Shaft Sinking Methods and Conventional Sinking Process

1
Ph. D. Eng. TADEUSZ S. GOLOSINSKI - tgolosinski@expo.intercade.org - Consultor Intercade

PIQUES y CHIMENEAS:
Diseo, Construccin y Operacin
PIQUES y CHIMENEAS:
Diseo, Construccin y Operacin
Ph. D., P. Eng. TADEUSZ S. GOLOSINSKI
tgolosinski@expo.intercade.org
Consultor INTERCADE
Junio 2008
2
2. EXCAVACION DE PIQUES
(Conventional Shaft Sinking)
2. EXCAVACION DE PIQUES
(Conventional Shaft Sinking)
2
3
SHAFT SINKING
SHAFT SINKING
3
4
VARIETY OF SHAFTS
VARIETY OF SHAFTS
Most likely choice:
Vertical shaft.
Circular shaft.
Combination one.
Concrete lined
shaft.
Steel sets.
Other decisions:
Drill or sink the
shaft?
Shaft diameter.
Shaft depth.
Type of rock.
5
In 1987 Shaft Sinkers set an international
mechanised sinking record (200.4 m in one month at
Vaal Reefs No 10 shaft). To do this, a shaft sinking
jumbo - designed and manufactured by the Group
was employed.
Shaft Sinkers also holds claim to the deepest shaft
ever sunk (3 583m below surface at Western Deep
Levels) .
as well as the widest (a 19m diameter shaft at the
Drakensberg Pumped Storage Scheme).
RECORDS
RECORDS
6
7
PREPARATIONS
PREPARATIONS
Determination of geologic and hydrologic
conditions.
Permitting, surveying, documentation.
Site access.
Site preparation.
Prevent flooding!
Supplies & services.
Power, water, compressed air, maintenance,
storage
8
SITE PREPARATION
SITE PREPARATION
9
PREPARATIONS
PREPARATIONS
Covered storage for construction materials.
A ramp for unloading of heavy machinery ( or
have a crane available).
Installation of shaft sinking equipment.
Use final headgear?
Excavation / earthwork needed for shaft
collar.
10
MORE PREPARATIONS
MORE PREPARATIONS
Water
Use shaft water (industrial water?).
Wells outside of the shaft drainage cone.
Industrial (120 m
3
) & tap (60 m
3
) water.
Storm water: control measures.
Power
Substation of up to 2000 kVA.
Two independent sources of supply!
Diesel generators (a back-up?).
11
OTHERS (SOME)
OTHERS (SOME)
Explosives storage.
Fan housing (ventilation).
Transformer station.
Lamp / change house.
Compressor shed.
Stage hoist building.
Office trailer / building.
Living accommodations?.
..
12
1Headframe
2- Winder
3- Compressor
4- Fan
5- Maintenance
6- Concrete plant
7- Open storage
8- Concrete
winch
9- Stage winch
10-Office
11-Machine shop
12-Emergency
hoist
13-Water tank
14-Transformers
15-Compressed
air tank
16-Genset
13
SHAFT BORING SITE
SHAFT BORING SITE
14
SHAFT SINKING METHODS
SHAFT SINKING METHODS
Conventional
Drill-blast-vent-muck-line cycle.
Shaft boring.
Non-conventional methods
Rocks with extensive fracture pattern and
water inflows over 0.5 m
3
/min.
Loose, water bearing ground; also weak and
plastic.
Methods include grouting, freezing, & other.
15
CONVENTIONAL
SHAFT SINKING
CONVENTIONAL
SHAFT SINKING
16
17
CONVENTIONAL SHAFT SINKING
CONVENTIONAL SHAFT SINKING
18
Use the permanent (final)
headframe?
Three deck stage
19
Example: Three deck stage
Deck 1: shaft steel sets installation.
Decks 2 & 3: stripping, lowering and setting steel concrete
forms.
Deck 3: suspension for mucking units.
Three winch
stage suspension
(+ an emergency
one)
Weight: 35t
20
Crash doors
Crash beams
J ack catchers
21
22
23
Five deck stage
Weight 55 t
24
CONVENTIONAL SINKING
DRILL-BLAST-VENT-MUCK-LINE
CONVENTIONAL SINKING
DRILL-BLAST-VENT-MUCK-LINE
Simultaneous sinking and lining.
