Symmetrix Principle

Drilled Casings When using a drill casing, soil, rock and other debris is removed within the protection of a steel tube and brought to the surface. For foundations during the concreting process the pile support is transferred from the temporary drill casing, which is gradually withdrawn, to the concrete forming the pile shaft. Likewise, the casing may be left in place to be used as additional structural support and/or protection of the pile itself. For exploration and well drilling, the casing itself can become the conduit for bringing the bounty to the surface.

Rotex Symmetrix Principle

The Symmetrix system is a casing advancing method for drilled casings able to be used in any and all ground conditions and at any angle to depths beyond 100 meters (300ft +). Casing sizes range from 76mm (3 inches) to 1220 mm (48 inches) OD. Systems are designed to work with DTH drilling however some smaller sizes are also available as top hammer versions. The 3 main components work together as a single effective unit. These consist of: a pilot bit with large internal flushing holes and external flushing grooves; symmetrical ring bit [reamer] with internal bayonet coupling; and a casing shoe for driving of casing.

How Symmetrix Works

The pilot bit is attached to the ring bit with a bayonet coupling. Both rotate clockwise and together cut a hole, which is sufficiently large enough to allow the casing shoe to pull down the casing pipe. The ring bit rotates freely on the casing shoe, which is welded to the casing. During drilling, the casing does not rotate. Casings can be added together as required to drill holes of more than 100 meters. The flushing air is ejected through the holes in the face of the pilot bit and returns immediately up wide grooves between the pilot bit and ring bit and the annulus between the casing and the drill string. This ensures high flushing velocity with low hole degradation. When the hole is complete, the pilot bit is unlocked from the ring bit by a slight counterclockwise motion and withdrawn up through the casing. The casing can then be either left in place or retrieved from the hole.

Symmetrix Advantages
Straight holes always without deviation due to changing ground formations! Quick set-up and high production rates ! Less torque is required to drill through all formations than other methods! Easy to unlock/ Easy to relock! Drilling is easy at any angle! Effective internal flushing! Safe and controlled! Significant economic savings! Reaming for casing is done by concentric ring bit with no eccentric components! Simple foolproof structure equals no jamming and no lost bits!

1. Symmetrix STD

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

1. Symmetrix STD
Pilot bit has two shoulders; one at the ring bit; one at the casing shoe Has a wire or ring connection between the ring bit and the casing shoe For drilling medium to deep holes when the casing is left permanently in the hole For temporary casings it is used without the connection between the ring bit and the casing shoe resulting in the ring bit to be left in the hole

Pilot Bit Ring Bit Casing Shoe

Example 1, casing is used as a protective casing in the overburden part of the hole, after the overburden has been drilled through, the drilling is continued in bedrock without casing advancing. Using a normal rockbit (hammerbit).

Step 1: Casing is drilled through overburden and seated into bedrock. Step 2: The pilot bit is unlocked from the ring bit and withdrawn. Step 3: Drilling is continued with a smaller rock bit to complete the task (i.e. water wells, rock sockets, or rock anchors) the casing and ring bit are left in place

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

Example 2. Casing is drilled through the overburden to the bedrock. Drilling is not continued but the casing is filled with concrete and or load bearing steel for piling purposes.

Step 1: Casing is drilled through overburden and seated into bedrock Step 2: The pilot bit is unlocked from the ring bit and withdrawn Step 3: The casing, either a thick walled casing or thin walled with additional reinforcement, is filled with concrete to be used as a foundation pile. All Symmetrix systems include the pilot bit, casing shoe to pull the casing (except some shoeless models for double rotation rigs) and the reaming ring bit, which makes the space for the casing. The pilot bits are mainly done for DTH hammers but most small sizes are available also for top hammer drilling. All major shanks are provided according the make and the type of the DTH hammer.

