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1. IntroductionCONSTRUCTION HANDBOOK
ROCK EXCAVATION
HANDBOOK
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PREFACE
The construction business is continuing to grow at a fast pace worldwide.The construction business is closely related to the world economy as wellbuilding of infrastructure. The building volume is increasing even thoughthere are big regional variations. Interesting part of construction is rockexcavation and the big variation of rock properties is challenging everybodyinvolved; contractors, consultants, equipment suppliers etc. At the sametime development of technology is offering new methods and solutions forsurface and underground applications. Sandvik Tamrock has published thishandbook to present these applications as well basic information to assistselection.
Thus this handbook will serve anyone who deals with the construction exca-vation business. It is also good reference tool for those studying relatedsubjects.
Several people participated in writing this book and therefore I like toextend my thanks to Unto Ahtola, Karlheinz Gehring, Pekka Kesseli, PeterKogler, Pasi Latva-Pukkila, Arne Lislerud, Maunu Mänttäri, Jukka Naapuri andTuomo Niskanen. Special thanks to Kirsi Nieminen, Nordberg Inc, AimoVuento and his students at South Carelia Polytechnic, Raimo Vuolio,Finnrock Inc and Pekka Särkkä, Helsinki University of Technology. Finally I like to thank Leena K. Vanhatalo collecting and editing this handbook.
Matti HeiniöEditor in chief
ROCK EXCAVATION HANDBOOK
99-808-GB-6000 © Copyright Sandvik Tamrock Corp. 1999Any diagramm, picture schematic or other matter contained herein is provided forillustrative purposes only. Accordingly, any matter set forth herein schould not beexclusively relied upon by the reader.
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1. INTRODUCTION.............................................................................10
2. MATERIAL PROPERTIES
2.1 GEOLOGICAL CLASSIFICATION OF ROCKS ...................................12
2.2 MECHANICAL PROPERTIES AND ROCK BEHAVIOUR....................19
2.3 RATING ROCK MASS CUTTABILITY AND DRILLABILITY..............20
2.4 ROCK ABRASIVITY – TOOL SERVICE LIFE ...................................30
2.5 ROCK MASS CHARACTERIZATION.................................................46
2.5.1 Importance .............................................................................46
2.5.2 Interbedding ...........................................................................46
2.5.3 Rock mass discontinuities.........................................................47
2.5.4 Classification of rock mass properties ........................................48
2.5.5 Rock pressure ..........................................................................52
2.6 BENCH BLASTING OPERATIONS...................................................53
2.7 CRUSHABILITY..............................................................................57
2.8 CONCRETE .....................................................................................60
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TABLE OF CONTENT
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4.2.1 Drilling and Blasting..............................................................142