All work in the same section of the shaft.
Delayed lining.
Sinking and lining done at the same time
butin different shaft sections.
Separate sinking and lining.
Sinking first and then lining.
Center drillhole for mucking ??
If the access is available!
25
SIMULTANEOUS SINKING AND LINING
SIMULTANEOUS SINKING AND LINING
Sinking and lining done in one work cycle.
Lining erected upwards (blocks, bricks).
Lining lowered downwards.
(underhanging tubing).
No need for temporary rock support.
Lining can be delayed for up to 10 m (?) in
competent rock.
26
PARALLEL SINKING & LINING
( IN SEPARATE SECTIONS)
PARALLEL SINKING & LINING
( IN SEPARATE SECTIONS)
High capital cost.
Long shaft life?
Used in large diameter
and deep shafts.
Temporary rock support
usually is needed.
27
SEQUENTIAL SINKING AND LINING
SEQUENTIAL SINKING AND LINING
Shaft sunk in sections of up to 50 m deep.
Actual length depends on rock quality.
Temporary lining installed during sinking.
To prevent rock falls & accidents.
Lining of the section done when the sinking
stops.
Slow sinking rate.
Low capital expenditure.
Suitable for small dia & shallow shafts.
28
Begin cycle.
Lower drill jumbo.
Drill out and
Load round
Raise stage 60 m
Clear shaft and blast.
Blow fumes.
Lower stage
Lower buckets
Lower loader
Muck .
29
Lower drill jumbo
Drill out and load
round
Raise stage 60 m
Clear shaft
Blast.
_____________________
Blow smoke
Lower stage
Break kerb & A-ring
Install dashpot
Position kerb & A-ring
Pour.
_____________________
Break forms
Lower & position forms
Lower loader & buckets
Muck
Pour through doors
& top off
Complete mucking
Repeat cycle.
30
31
1- Ring, 2 Rock bolt supporting the ring, 3 Suspending hook for the next
ring, 4 Iron sheet liners, 5 Fastening wedges, 6 - Permanent lining
SIMPLE TEMPORARY LINING
SIMPLE TEMPORARY LINING
32
DEWATERING
DEWATERING
Kibbles.
Submersible pumps.
Airlifts.
Combinations of some /
all of the above.
Max. inflow 0.5 m
3
/min.
33
SHAFT COLLARS
SHAFT COLLARS
33
34
34
35
Foundation on :
Shaft head Circular wall
Total depth:
15 to 25 m
36
Force distribution in
the shaft collar
35 deg.
37
Shaft Collar:
(example #1)
1, 2 heated airways.
3 - water pipes.
4 ladder compart-
ment access.
5 power cables.
6 compressed air.
7 - Basement for
pushers.
38
Shaft Collar:
(example #2)
1 lining.
2 heated air
channels.
3 ladder compart-
ment access.
4 power cables.
5 compressed air
and water pipes.
6 Basement.
39
Ventilation Shaft
Collar:
1 lining.
2 insulation .
3 ventilation air
channel.
4 safety grate.
5 ladder.
6 railing.
40
DIMENSIONING LEVEL ACCESS
DIMENSIONING LEVEL ACCESS
L maximum length
(transported material)
D shaft diameter.
H clearance
H = 0.7 (L D)
Note:
For = 45
0
, D = 0.7 D
41
42
SHAFT BOTTOM DEPTH
SHAFT BOTTOM DEPTH
A fixed guides.
B rope guides.
1 Fixed guides.
2 tail rope
loop.
3 - guide rope
weights.
4 rope guides.
43
DRILLING AND BLASTING
DRILLING AND BLASTING
Reduce the drilling time.
Reduce the hole loading time.
Assure good fragmentation.
Clean break from the shaft walls.
Easy water management.
44
Time needed to
Sink 1 m of shaft
(an example):
1 Mucking.
2 Drilling.
3 Loading of
holes..
4 Total time
Optimize!
Optimize!
45
DRILLING PATTERNS
DRILLING PATTERNS
Accuracy of excavation (overbreak!).
Clear rock separation at the hole bottoms.