Different shanks and bit designs for different hammers

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

Symmetrix STD in Well Drilling

The development of Symmetrix occurred due to the requirements from well drillers to have an easier and more reliable overburden drilling system. Today well drillers are one of the main users of Symmetrix worldwide. Typical wells are referred to as screen wells whereby a fairly large diameter casing is drilled to penetrate the water table; a sand packer and well screen are installed inside the casing; a pump shaft is installed; and finally the temporary casing is pulled out.
Screen Well

Well Drilling in Alberta, Canada Using Symmetrix Method

In Symmetrix well drilling, the wells have either steel or PVC casing drilled through the overburden layers. The pilot bit is then unlocked from the ring bit and withdrawn. The casing is then grouted to seal it to the bedrock thus preventing surface water from contaminating the well. The lower part of the well is then drilled with standard rock bits and drilling methods. The Symmetrix Method has been extremely well received by well drillers worldwide who, thanks to Rotex and Symmetrix, can considerably shorten the work time necessary for overburden drilling.

Symmetrix Method of Well Drilling

Withdrawing the Pilot Bit

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

Symmetrix STD in Piling

With the development of the Symmetrix System, drilling contractors and design engineers have quickly come to realize that the used of drilled casings as foundation piles were becoming more economical. With the Symmetrix System the installation of large casings with relatively small drill rigs is possible this has lead to wide spread increases in the use of drilled casings especially in across Scandinavia and other parts of Europe.

Klemm KR 807 drilling 16 inch permanent casings for a railway bridge in Finland

Piling with drilled casing is a fairly common practice in most parts of the world. The selection between friction piles and end bearing piles as well as best methodology and construction technique will depend on the local ground conditions. In areas with varying ground conditions, boulders, extreme hard ground or the need for rock sockets, Symmetrix Casing Advancing System will prove to be the quickest and most economical tool.

Retaining wall with soldier piles (casings) drilled into bedrock

Operators of small drill rigs really appreciate the ease of drilling and the small torque required when using Symmetrix. A small drill rig can easily match the productions of larger drill rigs with the same feed length when Symmetrix is used and get productions of 200% or more in comparison to other methods.
Small drill rig using Symmetrix does the work of a big rig in Hong Kong

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

Symmetrix STD in Underpinning

Underpinning in non-homogeneous conditions has always been a problem especially in areas where till, boulders, and hard rock formations are encountered. Due to penetration problems, piles have been left on unstable layers, later settling and causing damage to the structure it was meant to support. Only through the use of Symmetrix in underpinning can consecutive penetration through cemented sands, hard clays, boulders and till be possible. When underpinning in conditions where the existing foundation has been damaged, the work must be performed with the least obtrusive method in order to prevent stress to the foundation, With the Symmetrix System, piles can be drilled through all obstructions to the required depth without disturbing surrounding structures.

Three additional floors were excavated below an old building after underpinning using Symmetrix

Symmetrix STD as an Alternative to Driven Piles

In areas where vibrations from pile driving may have caused damage to nearby structures, Symmetrix has been the economical alternative. Symmetrix drilling does not cause lateral movement or soil displacement making it ideal in such sensitive areas.

This is very evident in railway works where quick non-obtrusive methods are a must. Here, at a railway realignment project in the UK, 1860 steel casings were drilled through overburden and voids (including old mines) to bedrock to a new railway track foundation.

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

Symmetrix W Ring Bit with Integrated Casing Shoe

The W version was originally developed to maximize the drill through diameter in order to allow a 6 inch hammer with 7 inch casing. This was possible by integrating the casing shoe and the ring bit together. W153, the original system for 7 inch casings, is very popular with water well driller. W140, for 6 5/8 inch casings, was also created for well drillers. Today W190, for 8 5/8 inch casings, and W240 are available as W versions with the ability to develop W versions from any Symmetrix size. W versions have proven very reliable in drilling deep casings with holes of 740 feet deep already having been cased with the W version.

New W-systems have longer casing shoe sleeves over the casing to allow better guidance and the use of additional plug welds.

Rotex Oy has patented the manufacturing method of the W systems a method allowing the models to be made in large quantities

Integrated ring bit and casing shoe of the W153

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

2. Symmetrix Econ
Symmetrix Econ is used for the same purposes as STD. The only obvious difference is that the ring bit (reamer) is not attached to the casing shoe with wire locking but instead is locked to the pilot bit only. The pilot bit is the same as in the STD System The ring bit and casing shoe are not mechanically connected Designed especially for shallow holes with permanent or temporary casings

Econ Set

STD Set

Symmetrix Econ Principle

Step 1: Casing is drilled through overburden into sufficiently firm till or seated in bedrock Step 2: The pilot bit is unlocked from the ring bit and withdrawn Step 3: The casing is filled with concrete and, if needed, with reinforcement

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

When a large number of piles is needed to be installed in fair to medium-difficult conditions, Symmetrix Econ is the right tool. Easy drilling, fast hole-to-hole movements and adaptation of new casing are the elements of efficiency in the Econ bit.

