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7/29/2019 tunnels and a ten years
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4
MINING &CONSTRUCTION
TUNNELSAND A TEN-YEAR
The Atlas Copco Rocket Boomer WL3 C drill
rig (above and top right) at work on the Torres
Finale road scheme in Sicily.
SPO
TLIGHT
ON ITALY
M&C
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MINING &CONSTRUCTION
, TALCWAITAs Italy goes ahead with nationwide construction and
mining projects, a number of worksites have one
important similarity the same project partner.
M&C reports fromthree of the most interesting loca-
tions. First, a series of tunnels to complete a major
motorway scheme in Sicily. Second, an unusual exam-
ple of small-scale mining in the Alps. And last, a long-
awaited road bypass to skirt the countrys largest lake.
5
All systems go in Italy: Excellent results are being achieved at these
three worksites just a few examples of many around the country.
PalermoPalermo
Brusada-Ponticelli mineBrusada-Ponticelli mine
MessinaMessina
Mori bypassMori bypass
Lake GardaLake Garda
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TThe words Torre Finale, Piano Par-
adiso and Cozzo Mineria have an
exotic ring. Something to do with
Italian opera, perhaps? Not quite. They
are the elegant names of tunnels being
constructed along the Sicilian coastline.
The 250 km coastline motorway
between Palermo and the city of Messina
has been under construction from bothends for the past 10 years.
For most of the way, the sea is in sight
and the views are stunning. And where
the motorway is forced inland to avoid
coastal towns, the elevation increases dra-
matically and the highway becomes a
series of tunnels and spectacular viaducts.
Italian tunnelling contractors excel in
this kind of situation and those working
for Consorzio per le Autostrade Siciliane
(CAS), the consortium of contractors at
work here, are no exception. Some 26
km of twin tunnels are complete, exceptthe last missing link a 10.7 km tunnel
which is now being constructed.
Access to the two Torre Finale tun-
nels (1.02 km and1.07 km long) is via a
steep, unpaved construction road. The
portals have been established with a 12
m width and 40 m separation, and the
hillside around them is secured using
grouted cable bolts at 2 m intervals.
The first 54 m in each drive required
umbrella drilling, where inserted steel
pipes were pressure-grouted in position.
The fullface section is 98 sqm and this
achieved by driving a top heading in
advance and following on with bench or
trench, according to rock conditions. The
geology consists mainly of flysch.
Advanced drill rig
An advanced drill rig, an Atlas Copco
Rocket Boomer WL3 C three-boom unit,
is being used by contractor C.E.C Gitto,
to handle all the drilling. During M&Cs
visit, the rig was drilling 4.5 m-long
blast holes, but is equipped for up to
5.9m. The face is lightly shotcreted
before drilling, and only gelatine explo-
sives are used. The advance rate is some
50-60m per week.
In addition to Atlas Copcos Rig Con-
trol System (RCS), the rig features inter-
MINING &CONSTRUCTION
Torre Finale
Building t he missinglink on Sicily s
beaut if ul coast l ine
Site Manager Monaco Sebastiano (right) with
Atlas Copco Italias Ivan Sinibaldi: We
dont expect problems and we dont get them.
Francesco Ranazzo, Site Man-
ager: The WL3 C rig has ex-
ceeded our expectations.
Operator Filippo Parisi: The WL3 C seemed
an amazing machine, but after only a week, I
found it pretty simple to drive.
Making headway:
The Rocket Boomer
WL3 C drills 50, 70
or 90 holes in the top
heading depending
on the friability of
the rock.
SPO
TLIGHT
ON ITALY
M&C
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7
OOne of the worlds most interesting
small mines lies at an altitude of
between 1,165 and 1,500 m in the
Italian Alps, north of Sondrio and just
five km from the Swiss border.
