7th BALKANMINE CONGRESS – Proceedings, Prijedor 2017

DOI: 10.7251/BMC170702039H

UNDERGROUND RESEARCH DRILLING FOR THE NEEDS OF

DESIGNING EASTERN TUBE IN THE KARAWANKS TUNNEL IN
GEOLOGICAL FORMATIONS WITH THE RISK OF METHANE
OUTBREAK

Marjan HUDEJ1, Tadej VODUŠEK1, Miran HUDOURNIK1

1
RGP d.o.o., Velenje, Slovenia: marjan.hudej@rlv.si, tadej.vodusek@rlv.si, miran.hudournik@rlv.si

ABSTRACT

Tunnel Karavanke lies on the trans-European transport Corridor X and connects the A2 motorway in
the Republic of Slovenia to the A11 motorway in Austria. Existing Karavanke tunnel was built over
30 years ago as a single-tube and is currently a safety problem in the trans-European transport
corridor. Based on the Directive of the European Parliament and the Council on minimum safety
requirements for tunnels in the trans-European road network, the Republic of Slovenia and the
Republic of Austria has decided to participate in the construction of the new eastern tunnel tube and
the rehabilitation of existing western tunnel tube until 2019.
In 2016, we started with a drilling research work in the context of the implementation of geological,
geotechnical and hydrogeological investigations. We got more than 1000 meters of drilling core.
Particular attention during the drilling was in very demanding conditions in the geological layer,
which content methane. Some of the geological formation in this area contains a large amount of
methane (over 30 %).
In this article, we want to describe the technology that allowed drilling in a manner appropriate to
ensure the core of the high degree of security.

Key words: methane outbreak, geological formations, drilling

1. INTRODUCTION

The Karawanks tunnel is located on X. Pan-European Transport Corridor and it connects the
A2 motorway in the Republic of Slovenia with the A1 motorway in the Republic of Austria.
The existing tunnel was build more than 30 years ago as a single two-way tube tunnel, but it
is now perceived as the bottleneck in Pan-European transport corridor. Under the directive of
the European Parliament and the Council of minimum safety requirements for tunnels on
trans-European road network, the Republic of Slovenia and the Republic of Austria decided
to cooperate in construction of new eastern tube and rehabilitation of the existing western tube
by 2019.

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For the purpose of geological, geotechnical and hydrogeological surveys, the drilling started
in 2016. Drilling in Permo-Carboniferous layers was demanding and required special
attention. The formation is gas-bearing and contains large quantities of methane (more than
30 %). This article aims to describe technology used for drilling in order to obtain core and
also maintain high level of safety.

2. TUNNEL SURVEYS

Good knowledge and understanding of geological, geotechnical and hydrogeological

conditions on the future tube route is a precondition for making a quality tunnel construction
project. Geotechnical characteristics of the rocks that will be crossed by the new eastern tube
still remain unknown, because there is not much known about deformation made while
building the western tube. There is also another factor influencing geotechnical characteristics
of the rocks, that is the presence of water and water is present in at least four water-carrying
zones within Slovenian tunnel area.
The results of geotechnical findings are a necessity, because based on their findings the
construction of a new tunnel tube is defined, taking into account temporary and permanent
support measures and time needed to build the entry tube. In addition to the geotechnical
findings, the impact of constructing a new tube to the existing tube with two-way traffic, will
also be defined [1].
The following research work was implemented within the tunnel surveys:
- drilling fourteen horizontal structural boreholes,
- geophysical measurements in the boreholes,
- geotechnical measurements in the boreholes,
- collection of intact samples and implementation of adequate geotechnical,
mineralogical and paleontological laboratory tests,
- implementation of hydraulic pouring tests, testing water permeability of soil and
pumping tests,
- conversion of some boreholes into metric hydrogeological facilities,
- flow measurements in central drainage system of existing tube by segments,
- re-interpretation of the data collected and the creation of complete 3D geological,
geotechnical and hydrological model,
- processing data collected and synthesis.