Even and sufficient rock fragmentation.
Eliminate damage to any shaft installations
or structure.
Avoid cut-offs of neighboring active holes.
46
Drillhole pattern: (a) siltstone, (b) shale, (c) sandstone
Small diameter, circular shafts
47
DRILLHOLE PATTERN IN INCLINED
STRATA
DRILLHOLE PATTERN IN INCLINED
STRATA
Inclination
over 45 deg.
Wedge holes
located along
strike.
Overbreak
larger on
hanging
Strata.
48
Wedge Cut Pyramid Cut
Rectangular shafts
49
Step cut Wedge-side cut
Blasthole pattern in rectangular shafts
50
Sample drilling pattern
for a 9 m diameter shaft
(wedge cut)
51
TREND TOWARDS BURN CUTS & LONGER HOLES
(WITH SUSPENDED DRILL JUMBOS)
TREND TOWARDS BURN CUTS & LONGER HOLES
(WITH SUSPENDED DRILL JUMBOS)
52
CASE STUDY
CASE STUDY
2007
Dyno Nobel Ltd.
North America
53
Typical bench cut
Using 1-3/8 or 1-174 holes
Roach and Roy, 2007
54
Typical bench cut
Using 1-3/8 or 1-174 holes
Roach and Roy, 2007
55
BENCH CUT: FEATURES
BENCH CUT: FEATURES
Easier water handling due to availability of a
sump.
Bench can be blown clear to check for misfires.
The force of the blast is directed into the shaft
wall.
Rather than into stage /Galloway minimizing
damage from fly rock.
Rockbursts are minimized.
Shaft bottom has a chance of relieve itself of
the stress in section.
56
Typical cut
Design
(full face circular
shaft round)
25-6/ 7.8 m
diameter
Shaft
Roach & Roy, 2007
57
Shaft layout
and timing
2 dia holes
Roach & Roy, 2007
58
MORE ON FULL FACE ROUNDS
MORE ON FULL FACE ROUNDS
Reamer holes one foot longer.
Boreholes break fully.
Provides concave sump.
59
BLASTHOLES
BLASTHOLES
Currently at 200 to 250 mm maximum (reamer
holes).
Large hole diameter:
Reduces footage of drilling.
Reduces consumption of explosives.
Small hole diameter.
Hand drilling only.
Bulk loading of explosives is becoming common.
60
EXPLOSIVES
EXPLOSIVES
Anfo- based slurries and emulsions largely
replaced the nitroglycerine based
explosives.
Safety, bulk loading.
Consumption is largely independent of
shaft diameter.
Consumption decreases with blasthole
size.
61
LOADING OF EXPLOSIVES
LOADING OF EXPLOSIVES
Bulk explosives allow faster loading
Cartridged explosives largely phased-
out.
Pneumatic loading common.
Several holes loaded at the same time.
Shaft extruder vesselemployed.
Loading four holes simultaneously all 76
two inch blastholes are loaded within 32
minutes.
62
BULK EMULSION EXPLOSIVES
BULK EMULSION EXPLOSIVES
Less expensive than cartridged ones.
Faster loading.
Reduced drilling time.
Ability to use larger, longer blastholes, thus
fewer holes.
Eliminates misfired holes due to cartridge
ejection.
Reduces hazards.
Vs. detonator sensitive explosives.
63
CONSUMPTION OF EXPLOSIVES
CONSUMPTION OF EXPLOSIVES
Depends on physical properties of rock
20 to 30% less in shales than in hard
sandstones.
Still higher in hard, homogeneous rock.
Depends on hole size (see above) and
length.
Consumption decreases with increasing
hole utilization factor.
64
CONSUMPTION OF EXPLOSIVES, kg/m
3
CONSUMPTION OF EXPLOSIVES, kg/m
3
Hole utilization
factor, l
o
/l
65
HOLE UTILIZATION FACTOR
HOLE UTILIZATION FACTOR
Rock does not fragment at bottom of the
Blasthole.
Blasthole utilization factor:
F = L
o
/ L
Where:
L
o
utilized length of Blasthole.
L - drilled length of blasthole.
F grows with increasing hole diameter.
There is an optimum F (see below).