4.2.2 Primary Breaking by Hydraulic Hammer ...................................183
4.3 QUARRY CASE .............................................................................187
5. GENERAL CONTRACTING
5.1 GENERAL.....................................................................................188
5.2 METHODS ....................................................................................189
5.2.1 Drill and Blast Excavation ......................................................189
5.2.2 Demolition and Recycling .......................................................204
5.3 CASES..........................................................................................211
5.3.1 Highway and Railway Cutting .................................................211
5.3.2 Demolition and Recycling .......................................................213
6. TUNNELLING
6.1 GENERAL.....................................................................................214
6.2 METHODS ....................................................................................216
6.2.1 Drilling and blasting..............................................................216
6.2.2 Mechanical tunneling .............................................................254
6.2.3 Shaft Excavation ...................................................................281
6.2.4 Rock reinforcement ................................................................290
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3. PRINCIPLES OF ROCK EXCAVATION TECHNOLOGIES
3.1 MECHANICS OF ROCK BREAKING.................................................62
3.2 TOP-HAMMER DRILLING...............................................................63
3.3 PRINCIPLE OF DTH DRILLING.............................................71
3.4 ROTARY PERCUSSIVE DRILLING .........................................71
3.5 HYDRAULIC HAMMERS ......................................................71
3.6 CUTTER-CRUSHERS AND PULVERIZERS .......................................73
3.7 CUTTING .......................................................................................74
3.8 LOADING AND HAULING..............................................................76
3.9 CRUSHING OPERATIONS...............................................................82
3.10 ROCK BLASTING ...........................................................................93
3.10.1 Blasting products ..................................................................93
3.10.2 Rock blasting theory ............................................................120
3.10.3 Blasting and environment.....................................................123
4. QUARRYING..............................................................................
4.1 GENERAL.....................................................................................140
4.2 METHODS ....................................................................................142
ROCK EXCAVATION HANDBOOK
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8. WATER WELL DRILLING
8.1 GENERAL.....................................................................................324
8.2 METHODS ....................................................................................325
8.3 WELL DRILLING PROCESS ..........................................................336
9. EXPLORATION DRILLING
9.1 GENERAL.....................................................................................340
9.2 METHODS ....................................................................................340
10. PROJECT PLANNING AND IMPLEMENTATION
10.1 PROJECT COSTS ..........................................................................344
10.2 TAMROCK PROJECT STUDIES......................................................347
10.2.1 Excavation Process recommendations .....................................347
10.2.2 Equipment selection.............................................................347
10.2.3 Performance and cost studies................................................348
10.3 SERVICE SUPPORT ......................................................................354
REFERENSIS ........................................................................................364
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6.3 CASES..........................................................................................299
6.3.1 Railway tunnel ......................................................................299
6.3.2 Oil and gas storage................................................................300
6.3.3 Hydropower stations and waterworks.......................................301
6.3.4 Hammer tunneling .................................................................302
6.3.5 Roadheader tunneling ............................................................303
7. DIMENSIONAL STONE QUARRYING
7.1 BUILDING STONE MATERIAL......................................................306
7.2 METHODS OF ROCK EXTRACTION ...............................................308
7.2.1 General.................................................................................308
7.2.2 Extraction and Cutting of Hard Rock........................................309
7.3 QUARRY PLANNING....................................................................315
7.4 FINANCIAL RESULT OF QUARRYING..........................................317
7.4.1 Costs ....................................................................................317
7.4.2 Methods of succesful quarrying ..............................................320
7.5 FOUNDING A QUARRY................................................................320
7.6 DRILLING TOOLS SELECTION FOR DIMENSIONALSTONE INDUSTRY .......................................................................321
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1. INTRODUCTION
Excavation activities at construction sites are very diverse. Contracting customers also varysignificantly in size. What is a typical construction project made up of? The answer is that allconstruction projects are time-limited. Project duration varies from one month to severalyears, and the schedules are almost always tight. Usually, immediate mobilization takes placeonce the contract has been awarded and often there are penalties involved if the originalschedule does not keep. It is therefore important to choose the right excavation methodtogether with the right equipment to keep the project on schedule. This handbook covers allmodern excavation methods and also provides some recent case stories.
Excavation methods can be divided into groups. The following classification shows how it ishandled in this book.
Both aggregate and limestone quarrying by the drill & blast method and mechanical methodis discussed in the chapter called “Quarrying”.
General contracting includes a wide range of projects from rock foundation in buildings androads to channel excavation in dams, road cuttings etc. Underwater excavation is also includ-ed in this section.
Today, demolition and recycling play an important role and are discussed in detail in thechapter on general contracting.
In the “Tunneling” chapter, which also includes underground excavation, both traditional drill& blast and mechanical method are discussed. Underground excavation varies significantlyfrom sewage tunnels and powerhouses to railway and highway tunnels as well as from ware-houses and parking halls to theaters, swimming pools and ice-hockey halls.
Dimensional stone quarrying is explained according to each method in use. The last chapter concerning excavation methods describes water well and exploration drilling.
The final chapter is dedicated to project management. It describes issues that should be con-sidered and remembered when handling an excavation project. Last but definitely not least isservice support.
At the end of every chapter, there is a case description providing a real-life example of atypical excavation site.
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ROCK EXCAVATION HANDBOOK