3. DRILLING – STRUCTURAL BOREHOLES IN THE TUNNEL

For the purpose of geo-mechanical core research, drilling of fourteen horizontal structural
boreholes of various lengths was planned. The drilling locations within the existing tube were
in the existing blind underground facilities, existing partially-built walking paths (type GQ)
and in turning point PBN2, which consists of two trafficked crossbeams (type FQ) and
another tunnel tube finished in the pre-construction phase. Transport of drilling units and
equipment to specific locations was carried out when the road in the existing tube was
completely closed. Construction site preparations consist of drilling unit installation,
installation of settling-tanks, electrical wiring and installation of ventilation system. Diesel
generator was used as a primary energy source to supply all energy consumers on the site.
The generator was located in storage spaces, out of the main tunnel tube. Electrical equipment

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used for electrical supply on the sites was in accordance with designed project documentation.
Building site management was designed in order to give special attention to ventilation
system, since the presence of methane and other toxic gases was expected during the drilling.
Therefore separate compression ventilation was established. Fresh air supply was provided
from the main tunnel tube. Establishment and use of necessary ventilation equipment was
organized in accordance with designed project documentation on building site ventilation.
The drilling was performed by drilling rig DIAMEC 262 (Figure 1a) and CMV MK1400 FG
(Figure 1b).

Figure 1: (a) Drilling rig DIAMEC 262 on site, (b) Drilling rig CMV MK1400 FG on site

Two smaller drilling units were used on site PBN2, as with cross-beams type GQ and FQ, and
a larger drilling unit could only be used on turning point PBN2, because of its size. At any
time during the contractual relationship, the contractor was bound to specific requirements;
organizational special requirements, technical special requirements and formal special
requirements. In addition, the contractor has undertaken to carry out the drilling in tunnel
outside the tourist season and without hindering transport through the Karawanks tunnel.
The biggest challenge was presented by specific technical requirements, such as adequate
ventilation with continuous monitoring of toxic gasses presence, or appropriate reaction in
case of maximum permitted gases level overrun, and preserving a 100% intact core. In order
to preserve a core, the contractor implemented technology using a single coring unit in the
area to a depth of 6 meters. Drilling to the final depth was carried out by a double coring unit
with inner dividable tube and use of triple coring unit. This technology provides extracting the
intact core by extrusion, using devices such as extrusion with water and similar. In the areas,
where the core loss had been foreseen or poor geo-mechanical conditions were expected,
triple or double coring unit with inner dividable tube was used. The drilling equipment used in
this project met the criteria ISO 22475-1:2006 [2]. Directions of boreholes are different, that
is in direction of the existing tunnel tube or transverse to the existing tunnel tube. Inclination
of boreholes is 5 degrees downwards from the horizontal. Diamond drill bits of different
granule sizes were used most of the time (95 %).

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4. DRILLING – IN GAS-BEARING LAYERS

As already noted, special attention was given to the process of drilling in the area of gas-
bearing layers. Those layers are parts of geological formations from the Precambrian period
or contacts between Permo-Carboniferous layers and other geological formations. The
presence of methane and other dangerous gases was detected by combined detectors that were
installed above the mouth of the boreholes and in various parts of building sites, where lower
air-flow was expected. Gas detectors Drager X-am 7000 and Drager PAC 7000 were
measuring the presence of oxygen (O2), methane (CH4), carbon dioxide (CO2), carbon
monoxide (CO) and hydrogen sulfide (H2S). Detectors were equipped with light and sound
signalization, and programmed to trigger an alarm system in case of increased concentration
of dangerous gases [3]. In addition to the above-mentioned measures, there was also a
preventer in every borehole, ensuring borehole closing in case of dangerous gas intrusion.
While drilling, the contractor met some unfavorable conditions, especially when maximum
permitted levels of dangerous gases, methane and carbon monoxide, were exceeded and also
exhaled. With the first larger methane exhalation, the presence of this gas had to be measures
in the main tunnel tube as well, and consequently, the road through the Karawanks tunnel had
to be closed. In order to prevent these kinds of events, the contractor, the tunnel operator
DARS and fire brigade GARS Jesenice together established a protocol, which was drawn up
to foresee actions in case of dangerous gases occurrence in the construction site itself as well
as in the main tunnel tube. When exhalation of methane and/or carbon dioxide was measured
and detected, the drilling in such conditions caused many problems to the contractor. This
meant that the drilling was performed in atmosphere, where additional ventilation was
necessary and the speed of drilling process decreased substantially, due to degasification for
boreholes and building site itself. During the gasification of the boreholes, unfavorable geo-
mechanical conditions were identified. Due to pressure, those conditions are likely to
additionally affect the core collapse. To prevent this situation, the contractor used special
pipes, but after the pipes were used, they detected pressures on the borehole mouths and the
drilling in safe conditions was not possible anymore. After measuring, presence of dangerous
gases was detected, exceeding 10 bars.
While drilling works were in progress, National Laboratory of Health, Environment and Food
from Maribor performed measurement of gasometry within some boreholes. The data
generated are presented in the following table:

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Table 1: Results of gasometry measurements

Further on, all the boreholes were also equipped with safety valves with manometers that
monitor and detect pressures of gases. This monitoring is still applied.

