TUNNELING SHORT COURSE

Colorado Boulder

2016

Breakthrough in Tunneling

Ground Consolidation with traditional methods

World Leader in fabrication and

technological solutions of Steel and

derivatives of wire.

• Founded in Belgian in 1880

• Clients in more then 120 Countries

• 27,000 employees world wide

• Sales combined in 2013: € 4.1 billions

• Plants in more then 80 Countries

Who we are?

Every year

more then 500

milliones of

Champange

Bottles are

locked with a

BEKAERT cable

5 milliones m3

of reenforced

concreto are

made with

Dramix® fiber

1 of 4 Tires in

the world is

made in side

with the Steel

reinforcement

of Bekaert.

Bekaert

maintains

Allianz's with

Companies on

a global level

worldwide

Did you know we ….?

Market Segments

Ground

Stabilisation

Tunnels Mining Other ProductsExcavatión

Specialists in the markets

• Friction Bolt (SPLIT SET)

• Electro- welded Mesh

• Mesh MFI 3500

• Steel Arches – TH, H ..

• Mechanical bolts & anchors

• Inflatable Friction Bolts (SWELLEX)

• Rebar bolts

• Cable Bolt

• Self drilling Bolts

• Steel fiber “DRAMIX”

• Resin in Cartridges LOKSET

• Resin in containers

• Additives for Shotcrete

• Accessories for Installations

Product Range

Strategic Alliances in Mining and Underground

Creating

more value

for our

clients at

regional

and global

levelsIntegrated

Solutions,

innovative for a

sustainable,

stabilization and

support of the

ground

Technical

assistance in

situ with

qualified

professional staff

International

support from our

global network

strategists

searching for

optimizing the

recourses in the

Mining sectors

We are ready for the global M & U markt

Ground Consolidation with traditional methods

Is always a combination of different methods and products!

But a failure of a single element of the support system could lead to complete failure of

the whole support system.

Therefore the development of yielding support elements are in progressed in the last

years, and different types of yielding rock bolts are now in the market available.

This could be an interesting presentation for next year

But also elements used with our current conventional methods must be modified such

as fiber reinforced shotcrete and wire mesh, with specifically designed energy

absorption or yield capability.

With projects around the world in Mines and Infrastructure and overburden of 800-1200

meter it is important the we know how to solve rockbursts or at the minimums reduce

risk and damage.

Long forpoling Systems

Self drilling Pipe casing

Short forpoling System

Self Drilling-Tube Spile

Special Products

Line Stress Control Elements

Self-drilling Hollow bar

injection bolts

Selfdrilling friction bolt

Power set

Ground reinforcement, ground stabilization

Reinforcement Material

Pantex Lattice Girders

Distance [m] 3 6 9 12 15 18 21 24 27 30Repeat

Factor

Spiles 10

Self drilling spiles 3

Pipes 1

Drill accuracy +/- 3% , needs

a stable borehole, suitable

only for small size failur, low

effectiveness,

Drill accuracy +/- 2% , needs a stable

borehole for complete injection of

the ring room, injection ring room

should be 2x the diameter of the

spile, support only after injection

Drill accuracy +/- 1% , independent of ground situation, post grouting,

improvement of the overall situation, high effectiveness, immediate support,

Demands on forepoling

Forepoling system should provide sufficient stiffness to compensate already

small differential deformations in order to secure a pre failure stress distribution

Short - Forepoling System

The most simple products used in Mining & Underground

- Predrilled and installed manually or

- semi-automatic with simple devices on different equipment

- In combination with mesh, shotcrete, arches, stripes ….

Pusher plates

In soft and sandy ground conditions

In individual length due to suitable equipment

In combination

- with face bolts

- mesh

- shotcrete

• Other dimensions are available on request

• Available with tapered or plane end

• Spiles made from concrete reinforcement steel

– BSt 550 1.) ÖNORM B 4200-7

– BSt 500 S 2.) DIN 488-1

Diameter [mm] 20 1.) 25 2.) / 26 1.) 30 1.) 36 1.)

Standard lengths [m] 3.0 3.5 4.0 6.0

Rebar Spile

Fully grouted concrete reinforcement steel rebar

Concrete Reinforcement Steel

Store-Norfors Anchor (named after the first usage location

Standard-Friction bolt

Split set friction bolt

Swellex inflamabele friction bolt

Swellex 100 kN – 200 kN

Activation pressure 250 bar – 300 bar

Advantages over other bolt-systems

Friction bolt

Swellex

Drilling of the hole

High safety risks + higher costs !

