platform at the front of the
the cement level is low. On the top of the
Unigrout truck.
136
Grouting Quantities for the 50 metre
section 700-750
Drill metres: 9,081 m
Micro cement: 426,255 kg
Grout Aid: 88,609 kg
Standard cement: 81,234 kg
Grouting time: 925 h
Total cost: NOK6.5 million
Grouting cost/m: NOK125,000
silo there are also a safety grill and a pro-
tecting lid.
The electrical cable reel is located
alongside the larger silo. On the right side
of the container there are two doors, one
for entry when the unit is not operating and
there is no hydraulic power, and the larger
one for installation and removal of equip-
ment.
Grout control station.
The left side of the grouting container
features a wall divided into two flaps, both
of which are operated hydraulically. The
lower part acts as a walkway during the
grouting operation, and the upper part acts
as a protecting roof for the operator. On the
silo section there is also a foldable walk-
way for the operator. On the forward end
there are protected connectors for the
hoses.
An operative works from the elevating
basket, placing the packers and grout lines
in the grout holes in the order specified,
while the supervisor controls the results at
the face.
The grouting operator carefully follows
the different steps in the production, pump-
ing and placing of the grout. Every step is
recorded simultaneously on the Logac and
the WBP.
The grouting operator has full control of
all the equipment and recorders within an
arms reach. He has three different opera-
tion modes to choose from: grout for the
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OSLO, NORWAY

standard grouting operation; GIN for per-

forming grouting according to the GIN
(Grouting Intensity Number) method; and
Lugeon for water pressure tests. A roof
over the control position protects him from
dripping water and falling rock particles.
The safety rack is folded in when the
two flaps are unfolded, and the lights in the
container roof reflect against the walls to
provide good visibility for the grouters.
Consultants set the GIN values based on
the rock parameters for the maximum pres-
sure, maximum volume/m/drillhole, and
the allowed GIN max curve.
They report that logging of the grouting
operations and feedback from the LOGAC
programs is a tremendous improvement. The
quantities of cement per time unit for every

Typical Logac screen dump.

order receipts and mixing times are con- Controlling overall grouting operation.
trolled by the formula system.
The mixer is suspended on three strain
gauge load cells.
The Pumpac hydraulic control block
has levers and knobs for the high pressure
and low pressure valves and knobs for the
flow setting valves. Beside the hydraulic

Logac displays information about worksite and hole data.

Worksite: 10 digits available
Section: 10 digits available
Hole No: 2 digits available
Hole length: 3 digits + one dot(comma) digit
Stage number: 3 digits available
Recipe No: 2 digits available
Injection round no: 1 digit
File Name: A specific number for each and every hole

single hole and for every water cement ratio

are recorded, together with the start and stop Cemix with two admixture tanks.
times of grouting. The pressure history for
every drillhole is also available.

Weight Batching
The electronic weight batching processor
Dosac SV 6804 is a compact modular-
Pumpac hydraulic control.
built, micro-controlled unit specifically
designed for use on systems utilizing strain
gauge load cells. control blocks are the hydraulic oil
It automatically weighs water, cement 1 manometers.
and cement 2 on scale 1, and admixture 1 The Cemix 403 HWB mixer container
on scale 2 and admixture 1 on scale 3. is supported by three load cells which send
All weighing can be done simultaneous- the weight information to the WBP, which
ly. All instructions for weighing, emptying, also controls the two admixture tanks