5. PROBLEMS WITH DRILLING IN GAS-BEARING LAYERS

Preparation for drilling in conditions where it is expected to encounter dangerous gases is

highly challenging for both, the contractor and the design engineer. They both have to place
great emphasis on safety of employees and other personnel involved in the project as well as
the broader area of the already existing tunnel. Safety and health at work, fire safety and
protection of the environment were designed in concordance with safety requirements. The
requirements were based to ensure adequate protection of the building site towards its
environment, security measures used in drilling, protection against sudden outbreak of water
or gases, protection against dust and air pollution, protection of water and fire protection. In
order to ensure a high level of safety, the contractor must provide all technical documentation
before the project starts (implementation plan, a document operating procedures in case of
increased amount of dangerous gases) and prepare a plan of defense and rescue for specific
location where the drilling is taking place. All the documentation has to be prepared in close
cooperation between the contractor and the design engineer, since it contains information
referred to current legislation, technical regulations, specific safety requirements and
technology of implementation.
Other similar projects are challenging to the contractor and the design engineer, because there
is a possibility to encounter gas while drilling, but it is on the contractor to foresee and carry
out all the measurements to ensure the highest level of safety. Preparation of documentation,
exploration and drilling in the Karawanks tunnel were implemented in such manner, that
when increased levels of methane were detected (detection during constant unsmoked control
of dangerous gas presence) on the mouth of the borehole, the methane could not have been
diluted under 0,5%. 0,5% was also the level of methane that was set to be the maximum
permitted level by which the contractor is still allowed to perform work [3].
A dilemma arises; whether to continue drilling when the amounts exceed concentrations
defined in the documentation. To this end, the contractor prepared a cost assessment that
includes continuation of drilling in conditions which are applied in hazardous places with

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methane. It was concluded, that some parts of electrical equipment, preventing explosive
atmosphere to form, should be provided. At the same time, the supply of such equipment
would have great impact on estimated cost and the project termination date.

6. CONCLUSIONS

Throughout the project cycle, the building contractor has concluded or got confirmation to
some previously asked questions:
 Research work concept has to be prepared in close cooperation between the design
engineer and the potential contractor. Only close cooperation will ensure achieving
results, necessary for constructing underground facilities. The contractor will research
technical solutions of the implementation work and the design engineer will study the
amount of research work which will lead to quality preparation of documentation for
executing the project.
 Research work needs to be carried out in order to reach sufficient level of quantity and
quality. Assessment of investment and implementation of investment depend on level of
exploration and quality of work performed. Sufficient quantity of research work and its
quality determine the accuracy level of investment assessment.

 In the phase of research, close cooperation between the contractor and the investor is
needed. It is acknowledged that geological, mining and building projects are of most
complex ones, because they largely deviate from original plans. When there are geological
surprises, the situation becomes even more complex. The work here needs to be carried
out in such a way, that the investor realizes their goals and that the contractor can work in
safe environment. That is why, all the possible risks have to be predicted in the research
stage. At the same time all measures providing safe and quality work need to be
implemented.
 It is necessary that project documentation includes all risks and appropriate measures, that
were detected and carried out and on the basis of those provide new ones. New risks and
measures need to be carefully specified, because this is the only way to implement the
project allowing the investor to use financial resources within the forecast budget and
financial implementation will ensure safe and quality performance at the same time.

REFERENCES

[1] DARS, 2015, Predlog programa geoloških, getehničnih in hidrogeoloških raziskav za izdelavo
strokovnih podlag projektne dokumentacije za dograditev vzhodne cevi predora Karavanke, DRI
Ljubljana
[2] Vodušek Tadej in Hudournik Miran, 2016, Tehnološki elaborate vrtalnih del – izvedba raziskovalnih
vrtalnih del v predoru Karavanke, RGP Velenje
[3] DARS, 2015, Elaborati - Geološke, geomehanske in hidrogeoloških raziskave za izdelavo strokovnih
podlag projektne in varnostne dokumentacije za dograditev vzhodne cevi predora Karavanke, Akis
Trbovlje

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