Symmetrix Econ can also be used for temporary casings, especially where it is difficult to pull out the casing. The casing is drilled through the overburden and seated into bedrock or to the designed tip elevation. The pilot bit is unlocked from the ring bit and withdrawn. Rebar or a structural beam is inserted with concrete to form a pile. The casing is then extracted leaving the ring bit behind.

Drilling with Rotary Head/Drill Table Machines

There are several double head units developed for anchoring works whereby the casings are pushed or rotated consecutively with the drilling action. The Symmetrix system is easily adapted to work with these machines by eliminating the casing shoe striking shoulder (as in the STD SL pilot). In this case the pilot bit and ring bit do all the actual drilling work and do not restrict the action of the casing rotator. Rotary table machines, which push and rotate the casing simultaneously while drilling with a DTH hammer inside have difficulties when facing hard rock conditions. Symmetrix SL versions, which have no casing shoe and pilot shoulders, can solve this problem. The pilot bit breaks up the center of the drill hole and the attached ring bit clears the way for the casing, which is maneuvered into place by the rotary table. As the impact energy of both the pilot bit and ring bit is combined, hard rock formations can be drilled easily and quickly with no additional assistance. With the use of the Symmetrix STD-SL version the drilling time is cut considerably with comparative studies showing that the Symmetrix system is 3 to 8 times more productive than rotary head/drill table machines alone.

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

3. Symmetrix SE
Symmetrix SE is a new ring bit design made especially where there is no need to continue drilling beyond the bottom of the casing. When the ring bit ID is not a critical concern, strong shoulders can be built into the pilot bit and ring bit.

The SE type is specified according to the casing OD as in SE applications the drill through diameter is regarded as insignificant.

SE Set Principle: Simple casing shoe and ring bit are very economical yet still strong enough for deep holes and difficult rock conditions. The ring bit thickness is the same as the pilot bit groove width with a deep striking shoulder giving it excellent wear resistance and long pilot bit life. This system is perfect for drilled foundations where the casing is brought to the bottom of a rock socket (in which case additional drill through is not necessary).

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THE SOLUTION IN OVERBURDEN DRILLING

SE is designed to be the most costeffective solution for single-use drilling allowing the casing to be drilled to the bottom of the rock socket SE is designed for drilled foundations where there will be no additional drilling beyond the tip of the casing SE system consists of the SE pilot bit, SE ring bit, and SE casing shoe SE type is specified according to the casing OD as the drill through diameter is insignificant The ring bit thickness is the same as the pilot bit groove width The impact shoulder is deep giving excellent wear resistance and long pilot bit life Simple ring bit and casing shoe are strong enough for deep holes and difficult rock conditions Maintenance welding of worn impact shoulders is easy to perform when necessary

Symmetrix SE is a family of products designed for applications where drilling is not necessary beyond the tip of the casing.

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THE SOLUTION IN OVERBURDEN DRILLING

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4. Symmetrix N System
Symmetrix N Version is designed for temporary casings. The ring bit is integrated with the casing shoe and designed to allow the casing to be pulled out from great depths. N-type pilot bit Designed for applications where casings are retrieved and the same ring set is used multiple times N-type multi-use ring sets; ring bit and casing shoe are connected by a strong mechanism System also suitable for thick wall casings

Symmetrix N System Principle

Step 1: Casing is drilled through overburden to the required depth Step 2: The pilot bit is unlocked from the ring bit and extracted Step 3: Reinforcement, in the form of a rebar cage or structural beam, and concrete is place in the casing Step 4: The casing is extracted (even from great depths) leaving a suitable friction pile

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THE SOLUTION IN OVERBURDEN DRILLING

Symmetrix N352 for 406 mm (16) casing pulled out to be used again

Symmetrix N in Anchoring
A typical application for the Symmetrix N-system is in the construction of ground anchors. Temporary casings with the Symmetrix N-system are extracted after the anchors have been completed. Quick and economical installation of ground anchors is possible especially in the case where the anchor length is working as the bonding unit.