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OSLO, NORWAY

can be different in each of the three agita-

Refilling cement silos.
PUG 45 power unit grouting.
hanging on load cells and the water inlet
valve.
Admixture Control
The different types of admixture are sup-
plied from 1,000 lit-capacity containers
standing beside the Unigrout. Two pumps
send the admixture up to two separate spe-
cially-designed distribution containers sus-
pended on load cells for very accurate
measurements. The load cells are moni-
tored by the Dosac processor.
A High Pressure Cleaning hose reel is
placed next to the cement inlet for easy
accessibility.
Cement input is through a separate
moisture-proof, dust-proof connection
offering protection from splashed water.
A special 300 lit-capacity water tank
and booster pump are used for improving
on the water filling speed.
A good grout must be mixed according
to specification and standard of cement,
admixtures and other additives. There is a
considerable difference in mixing Ordinary
Portland Cement and microcement, and the
admixtures also alter the quality of the
grout considerably.
tors.
At the Oslo Subway job, Veidekke
chose to have two Cemags of different
sizes in order to be better prepared for
different qualities of grout. Both Cemags
are supported by load cells, with weigh-
ing controlled by the operator from his
panel
Three Pumpac with 110 mm grout
cylinders and standard ball valves are
installed in the container, with room for
a fourth pump above the third pump.
Pumpac No 2 is installed above Pumpac
No 1. All three installed pumps are
easily accessible for service, and each
can be supplied with a manifold with
several grout lines if required. A drip
pan under No 2 Pumpac collects any
spillage.
The grouting container is driven by two
Power Unit Grouting PUG 45s with 45 kW
electrical motors positioned to the front
outside the container, in order to minimize
any noise and disturbance. The compressor
which operates the air regulated valves and
cylinders is located between the two PUG
45s.
The hydraulic pumps are lowered into
the hydraulic oil in the tank beneath the
electric motors.■
For more info see the Atlas Copco
Craelius Selection Guide on the Atlas
Copco homepage.
Twin Pumpac 110 B units.

Agitation and Delivery

The three-way distribution valve is
hydraulically operated from the opera-
tor’s panel, and the ready mixed grout
can be directed to either of the two sepa-
rate Cemags or to dump. Grout quality

138 ROCK & SOIL REINFORCEMENT

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ROCKBOLT SPECIFICATIONS

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ROCKBOLT SPECIFICATIONS

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ROCKBOLT SPECIFICATIONS

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ROCK & SOIL REINFORCEMENT 163

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DRILLRIG SPECIFICATION

Main specifications

Recommended hole range for ROC D5

R32,T38,T45 35-89 mm 13 /8"-31/2"
Hole depth 28 m approx.92'
Recommended hole range for ROC D7
T38,T45 64-102 mm 13 /8"-4"
T51 89-115 mm 31/2"-41/2"
Hole depth 28 m approx.92'
T51 21 m 69'
Hydraulic rock drills ROC D5
COP 1238ME
Impact power,max. 12 kW 16 HP
COP 1838 LE
Impact power,max. 16 kW 22 HP
Hydraulic rock drill ROC D7
COP 1838ME/HE,COP 1840
Impact power,max. 18 kW 24.5 HP
Compressor
Atlas Copco C 106 screw compressor
Working pressure,max. 8.5 bar 125 psi
FAD 85 l/s 180 cfm
or
Working pressure,max. 10.5 bar 152 psi
FAD 105/127 l/s 215/270 cfm
Engine ROC D5/D7
Caterpillar Diesel CAT 3126B
Rating at 2200 rpm 131/149 kW 176/203 HP
Boom
-0,1 Folding boom
Fuel tank
Capacity 280 l 73 US gal.
Feed
Feed length,total 7140 mm 24'
Travel length 4240 mm 15'
Feed extension 1400 mm 4'3"
Feed force,max. 20 kN 4400 lbf
Tramming
Tramming speed,max. 3.1 km/h 2.0 mph
Tractive force 110 kN 2500 lbf
Hill climbing ability 20 ° (30 ° with winch)
Track oscillation ± 12 º
Ground clearance 455 mm 171/2"
Transport dimensions ROC D5/D7
Total weight,approx. 11700/13000 kg 25700/29300 lb
Width 2370 mm 7'10"
Length 10710 mm 35'2"
Height 3100 mm 10'2"
Visit www.surfacedrilling.com for more information