66
Shale
Q = 1.1 kg/m3
Cartridge 32 mm
67
Time needed to
sink 1 m of shaft
(an example):
1 Mucking.
2 Drilling.
3 Loading of
holes.
4 Total time.
Optimize!
68
Three-ring connection
of electric caps:
1 Cable.
2 Protecting pipe.
3, 4 Active antenna.
5 Passive antenna.
6 Electric caps
(in holes).
7 Supporting sticks.
69
NONEL SYSTEM
REPLACING ELECTRIC DETONATORS
NONEL SYSTEM
REPLACING ELECTRIC DETONATORS
Extremely resistant to accidental
detonation.
By static electricity and stray electric
currents.
By radio transmission.
Flames, friction or impact.
By now an industry standard.
Electronic detonators?
70
MUCKING
MUCKING
70
Cryderman
mucker
71
72
TYPES OF MUCKERS
TYPES OF MUCKERS
Cactus grab.
Either light or heavy on central pivot.
Hand-guided while hanging from the platform.
Muckers.
Usually rocker muckers, eg Eimco.
Driven by an operator.
Cryderman muckers.
Scrapers.
Rectangular & large diameter shafts.
73
74
WHAT AFFECTS MUCKING EFFICIENCY?
WHAT AFFECTS MUCKING EFFICIENCY?
75
TYPICAL CYCLE TIME 4 TO 10 HRS
TYPICAL CYCLE TIME 4 TO 10 HRS
Example: Bechtel, Nevada
76
Time needed to
Sink 1 m of shaft
(an example):
1 Mucking.
2 Drilling.
3 Loading of
holes.
4 Total time.
Optimize!
77
78
COMMENT
(CIM MAGAZINE)
COMMENT
(CIM MAGAZINE)
1970 to 2007 was the only time period to date
where sinking rates were not increased
drastically through some improvement in
technology.
One very important aspect of shaft sinking did
improve, however, and that is safety. Accident
rates on shaft sinking projects have dropped
appreciably over the period.
79
CIM: HISTORY OF SHAFT SINKING
CIM: HISTORY OF SHAFT SINKING
80
(SAMPLE)
REGULATIONS
(SAMPLE)
REGULATIONS
A good guideline
for shaft
sinking operation.
80
81
GENERAL DUTY OF CARE
GENERAL DUTY OF CARE
An employer, contractor or owner must ensure
that all shafts in a mine are designed,
constructed and maintained to safely bear the
loads that may reasonably be anticipated to be
placed on them.
82
NOTICE
NOTICE
As soon as is reasonably possible but not later than 90
days before a shaft-sinking operation commences, an
employer, contractor or owner must give notice of the
shaft-sinking operation by submitting to the chief mines
inspector:
(a) the drawings and specifications for:
(i) the sinking procedure to be used.
(ii) the shaft lining program.
(iii) the equipment to be used in the sinking
rocess, including dump doors; and
(iv) the shaft collar; and
(b) the primary and secondary signal systems to
be used during a shaft-sinking operation.
83
SHAFT COLLAR
SHAFT COLLAR
An employer, contractor or owner must ensure that
every shaft or raise opening at the surface is
provided with a collar that is:
a) designed and constructed in accordance with
sound engineering practices to prevent any
person or equipment fromfalling into the shaft or
raise.
b) made of concrete or equivalent material; and
c) if reasonably practicable, secured to the
bedrock.
84
DESIGN OF SHAFT SINKING EQUIPMENT
DESIGN OF SHAFT SINKING EQUIPMENT
An employer, contractor or owner must ensure that the
conveyance used in the shaft sinking, its components, the
hoisting system and mountings, and the crosshead are
designed, constructed, installed, operated and maintained
so that the conveyance is capable of transporting workers
safely.
2) Without limiting the generality of subsection (1), if a shaft
is being sunk, an employer, contractor or owner must
ensure that:
a) the conveyance measures at least 1 070
millimetres fromthe floor of the conveyance to the
top of the side of the conveyance; and
b) the suspension members of the conveyance are
securely attached to the hoist rope.
85
MORE .
MORE .