Installation of bolts

Connecting of the high-pressure pump

Inflaming of the bolt

120 kN

250 kN

320 kN

Friction bolt

CT Bolt

CT-M20 and CT-M22 170 kN – 290 kN

Rebar diameter 18,5 mm, 21,7 mm

Borehole diameter 44 – 51 mm

Length 1,5 – 6,0 m

• Components

– Expansion shell

– Anchor rod

– Polyethylene sleeve

– Hemispherical dome

• Welded-on cladding tube

• Injection hole

– Bolt plate

• Installation

– Drilling of the boreholes Ø 44-49 mm

– Expansion shell and bolt plate

– Bolt insertion

– Anchor expansion Torque: 200-300 Nm

– Grouting W/C-ration: 0.35-0.40

CT Bolt

CT Bolt

Advantages

Fast and easy installation

Immediat anchorage

Double corrosion protection

Split set

Drilling of the hole

Insert bolt

Bolts and Self-drilling bolt

Resin bolts

Drilling of the hole

Insert resin

Insert bolt

Spin

Mechanical bolts

Drilling of the hole

Insert bolt

Tighten bolt

Check torque

Retorque if required

Advantages over other bolt-systems

Installation steps of Bolt / Anchors

Conventional Bolt / Anchor Instalation steps

Mechanical bolts Drilling borehole Insert bolt Thighten bolt Check bolt Thighten bolt

Resin bolt Drilling borehole Insert resin Insert bolt Spin bolt

Split set Drilling borehole Insert bolt Installation

Selfdrilling Bolt / Anchor

Self Drilling Injection Anchor Drilling + Insert bolt + Grouting Simult. Drilling and Inserting + Grouting

Self Drilling Friction Bolt Drilling + Installation Simult. Drilling and Installation

Time (min)

• Delivery lengths

– 3.0 - 4.5 m

• System components

– Power Set Self-drilling Tube Spile Ø 51 x 3.2 mm

– Single-use drill bit Ø 52 mm with HEX 28 connection

• Button drill bit Ø 53 mm

• Arc-shaped drill bit Ø 52 mm

– Power Set Drill Steel HEX 28 / T38

– Adapter T38 with integrated impact ring

• Advantages

– One-step installation procedure

– Safe and fast installation using standard drilling equipment

– Careful ground treatment due to self-drilling installation

– Easy adjustment to changing ground conditions

– Unproblematic installation in case of unstable boreholes

– Customized arrangement of perforation holes, drainage filter tubes, and threaded couplings

Self-drilling friction bolt

Drill bit

Drill rodSet adapter

Bolt plate

Impact ring

Friction Bolt set

Self-drilling friction bolt

Self-drilling friction bolt

47,5 mm 48,5 mm 49,5 mm

Power set (self-drilling friction bolt)

Self drilling tube Spile system

Outer Diameter Wall Thickness

[mm] [mm]

38 4

51 3.2

• Injection Tube Spiles (B/B)

• Optionally available with steel point (welded on) and

injection boreholes Ø 9 mm

• Other dimensions are available on request

Self drilling tube Spile

Self drilling tube Spile (for drainage)

• Field of application

– Reinforcement of the tunnel face

• Spiles

• Spile umbrella support

• Additional reinforcement

• Supplementary anchor works

Self drilling Hollow Bar - injection bolts

System Components

– drill bit (with threaded piece)

– anchor bar

– coupling

– post-grouting coupling

– anchor plate

– nut (with threaded piece)

Self drilling Hollow Bar - injection bolts

Hollow Bar Inside / outside threats – for loos and soft ground

Simultaneous or multiple Injection

Self drilling Hollow Bar - injection bolts

Anchor type 1.) Unit R32L 2.) R32N 2.) R32S 2.) R38N 2.), 3.)

Outer diameter [mm] 32 32 32 38

Max. tensile load [kN] 200 280 360 500

Yield load [kN] 160 230 280 400

Weight [kg/m] 2.7 3.4 4.1 6.1

• Field of application

– Reinforcement ahead of the tunnel face

• Spiles

• Spile umbrella support

• Additional reinforcement

• Supplementary anchor works

Self drilling Hollow Bar - injection bolts

Anchor type 1.) Unit R51L 3.) R51N 3.) T76N 3.) T76S 3.)