164 ROCK & SOIL REINFORCEMENT

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DRILLRIG SPECIFICATION

Main specifications

Recommended hole range for ROC D5

R32,T38,T45 35-89 mm 13 /8"-31/2"
Hole depth, 28 m approx,92'
Recommended hole range for ROC D7
T38,T45 64-102 mm 13 /8"-4"
T51 89-115 mm 31/2"-41/2"
Hole depth 28 m approx. 92'
T51 21 m 69'
Hydraulic rock drills ROC D5
COP 1238ME
Impact power,max. 12 kW 16 HP
COP 1838 LE
Impact power,max. 16 kW 22 HP
Hydraulic rock drill ROC D7
COP 1838ME/HE,COP 1840
Impact power,max. 18 kW 24.5 HP
Compressor
Atlas Copco C 106 screw compressor
Working pressure,max. 10.5 bar 152 psi
FAD at 10.5 bar 105 l/s 215 cfm
Engine ROC D5/D7
Caterpillar Diesel CAT 3126B
Rating at 2200 rpm 131 kW/149 kW 156 HP/203 HP
Boom
-11 Folding boom,cab version
Fuel tank
Capacity 280 l 73 US gal.
Feed
Feed length,total 7140 mm 24'
Travel length 4240 mm 15'
Feed extension 1400 mm 4'3"
Feed force,max. 20 kN 4400 lbf
Tramming
Tramming speed,max. 3.1 km/h 2.0 mph
Traction force,max 110 kN 25000 lbf
Hill climbing ability (30 º with winch) 20 º
Track oscillation ± 12 º
Ground clearance 455 mm 171/2"
Transport dimensions
Total weight,approx. 12500-13600 kg 27500-30000 lb
Width 2370 mm 7'10"
Length 10710 mm 35'2"
Height 13100 mm 10'2"

Visit www.surfacedrilling.com for more information

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BOLTING RIG SPECIFICATION

Main specifications
Boltec 235H-DCS
Rock drill 1 x COP 1532/1132
Bolting unit 1 x MBU
Boom 1 x BUT 35HB
Drilling system DCS 12-55
Bolting system DCS
Carrier DC 15C
Length,excl.bom 6192 mm
Width with bolt rack 2205 mm
Height 2300 mm
Turning radius 5800/3000 mm
Weight 16600 kg

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BOLTING RIG SPECIFICATION

Main specifications
Boltec SL
Rock drill 1 x COP 1028
Bolting unit MBU 16SL
Boom 1 x BUT 32SL
Drilling system EDS
Length,tramming 10000 mm
Width 2480 mm
Height,carrier 1300 mm
roof min/max 1300/1700 mm
Turning radius 6180/3550 mm
Weight 12800 kg

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BOLTING RIG SPECIFICATION

Main specifications
Boltec MC
Rock drill 1 x COP 1532/1132
Bolting unit 1 x MBU
Boom 1 x BUT 35HB
Drilling system RCS
Bolting system RCS
Carrier L-series
Length,tramming 13156 mm
Width,excl .bolt rack 2210 mm
Height,standard 3010 mm
Turning radius 6500/3600 mm
Weight 21600 kg

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BOLTING RIG SPECIFICATION

Main specifications
Boltec LC
Rock drill 1 x COP 1532/1132
Bolting unit 1 x MBU
Boom 1 x BUT 35HBE
Drilling system RCS
Bolting system RCS
Carrier L-series
Length,tramming 14096 mm
Width,excl bolt rack 2510 mm
Height,standard 3100 mm
Turning radius 7650/4450 mm
Weight 26000 kg

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BOLTING RIG SPECIFICATION

Main specifications
Cabletec LC
Rock drill 1 x COP 1838/1638
Boom 1 x BUT 35BB
Feed 1 x BMH 210-series
Drill steel support BSH 55
Rod handling RHS 17D
Control system RCS -Drilling
RCS -Cable installation
RCS -Cement handling
Carrier L-series
Length,tramming 14042 mm
Width,excl bolt rack 2710 mm
Height,standard 3100 mm
Turning radius 7500/4550 mm
Weight 28000 kg

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SCALING RIG SPECIFICATION

Main specifications
Scaletec LC
Hammer 1 x SB 300 Scaler
Boom 1 x BUT SC
Control system RCS
Carrier M-series
Length,tramming 13828 mm
Width 2196 mm
Height,standard 3010 mm
Turning radius 6500/4000 mm
Weight 21000 kg

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DRILL RIG SPECIFICATIONS

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DRILL RIG SPECIFICATIONS

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HYDRAULIC DRILL SUPPORT

BSH 110-SDA Kit

Basic kit includes control panel,mounting kit and
bushing halves.
Bushing halves
For Anchor rod R25 3128 2021 23
For Anchor rod R32 3128 2021 22
For Anchor rod R38 3128 2021 21
For Anchor rod R51 3128 2021 20
COP Conversion kit
For COP 1238 3128 3124 80
For COP 1838 3128 3124 79
For COP 1440 3115 3129 90

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ROCKDRILL SPECIFICATIONS

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ROCKDRILL SPECIFICATIONS

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ROCKDRILL SPECIFICATIONS

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HYDRAULIC FEEDS

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HYDRAULIC FEEDS

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OVERBURDEN DRILLING

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OVERBURDEN DRILLING

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OVERBURDEN DRILLING

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OVERBURDEN DRILLING

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OVERBURDEN DRILLING

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OVERBURDEN DRILLING

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OVERBURDEN DRILLING

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OVERBURDEN DRILLING

Symmetrix Overburden
Casing System
The patented Symmetrix system can drill straight holes at
any angle, including horizontal, and to depths
beyond 100 metres.