Seismic Retrofit with N131; Vancouver, Canada

Different anchor applications, such as ground anchors and rock anchors, have different bonding lengths. Both anchors can easily be installed with the N-system. The resund Bridge between Denmark and Sweden required the Symmetrix N109 to drill 2200 anchors.

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THE SOLUTION IN OVERBURDEN DRILLING

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Symmetrix Drill-Through Systems: N-DT and W-DT

The Symmetrix system also includes two models where the drilling can be continued with the pilot bit beyond the tip of the casing by passing through the ring bit. Typical applications for the Drill-Through Systems include most anchoring applications and foundations where sufficient skin friction for uplift is not available and a rock socket is necessary.

DT in normal drilling mode drilling through the ring bit and being retrieved though the ring bit

The use of drill-through in piling operations where a separate rock socket is required brings about tremendous savings in cost and time by avoiding the need of an additional drill rig and/or the use of a crane for handling additional tools and switching out the hammer and drill strings. The reduction of time equals an increase of 100% over methods in which the rock socket is drilled separately. Anchoring is another application for Symmetrix DT systems as a separate rock bit is no longer needed for the rock socket saving both time and cost.

N-DT

W-DT

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THE SOLUTION IN OVERBURDEN DRILLING

5. Applications for Symmetrix STD, Econ, SE, N & DT Versions

The use of drilled casings is becoming increasingly popular worldwide primarily due to the expansion of building and infrastructure growth to areas that are less than perfect for their construction. In complex ground conditions the use of driven piles, CFA and other displaced or bored pile types becomes either physically or economically infeasible. Pile driving in dense urban conditions can disturb surrounding structures or utilities and is often difficult to estimate its costs in areas with sloping or changing bedrock. Additionally undue problems such as settlement, soil compaction and lateral soil displacement/heaving can occur. For these reasons, most designers and owners have turned to drilled casings to overcome the potential problems and liability. DTH drilling is the only drilling method that can drill through all ground conditions, boulders and hard solid rock. The Symmetrix system is the most advanced system for drilling casings with DTH hammers due to its vast array of applications and noted field experience.

Piling Applications
For end bearing piles: the casing is drilled through overburden to the required elevation; the pilot bit is unlocked from the ring bit and withdrawn: the casing is filled with concrete (and when necessary additional steel reinforcement). In most cases the casing, typically thick walled, is left in place and acts solely or, along with the steel reinforcement, partially as the load bearing member.

If stable bedrock is not within feasible piling depth, the casing itself may be used only as additional corrosion protection or as a liner to keep the hole open. The main load is then carried out by an internal casing, pile or beam installed inside the drilled casing. The internal load bearing element would require a length for bonding the pile to the ground through a rock socket.

Drilling with N532 DT at Hong Kong Airport

There are numerous ways to apply the Symmetrix system to foundation piling ensuring that the right tool is available for every possible project.

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

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Thick Wall Casings Used as End Bearing Piles

Permanent thick wall casings can be included in the structural makeup of a pile whereby the casing is not only used for corrosion resistance but also as a load bearing member as well.

Rebar cage inside drilled casing before concrete pumping

Work phases of drilled bridge foundations seated in bedrock

End bearing piles for this bridge were installed prior to rock excavation (accomplished by drilling and blasting)

In the case where the pile is required to have a designated capacity in both bearing and tension, the casing pile will typically require a rock socket with friction pin to take the tension loads.

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THE SOLUTION IN OVERBURDEN DRILLING

Friction Piles
When there is no composite material such as bedrock to seat an end bearing pile, a friction pile is utilized. Casings are typically used when the ground conditions will not allow the hole to stay open and the integrity of the hole and the drilling tools themselves must be protected. When working in areas where the ground conditions require the use of a DTH hammer, Symmetrix N, Econ or SE with temporary casings is the best choice.

Typically the N-system is the prescribed system however if the ground has numerous boulders or the casing is drilled deep through hard rock layers then the use of Econ or SE systems may be more feasible. Sometimes the foundation design for friction piles calls for rock sockets to extend beyond weathered or fractured rock for additional uplift capacity. In such cases a rock socket must be drilled beyond the tip of the casing and the load transfer is based on the bond between the socket element, such as an H pile, and the grouted rock interface.