Outer diameter [mm] 51 51 76 76

Max. tensile

load[kN] 500 800 1600 1900

Yield load [kN] 450 630 1200 1500

Weight [kg/m] 7,0 8,4 15,0 19,7

•Tunneling and Mining

Reinforcement of the face

Reinforcement for large underground

structures

Widening of tunnel cross-sections

Face anchoring

Foot piles

Tunnel portals, cut and cover areas

Self drilling Hollow Bar - injection bolts

Bolting feeds mounted on standard TBM-booms

Self drilling bolts

Bolting feed mounted on standard TBM-booms

Self drilling bolt

Distance [m] 3 6 9 12 15 18 21 24 27 30Repeat

Factor

Spiles 10

Self drilling spiles 3

Pipes 1

Drill accuracy +/- 3% , needs

a stable borehole, suitable

only for small size failur, low

effectiveness,

Drill accuracy +/- 2% , needs a stable

borehole for complete injection of

the ring room, injection ring room

should be 2x the diameter of the

spile, support only after injection

Drill accuracy +/- 1% , independent of ground situation, post grouting,

improvement of the overall situation, high effectiveness, immediate support,

Demands on forepoling

Forepoling system should provide sufficient stiffness to compensate already

small differential deformations in order to secure a pre failure stress distribution

Forepoling methods

Jet grouting method

Spiling method

Pipe roof method

Demands on forepoling

Forepoling system should provide sufficient stiffness to compensate

already small differential deformations in order to secure a pre-failure

stress distribution

Injection material is penetrating in narrow friction

Pipe roof umbrella

Pipe roof umbrella

Drainage systems

Injection systems

Long - Forepoling System

Tube Injection Systems

Tube Drainage System

Standard System

- Tube-outside diameter 76mm

- Tube-outside diameter 118mm

Tube Drainage System

Total integration with shotcrete

Become part of the reinforcement in the shotcrete lining

Lattice Girders

Underground profile reinforcement

Providing support in combination with spilling systems

Lattice Girders

Longitudial wall plates used for heading and bench advances

to reduce movements

Lattice Girders

With spaced diagonals

In form as spider + bars

becomes a stiff element

are supports for a wide range of ground conditions

are easy erected without special handling equipment

Providing support in combination with mesh

Thank you for your attention

Questions ??

Fibers for Ground Support:4

9

Fibers, Which One?

Fibers 101

Fiber types commonly used:

Micro polypropylene – early age shrinkage / fire resistance

15 TO 30 MICRONS IN DIAMETER

6 TO 20 MM IN LENGTH

Macro polypropylene – provides some ductile behaviour

0.5 TO 1.0 MM IN DIAMETER

30 TO 65 MM IN LENGTH

Steel – provides high ductile behaviour

0.5 TO 1.0 MM IN DIAMETER

30 TO 65 MM IN LENGTH

Practical Applications of fiber reinforced concrete

• The mathematical description of an object tendency to

be deformed elastically (i.e., non-permanently) when

a force is applied to it.

Young’s Modulus (E)

HIGH LOW

ELONGATIONAREA

FORCE

STRAIN

STESSE

Low Young’s Modulus Lead to Large Crack Openings

BACKGROUND

+

• Global Joint Venture formed October 2014

• Bekaert Dramix ® Steel Fibers and Macro/Micro Synthetics

• Dramix 3D 65/35BG and 4D 65/35BG – Shotcrete

• Dramix 4D 80/60BG – Precast Segments– Crack Width

Control

• Dramix 5D 65/60BG – “Game changer” for CIP

applications

• Duomix M6 Fire – micro-synthetic pp fibers for SFRC tunnel

segments

• Syn-mix macro-synthetic fibers for temporary and mining

support

5

3

Steel Fibers in Shotcrete

5

5

Steel fibers can be use in:

Dry

mix

Wet

Mix

Steel Fiber Reinforced Shotcrete:

Shotcrete – East Side Access – New York City

Photo Courtesy King Package Material

Flickr License Photo Use Approval -- Patrick Cashin MTA Staff Photographer.pdf

The MTA's East Side Access Project is a multi-billion dollar infrastructure

project designed to bring Long Island Railroad to Grand Central Station in

New York City. East Side Access is one of the largest transportation

infrastructure projects currently underway in the USA.

OWNER: NYC MTAN

CONTRACTOR: Frontier-

Kemper Constructors, Inc.

START DATE: March 2014

END DATE: February 2017

BUDGET: $10.178 billion

SFRC for Cast in Place Ground Support

Jansen Mine Shafts – Saskatchewan, Canada5

8

Shaft Basics – Construction:

• Shaft walls range from 800 mm (2.6 ft) thick

up to 1.1 m (3.6 ft) thick

• Interior Diameter of 8.5 m (27.9 ft)

• Shaft walls are slip formed with a scheduled

production of up to 3 m (9.8 ft) per day.

• Concrete strength 60 MPa (8700 psi)

• Dosage rate 40 kg/m³ (67 lb/yd3)

Questions ?

Thank You!!