The Brusada-Ponticelli mine is
owned by IMI-Fabi, which owns the
rights to a 2,400 hectare sub-vertical de-posit of industrial talc. With a mining
width of 1565 m and an average of 25
m, the mineralised section at the mine is
1.2 km long over a vertical distance of
335 m and with an 800-metre cover.
IMI-Fabi, which recently achieved an
ISO 14000 rating, produces 150,000
tonnes per year of which some 40,000 is
waste and reserves are plentiful.
Extension drilling
The mine operates a room and pillar sys-
tem with 12 m-wide pillars and 6 m widerooms. After driving two 30 sqm access
drifts at top and bottom of the future
room, excavation starts with 25 m-high x
2 m-wide slots from the far end of the
top heading down to the lower level. Talc
is blasted in 22.8 m retreats.
An Atlas Copco Diamec 252 drill rig
is used for exploration drilling while an
Atlas Copco Boomer H 251 mounted
with a single COP 1238 drifter has been
working on development. These have
been joined by a Rocket Boomer M2 Ctwin-boom drill rig equipped with the
COP 1838 rock drill. The rig uses
MINING &CONSTRUCTION
Ioris Manfroi, MD of IMI-Fabi:Every
aspect of our operation will improve.
Brusada-Ponticelli
Winning
t alc f romt he A lps
w
active operator control panels, full
colour display of the computer-based
drilling system, auto-collaring and anti-
jamming protection.
The rock drills, COP 1838ME, have
an impact power of 20 kW and an impact
rate of 60 Hz with double reflex dampen-
ing. The advanced boom control system
(ABC Total) supports and guides the
operator in drill hole positioning and
alignment to reduce costly overbreak.The rig uses Secoroc Speedrods, T38-
R32, Hex35, length 5530mm.
Before the rig was started up, there
was some concern about it being located
far from the Atlas Copco Service Centre.
But a combination of the well-trained rig
operators, the customers efficient ser-
vice team and the rigs reliability re-
duced problems to a minimum most of
which were easily solved over the phone.
Poor rock
At the Piano Paradiso tunnels (2 x 2.88
km) the twin tubes are being umbrella
drilled throughout their entire length.
This is due to extremely poor ground
conditions in the area. Each 12 m-deep x
34-hole umbrella is reinforced with ce-
ment pressure-grouted steel tubes and,
due to the plasticity of the strata, it is
necessary to arch the invert and install a
reinforced concrete lining.
Access at the Messina end of the tun-
nels is so difficult that the portals have to
be established at different elevations. A
large flood culvert is being installed
across the front of the portals to provideadequate access for tunnelling.
The mudstone and soil strata has poor
strength characteristics and tunnelling
will most likely be as difficult as it is
proving to be from the Palermo end.
The two top headings at the Cozzo
Mineria tunnel site (2 x 2.48 km) are being
developed with steel arch and concrete
support throughout. The softer rock in one
heading is being broken using a hydraulic
hammer while a Boomer H174 drill rig is
at work in the other heading drilling blast
holes and bolting holes when needed.
There are multiple faults and disloca-
tions in the strata at the face, and
advance is proving a difficult task.
Dramatic and
difficult ter-
rain:The tow-
ering road
bridge and
Castelbuono
tunnels.
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8
The Mori Bypass
All syst emsgo af t er adecade ofdelay
AAslowdown in the Italian construc-
tion industry in the early 1990s
was followed by a lack of funding
and resulted in long delays for the
Brenner Autostrada project.
So long in fact that the planned MoriBypass at the northern end of Garda,
Italys largest lake, has had to wait 10
years before a start could be made on re-
placing a part of the SS 240 motorway.
The project involves an intersection
with the motorway, a bridge which cross-
es it, a river and a railway, and twin tun-
nels 2.2 km-long with 90 m2 tubes to be
equipped with two lanes each.