3) If the distance between the shaft collar and the shaft bottomis
greater than 60 metres, the employer or contractor must ensure
that:
a. the crosshead:
I. lands on at least two chairs at the bottom
crosshead stop to prevent distortion of the
crosshead;
II. is equipped with a safety device for attaching the
conveyance to the crosshead so that the
crosshead cannot jamin the shaft compartment
without stopping the conveyance; and
III. is of a type that encloses the conveyance
unless the shaft compartment is tightly
lined and the conveyance is barrel-shaped.
4) An employer or contractor shall not require or permit persons to
be transported in a conveyance during a shaft-sinking operation
unless the requirements of subsections (1) to (3) are met.
86
DOORS
DOORS
During a shaft-sinking operation, an employer or
contractmust ensure that dump doors meeting the
requirements of subsection (2) are installed at the
conveyance dumping position.
2) The dump doors required by subsection (1) must:
a) prevent the conveyance frombeing
dumped while the dump doors are open;
b) prevent any material fromfalling down the shaft
while the conveyance is being dumped;
c) be equipped with devices that mechanically latch
the dump doors out of the shaft compartment
automatically when the dump doors are fully open.
87
MORE
MORE
3) During shaft-sinking operations, an employer or contractor must
ensure that service doors are:
a) installed at the collar; and
b) equipped with devices that mechanically latch the service
doors out of the shaft compartment automatically when
the service doors are fully open.
4) An employer or contractor must ensure that the doors required
by subsections (1) and (3) are closed while a conveyance is:
a) being loaded with tools or materials; or
b) being unloaded.
c) Except when a closed crosshead that provides
equivalent protection for persons is in use, an employer
or contractor must ensure that the doors required by
subsections (1) and (3) are closed while persons are
entering or leaving a conveyance.
88
SIGNAL LIGHTS
SIGNAL LIGHTS
An employer or contractor must ensure that dual
lights are installed at the hoist operator's position
that activate automatically to indicate to the hoist
operator that:
(a) the crosshead and conveyance are
descending together from the dumping
position; and
(b) the dump doors and service doors are
closed or open.
89
MULTI-DECK STAGE
MULTI-DECK STAGE
If a multi-deck stage is used during a shaft-sinking
operation, an employer, contractor or owner must
ensure that:
(a) the multi-deck stage is:
(i) designed by a professional engineer;
(ii) constructed, installed, operated and
maintained in accordance with the design
mentioned in subclause (i); and
(b) any ropes used with the multi-deck stage meet
the load factor requirements set out in section 160.
90
OPEN HOOKS ARE PROHIBITED
OPEN HOOKS ARE PROHIBITED
During a shaft-sinking operation, an employer or
contractor must ensure that no open hooks are
used to suspend any staging, working platform,
conveyance or other equipment in the shaft.
91
MEANS OF ESCAPE
MEANS OF ESCAPE
Subject to subsection (2), during a shaft-sinking operation, an
employer or contractor must ensure that a suitable manway is
constructed and maintained in the shaft fromthe collar to the
sinking stage.
2) An employer or contractor may install an independently-powered
escape conveyance in a shaft in place of a manway, but the
conveyance must be fully operational before the shaft exceeds a
depth of 30 metres.
3) The employer or contractor must provide an auxiliary ladder that:
a) extends fromthe permanent ladder or the sinking stage to the
bottomof the shaft; and
b) is located and attached so that it can be promptly lowered to
any point at which workers are working.
92
BEFORE HOISTING A SINKING BUCKET
BEFORE HOISTING A SINKING BUCKET
During shaft-sinking operations, an employer or contractor must
ensure that:
(a) a sinking bucket is not moved fromthe top or bottom
of a shaft until the worker in charge of the sinking bucket
has steadied the sinking bucket;
(b) a sinking bucket is not moved from the bottom of a
shaft until the worker in charge of the sinking bucket has
examined the sinking bucket and has removed any mud
or other material that may be sticking to it; and
(c) before a sinking bucket containing loose rock or
material is moved, no loose rock or material projects
above the rimof the sinking bucket.
93
RIDING IN SINKING BUCKET
RIDING IN SINKING BUCKET
(1) During shaft-sinking operations, no employer or contractor shall require or
permit any person:
(a) to ride on the rimor outside of a sinking bucket; or
(b) subject to subsection (2), to ride in a sinking bucket that
contains ore, waste or any other materials.