ROCK & SOIL REINFORCEMENT 187

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GROUTING

Main specifications UNIGROUT EH400-100-135WB

Agitator 2 x CEMAG 203HWB
Agitator 4 x CEMAG 402H
Grout pump 4 x PUMPAC 110B Basic
Hydr.power unit 3 x PUG 45
Length 12 m
Width 2.8 m
Height (transport) 3.9 m
(operation) 4.7 m
Line voltage 690 V
Installed power 150 kW
Total weight 23 870 kg

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ROCKDRILL SPECIFICATIONS

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DRILLING EQUIPMENT

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DRILLING EQUIPMENT

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DRILLING EQUIPMENT

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DRILLING EQUIPMENT

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DRILLING EQUIPMENT

Internet Guide Link and Product pages:

Atlas Copco divisions:
www.atlascopco.com/rde
www.atlascopco.com/secoroc
www.atlascopco.com/craelius
www.atlascopcowagner.com
www.atlascopco.com/cmtportal
www.surfacedrilling.com
www.boomer-rig.com
www.copdrill.com
www.raiseboring.com
www.swellex.com
Atlas Copco Photo Archive:
www.atlascopco.com/photo

194 ROCK & SOIL REINFORCEMENT

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DRILLING EQUIPMENT

ROCK & SOIL REINFORCEMENT 195

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DRILLING EQUIPMENT

Keep up to date with the world of mechanized

rock excavation –
Visit Mining & Construction on-line at
www.min-con.com

196 ROCK & SOIL REINFORCEMENT

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DRILLING EQUIPMENT

Drill bit designs

SECOROC Grind Matic:

How to spend less on Secoroc products

ROCK & SOIL REINFORCEMENT 197

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DRILLING EQUIPMENT

For a free subscription to

Mining & Construction magazine visit
www.miningandconstruction.com

198 ROCK & SOIL REINFORCEMENT

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DRILLING EQUIPMENT

cont.

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DRILLING EQUIPMENT

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DRILLING EQUIPMENT
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DRILLING EQUIPMENT

All current Atlas Copco Reference Booklets are

available on CD-ROM.
To order, visit www.miningandconstruction.com

202 ROCK & SOIL REINFORCEMENT

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DRILLING EQUIPMENT

This issue of Rock and Soil Reinforcement

is also available on CD-ROM.
To order a personal copy visit
www.rock reinforcement.com

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TAPERED EQUIPMENT

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TAPERED EQUIPMENT

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TAPERED EQUIPMENT

cont.
Button bit

156 exciting pages

all about
Surface Drilling
Get your own copy at
www.min-con.com

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TAPERED EQUIPMENT

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TAPERED EQUIPMENT

152 exciting pages all about Face Drilling – Get your own copy at
www.min-con.com

208 ROCK & SOIL REINFORCEMENT

 The face of innovation

Atlas Copco
Supporting your business
wherever you are
Rock & Soil
Reinforcement
third edition
www.rockreinforcement.com

Rock & Soil Reinforcement

Atlas Copco supplies the widest range of advance
cost-efficient rock reinforcement solutions for
mining and tunnelling, including fully-mechanized
Boltec rock bolting rigs, Swellex rockbolts, and
MAI self-drilling anchors.
Each and every product has been designed to help
maximize your tunnel advance and minimize costs
per drilled metre – and always with the highest
level of safety in mind.
Atlas Copco MAI
Because we’re a global organization, we have the
resources to be truly local.
Find out more at www.atlascopco.com and select
“Country”. Or give us a call. We’d be happy to listen
to your requirements, and even happier to meet them.
Talking Technically
Case Studies
Product Specifications
Third Edition

Phone: +43 4245 65 16 60

Fax: +43 4245 65 16 68 00

www.atlascopco.com
a technical reference edition
Printed matter no. 9851 6283 01b