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Preprint 10-108
EFFECTS OF INCREASED MECHANIZATION ON DRILL AND BLAST & NATM TUNNELING PRODUCTION RATES AND SAFETY
(1994 2009)
B. Briggs, Atkinson Construction, Golden, CO.
ABSTRACT
Equipment Selection
As the project called for substantial amounts of shotcrete, the
selection of shotcrete application and on-site batching equipment was
critical to the success of the project. Atkinson Construction employed
the use of two robotic shotcrete arms manufactured by Shotcrete
Technologies for the project. The arms were mounted on flatbed truck
carriers with on-board shotcrete and accelerator pumps. The shotcrete
was produced on-site with a fully winterized plant capable of producing
40 CY/Hour. Delivery from the plant to the working faces was provided
by modified 8CY transit mixers.
Production Summary
As stated above, shotcrete productivity was a critical component
to the success of the project. The Allegheny Tunnel was supported
with over 15,000 CY of fiber reinforced shotcrete; this equated to
approximately 4.3 cubic yards (CY) / Linear Feet (LF) of tunnel. The
average production rate achieved on the project was 0.86
Manhour(MHR)/ CY with peak performance reaching upwards of 0.5
MHR/CY. This equated to a typical placement rate of nearly 7 CY/HR
with peak placement rates nearing an average of 12CY/HR.
Project Overview
The Allegheny Tunnel is located near Altoona, Pa and owned by
The Consolidated Rail Corporation (CONRAIL).
The project consisted of the fast-track enlargement of two single
track rail tunnels totaling 4,300 feet in length to double-track structures,
including shotcrete and concrete lining. Utilization of both drill and
blast and mechanical methods were utilized to enlarge tunnels from 22
feet in diameter to 36 feet.
The excavation of the existing brick liner and the intact rock was
primarily performed using drill and blast techniques. The enlarged
profile required approximately 15 bank cubic yards (BCY)/LF of
excavation to reach the neat line excavation limit.
Atkinson
Construction realized an excavation rate of 0.495 MHR/BCY for the
61,000 BCY of excavation performed. This rate was inclusive of
drilling, blasting, smoke time and inspection, scaling and mucking.
Resin grouted rock bolts and steel sets were also used as
additional ground support measures on the project. The bolts were
installed at a rate of 0.096 MHR/LF of bolt with the steel sets installed
at a rate of 0.012 MHR/LB of steel.
Safety Narrative
The safety program on the project was tailored to maximize the
benefits of the mechanized gear. This project represented one the
earliest forays into the use of robotic shotcrete arms for Atkinson
Construction. The robotic placing system allowed for the nozzleman to
be a safe distance away from the placement area as well as limiting
operator fatigue. The use of exclusively wet shotcrete was also a vast
improvement over the dry shotcrete systems as it minimized the dust
hazard in the tunnel.
Production Summary
The production at the P-1 tunnel was extremely consistent and
overall very good. On a 24 hr/ day 3 shift schedule the tunnel
averaged 18ft/day of tunnel advance from a single heading.
This
equated to an excavation production rate of 6.15 MHR / LF or 0.465
MHR /BCY. This rate includes the drill, load, blast and mucking cycles.
Production Summary
In general terms the top heading excavation proceeded at
approximately 1 lattice girder placed per 8 hour shift. This equated to
heading excavation production rate of 0.316 MHR/BCY and a
shotcrete placement rate of 1.5 Mhr/CY or approximately 5.5 CY / hr.
Safety Narrative
The selection of highly mechanized equipment had an extremely
positive impact on this project. The combination of tunnel excavators
and robotic shotcrete arms allowed for excavation and initial support to
be installed without exposing any miners to open ground. The
installation of the lattice girders was aided by telescopic boom forklifts
with manbasket attachments. This allowed for the girders to be lifted,
placed and aligned mechanically with only minor adjustments and
hardware installation performed manually.
Production Summary
The layout of the project split the footage between five separate
access shafts and six individual NATM tunnel drives. Furthermore, the
top heading and benches were excavated as separate operations as
well. As a result, the roadheaders were routinely trammed between
headings to maximize overall job production at the cost of lower
individual heading productions.
The typical top heading advance rate on the project was 3.2 LF/ 8
hr shift. This rate breaks down to a 4CY/ HR shotcrete production rate,
and an average excavation rate (roadhead and muck) of 2.8 LF/HR.
The resultant manhour based production rate for the project were 1.75
MHR/CY for shotcreting and 0.17 MHR/BCY for excavating.
Project Overview
This project consisted of 15 ft. x15 ft. modified horseshoe tunnel
at a length of 7992 LF. The project also included the construction of
multiple drill stations, sump stations, muck bays, and facilities.
Equipment Selection
As stated above, an AM-75 Roadheader was employed as the
primary means of excavation with an AM-50 as the back-up / trimming
The project was constructed entirely in hard rock using drill and
blast techniques. The geology consisted primarily of monzonites and
quartz monzonite porphyry with intrusive dikes of varying composition.
The case studies above provide a strong basis to suggest that the
principle has actual merit and should be analyzed on a unit operation
basis.
Shotcrete Production
As the table shows, shotcrete production has slowed considerably
over the past 15 years. Examining the equipment used for each
project helps to justify the pattern shown. The robots used for the
Allegheny Tunnel were extremely basic units with limited moving parts
and mounted on very robust domestic carriers. The accelerator was
delivered to the nozzle using simple stainless steel barrel pumps. The
overall result was a highly productive system with very little downtime.
CY / HR
7
5.5
4
3
Year
1995
2002
2005
2007
Type
Drill/Blast
Drill/Blast
Mech.
Roadheader
Drill/Blast
The three drill and blast excavations analyzed all achieved very
similar production rates for the drill, blast and muck cycles when
leveled by manhours and excavation quantity. The conclusion can be
made that the increased mechanization in the drill jumbos, (anti-jam
technology, computer assisted drilling, auto return, etc.) have not
resulted in a significant production gain over the past 15 years.
The two mechanical excavations at Mission Valley and Dulles
provide an interesting contrast to the drill and blast rates and highlight
the production gains that can be achieved in suitable materials.
Year
1995
2007
Although the analysis over time bears out the Hancock principle
that production has slowed, the increase in miner safety is more than
an ample trade off. The development of the modern gear is pulling the
miners away from the unsupported excavation face and successfully
limiting the more dangerous hazards encountered during the typical
excavation cycle.