(2) Small items, including tools, may be carried in a sinking bucket if:
(a) it is necessary to do so; and
(b) adequate precautions are taken to ensure the safety of workers
being transported in the sinking bucket.
(3) An employer or contractor must ensure that, during shaft-sinking operations:
(a) the sinking bucket used to transport workers is in the charge of a
competent worker authorized by the employer or contractor; and
(b) no person other than an authorized competent worker gives
the signals for the movement of a sinking bucket used to transport
workers.
(4) A worker being transported in a sinking bucket must obey the instructions of
the authorized competent worker in charge of the sinking bucket.
94
LOWERING SINKING BUCKET TO BOTTOM OF
SHAFT
LOWERING SINKING BUCKET TO BOTTOM OF
SHAFT
Subject to section 89, if a sinking bucket is being lowered to the
bottomof a shaft during shaft-sinking operations, the employer
or contractor must ensure that:
(a) the sinking bucket is stopped at a distance of not less
than five metres and not more than 10 metres fromthe
bottomof the shaft and, beyond that point, lowered
slowly and only on a separate signal fromthe worker in
charge of the sinking bucket; and
(b) while the crosshead is being chaired and released,
the hoist is operated at creep speed only.
95
LOWERING WORKERS AFTER BLAST
LOWERING WORKERS AFTER BLAST
During shaft-sinking operations, on the first trip in which workers
are
transported down a shaft after a blasting operation, the
employer or contractor must ensure that:
(a) the sinking bucket does not transport more workers than
are necessary to make a proper examination of the parts of
the shaft that might have been affected by the blast;
(b) subject to clause (c), the sinking bucket is not lowered
beyond a point in the shaft beyond which the health or safety
of workers may be endangered and, in any case, is not
lowered beyond a point that is less than 15 metres above
the top of the blasting set or the multi-deck stage; and
(c) beyond the point mentioned in clause (b), the sinking
bucket is lowered slowly and only on a separate signal from
the worker in charge of the sinking bucket.
96
OVERHEAD PROTECTION
OVERHEAD PROTECTION
During shaft-sinking operations, if work in the shaft is to be
carried out at more than one elevation at the same time, the
employer or contractor must ensure that workers in the lower
elevations are protected from the danger of falling objects or
materials by installing a secure covering that:
(a) extends over a sufficient portion of the shaft to afford
adequate protection to the workers below; and
(b) is capable of withstanding the maximum load that may
reasonably be anticipated.
97
WORKING BELOW SHAFT MUCKING
MACHINE
WORKING BELOW SHAFT MUCKING
MACHINE
An employer or contractor must not require or permit a worker to
work on or belowa shaft mucking machine unless:
(a) the shaft mucking machine is secured in position by an
elevating systemthat is capable of supporting the full load of
the machine; and
(b) any ropes used with the shaft mucking machine meet the
load factor requirements set out in section 160.
98
SINKING SHAFT IN SEDIMENTARY
STRATA
SINKING SHAFT IN SEDIMENTARY
STRATA
If a shaft is to be sunk in an area underlain by water-bearing or
brine-bearing sedimentary strata, the employer, contractor or
owner must give written notice to the chief mines inspector of
any intention to drill any hole for the purpose of consolidating a
shaft site by a grouting or freezing method.
(2) A notice required by subsection (1) must:
(a) be given as soon as is reasonably possible but
not later than 90 days, before drilling begins;
(b) include the location of the proposed shaft
and the number and depth of the holes to be
drilled; and
(c) if subsection (3) applies, include the radius
and specifications of the pillar to be left around the shaft.
99
CONT .
CONT .
3) If a shaft is to be sunk in an area underlain by water-
bearing or brine-bearing sedimentary strata, the
employer, contractor or owner must ensure that:
a) a substantial pillar is left around the shaft at each
working horizon that is adequate to protect the shaft
from any damage resulting frommovement of the
strata; and
b) a professional engineer determines the appropriate
radius and other specifications of the pillar to meet
the requirements of clause (a).

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Ph. D. Eng. TADEUSZ S. GOLOSINSKI - tgolosinski@expo.intercade.org - Consultor Intercade

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