Eighty per cent of the tunnels is being
driven in sedimentary rock and 20% in
volcanic rock. The contractor, Cari-
boniStrade e Gallerie, started construc-
tion work in October, 1999 and is using
two Atlas Copco drill rigs a Robot
Boomer 353E unit and a recently deliv-
MINING &CONSTRUCTION
Spreading its wings: The new Rocket Boomer WL3 C drilling rig at the mouth of the
twin-tunnel Mori bypass project, fully-computerised for contractor Cariboni.
ered Rocket Boomer WL3 C, fully com-
puterised and equipped with advanced
boom control (ABC Total). Secoroc
Speedrods T38-R32, Hex 35, length
6,100mm are also used.
High pressure
Before the portals could be established,
vertical micropiles were constructed
across the entrances and tied back with
25 metre, 60 tonnes ground anchors and
beams. The anchors were grouted under
high pressure with a cement mix, which
hardened for 10 days before being
attached to steel cross beams and pre-
stressed in sections.
ate support and safety and some 25,000
bolts have been installed so far.
A mixed fleet of loaders, including an
Atlas Copco Wagner ST 3.5 Scooptram,
has been strengthened by a new ST 1010with a 10-ton bucket. A Wagner MT 413
14-ton dump truck complements the
Penetration rate has been increased
from 1.20 m/min to 1.70m /min and pro-
duction increased from 80 dm/hour to 175
dm/hour. Standard Swellex 2.7 and 3.2 m
rockbolts are in widespread use and themine was one of the first in Italy to adopt
Swellex for its quick installation, immedi-
Secoroc Speedrods, T38-R32, Hex 35,
length 4,300 mm. Scaling is carried out
by an excavator equipped with an Atlas
Copco SBC 255 hydraulic hammer.
Ioris Manfroi, Managing Director of
the mine says: We decided to go for this
new type of rig and it has been a great
success. I am more than satisfied. In the
M2 C we have purchased capability thatwe now have to adapt to. Every aspect of
our operation will improve.
w
Caribonis Renato Lusi, Tunnel Manager
(left) and Luigi Cimenti, Drillmaster:
We are very satisfied with the new rig.
SPO
TLIGHT
ON ITALY
M&C
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M & C 3 q0 1
Horizontal holes were then drilled
around the arches, into which steel tubes
were placed and pressure-grouted into
position to form micropile umbrellas.
Four umbrellas were needed in each tube
to reach stable ground. When the groundbecame rock, blastholes and minimum
explosive shook it up enough for hy-
draulic breaker excavation. The WL3 C is
equipped with the Atlas Copco rig con-trol system (RCS) and features operator
control panels with full colour display of
the computer-based drilling system.
Automatic functions provide highspeed drilling and outstanding drill steel
economy with the COP 1838 rock drill,
which achieves the maximum penetration
possible in any rock and maintains a high
hole quality with negligible deviation,
allowing easy insertion of explosives.
There is immediate identification of
faulty components and transfer of data
between office and drill rig by PC card.
Control system
ABC, the advanced boom control sys-
tem, guides the operator in drill holepositioning and alignment, helping to
reduce overbreak to a minimum.
The rig has also been used in semi-
automatic mode for face drilling while
its centre boom has been involved in
rockbolt drilling. Radial boltholes are
drilled at 1.5 m separation for 4 m-long
anchored and grouted bolts, followed by
steel arches at 1 m intervals with mesh
steel-fibre reinforced shotcrete.
loader fleet on long hauls. Virtually all the
mines loading machines are remote con-
trolled and can work in open stopes with-
out risk to drivers.
A tight team consisting of a director,
shift boss, maintenance fitter and 15miners work in shifts from 6am-10pm.
And a planned maintenance contract will
cover both the Rocket Boomer M2 C rig
and the Wagner ST1010 loader the firstcontract of its kind in an Italian mine.
Scooptram in thesnow: The ST 1010
comes to the surface
of the talc mine for a
change of shift. In the
foreground, visiting
the site is Antonio
Belcastro, General
Manager, Atlas
Copco Italy.