1.

Introduction
CONSTRUCTION HANDBOOK

R O C K E X C AVAT I O N
HANDBOOK

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P R E FA C E

The construction business is continuing to grow at a fast pace worldwide.

The construction business is closely related to the world economy as well
building of infrastructure. The building volume is increasing even though
there are big regional variations. Interesting part of construction is rock
excavation and the big variation of rock properties is challenging everybody
involved; contractors, consultants, equipment suppliers etc. At the same
time development of technology is offering new methods and solutions for
surface and underground applications. Sandvik Tamrock has published this
handbook to present these applications as well basic information to assist
selection.

Thus this handbook will serve anyone who deals with the construction exca-
vation business. It is also good reference tool for those studying related
subjects.

Several people participated in writing this book and therefore I like to

extend my thanks to Unto Ahtola, Karlheinz Gehring, Pekka Kesseli, Peter
Kogler, Pasi Latva-Pukkila, Arne Lislerud, Maunu Mänttäri, Jukka Naapuri and
Tuomo Niskanen. Special thanks to Kirsi Nieminen, Nordberg Inc, Aimo
Vuento 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 Heiniö
Editor in chief
99-808-GB-6000 © Copyright Sandvik Tamrock Corp. 1999
Any diagramm, picture schematic or other matter contained herein is provided for
illustrative purposes only. Accordingly, any matter set forth herein schould not be
exclusively relied upon by the reader.

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TABLE OF CONTENT

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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3. PRINCIPLES OF ROCK EXCAVATION TECHNOLOGIES 4.2.1 Drilling and Blasting..............................................................142

4.2.2 Primary Breaking by Hydraulic Hammer ...................................183

3.1 MECHANICS OF ROCK BREAKING.................................................62
4.3 QUARRY CASE .............................................................................187
3.2 TOP-HAMMER DRILLING ...............................................................63

3.3 PRINCIPLE OF DTH DRILLING.............................................71 5. GENERAL CONTRACTING

3.4 ROTARY PERCUSSIVE DRILLING .........................................71 5.1 GENERAL .....................................................................................188

3.5 HYDRAULIC HAMMERS ......................................................71 5.2 METHODS ....................................................................................189

5.2.1 Drill and Blast Excavation ......................................................189
3.6 CUTTER-CRUSHERS AND PULVERIZERS .......................................73
5.2.2 Demolition and Recycling .......................................................204

3.7 CUTTING .......................................................................................74

5.3 CASES ..........................................................................................211
3.8 LOADING AND HAULING ..............................................................76 5.3.1 Highway and Railway Cutting .................................................211

5.3.2 Demolition and Recycling .......................................................213

3.9 CRUSHING OPERATIONS...............................................................82

3.10 ROCK BLASTING ...........................................................................93 6. TUNNELLING

3.10.1 Blasting products ..................................................................93

6.1 GENERAL .....................................................................................214
3.10.2 Rock blasting theory ............................................................120

3.10.3 Blasting and environment.....................................................123 6.2 METHODS ....................................................................................216

6.2.1 Drilling and blasting..............................................................216

4. QUARRYING .............................................................................. 6.2.2 Mechanical tunneling .............................................................254

6.2.3 Shaft Excavation ...................................................................281

4.1 GENERAL .....................................................................................140
6.2.4 Rock reinforcement ................................................................290

4.2 METHODS ....................................................................................142

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6.3 CASES ..........................................................................................299 8. WATER WELL DRILLING

6.3.1 Railway tunnel ......................................................................299

6.3.2 Oil and gas storage................................................................300 8.1 GENERAL .....................................................................................324

6.3.3 Hydropower stations and waterworks.......................................301
8.2 METHODS ....................................................................................325
6.3.4 Hammer tunneling .................................................................302

6.3.5 Roadheader tunneling ............................................................303 8.3 WELL DRILLING PROCESS ..........................................................336

7. DIMENSIONAL STONE QUARRYING 9. EXPLORATION DRILLING

7.1 BUILDING STONE MATERIAL ......................................................306 9.1 GENERAL .....................................................................................340

7.2 METHODS OF ROCK EXTRACTION ...............................................308 9.2 METHODS ....................................................................................340

7.2.1 General.................................................................................308

7.2.2 Extraction and Cutting of Hard Rock........................................309 10. PROJECT PLANNING AND IMPLEMENTATION

7.3 QUARRY PLANNING ....................................................................315 10.1 PROJECT COSTS ..........................................................................344

7.4 FINANCIAL RESULT OF QUARRYING ..........................................317 10.2 TAMROCK PROJECT STUDIES......................................................347

7.4.1 Costs ....................................................................................317 10.2.1 Excavation Process recommendations .....................................347

7.4.2 Methods of succesful quarrying ..............................................320 10.2.2 Equipment selection.............................................................347

10.2.3 Performance and cost studies................................................348

7.5 FOUNDING A QUARRY ................................................................320
10.3 SERVICE SUPPORT ......................................................................354
7.6 DRILLING TOOLS SELECTION FOR DIMENSIONAL
STONE INDUSTRY .......................................................................321
REFERENSIS ........................................................................................364

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1. INTRODUCTION

Excavation activities at construction sites are very diverse. Contracting customers also vary
significantly in size. What is a typical construction project made up of? The answer is that all
construction projects are time-limited. Project duration varies from one month to several
years, and the schedules are almost always tight. Usually, immediate mobilization takes place
once the contract has been awarded and often there are penalties involved if the original
schedule does not keep. It is therefore important to choose the right excavation method
together with the right equipment to keep the project on schedule. This handbook covers all
modern excavation methods and also provides some recent case stories.

Excavation methods can be divided into groups. The following classification shows how it is
handled in this book.

Both aggregate and limestone quarrying by the drill & blast method and mechanical method
is discussed in the chapter called “Quarrying”.

General contracting includes a wide range of projects from rock foundation in buildings and
roads 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 the
chapter on general contracting.

In the “Tunneling” chapter, which also includes underground excavation, both traditional drill
& blast and mechanical method are discussed. Underground excavation varies significantly
from 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 is
service support.

At the end of every chapter, there is a case description providing a real-life example of a
typical excavation site.

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