Drawing of installing H piles with Symmetrix N532DT

Friction bars are sometimes welded along the rock socket length of the H pile for extra gripping surface

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

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N-system used for grout columns

When working in alluvial riverbeds and valleys jet grouting can be very problematic as rotary drilling through and within hard boulders is not possible. Percussive drilling is required for drilling. In such situation predrilling with casings is required to drill through strata with stones and boulders. Depending on the depth and ground, either N-system of Econ is used with temporary casings.

Jet grouting works going on through grout columns done with drilled casings, Sikkim

Phase 1

Phase 2

Phase 3

Phase 4

Phase 5

Phase 1 Casing is drilled with Symmetrix N or Econ system Phase 2 Symmetrix System is lifted out and hole straightness checked Phase 3 Casing is filled with grout in 4-5 meter intervals lifting the casing simultaneously or with packers while casing is lifted out Phase 4, Jet-grouting rods are drilled in to required depth Phase 5, Jet grouting is done

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THE SOLUTION IN OVERBURDEN DRILLING

Secant Pile Wall with Drilled Casings

Secant pile walls are commonly used in the construction industry for retaining walls in support of excavation. Using Symmetrix in their construction gives them significant advantages over slurry diaphragm walls typically constructed by grabs or hydromills among these are the ability to work in all ground conditions without changing the methodology or changing tools. Production time and scheduling can be accurately predicted and exact budgeting feasible. Symmetrix is especially suitable in ground conditions with boulders or when a footing in bedrock is required and/or advantageous. Primary piles (1) are drilled and rock socketed consecutively. After a suitable number of casings have been installed, the casings are filled with concrete then extracted

Secondary piles (2) are then drilled down to tip elevation. Rebar or other reinforcement is set into the casings, the casings filled with concrete and then the casings are extracted. A fully stable rock socketed and reinforced wall is now ready. A secant pile wall requires what appears to be an excessive amount of drilled length however the resulting cost is certainly much less expensive than a grab or mill constructed wall when significant boulders are encountered or when the bottom of the wall must be constructed into solid bedrock.

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THE SOLUTION IN OVERBURDEN DRILLING

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Using N-System with Leader Machines

The Symmetrix N-version is ideally suited to be used with leader type machines. The rotary head is raised and lowered by a cable network giving it the ability to pull back or give sufficient crowd when needed. In regular drilling operations when drilling deep, the drilling operation must be stopped to add additional drill string and casing. With this type of machine, the mast length can often be extended by adding additional segments or by lifting the foot off the ground this allows for drilling of the casing in a single pass. This type of machine allows for quick drilling of multiple holes without having to move the base of the machine equaling even greater productions (the reach dependent on the capacity of the crane and the weight of the operation).

Virtually any crane can be adapted for DTH drilling Nova Scotia, Canada

As the Symmetrix system requires only a minimal amount of torque it ideally suited to gravity fed drilling without a drill rig or leader only a crane is needed. This methodology, in use by several contractors, is the perfect solution for construction of temporary work trestles, temporary bridge foundations or in limited access situation where alternative methods would be costly due to the need for access and/or special equipment.

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THE SOLUTION IN OVERBURDEN DRILLING

Bulk Sampling and Rat Hole Drilling

Bulk sampling and rat hole drilling are typical applications for the use of large diameter casings. Traditionally these have been done with rotary rigs however as modernization has caught on with this industry the realization that the traditional methods are both time consuming and expensive (due to the need for large expensive drill rigs) has resulted in many drillers to turn to the Symmetrix system. A starter casing drilled with the Symmetrix casing advancing system is 4 to 5 times faster than traditional rotary systems making a tremendous impact in total productivity and cost. The Symmetrix system also allows for the use of smaller and lighter equipment highly regarded when transporting across rough terrain.

Bulk sampling with 28 inch Symmetrix system Drilling is done with dual stage drill rod with cuttings directed to a container

Underwater Drilling and Blasting

Underwater drilling and blasting operations can be sped up through the use of temporary drilled casings as charging tubes.

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THE SOLUTION IN OVERBURDEN DRILLING

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6. Symmetrix Horizon
Symmetrix Horizon is designed for situations where long horizontal drilling must occur. Due to the high friction levels experienced in horizontal drilling, the impact shoulders have been designed as heavy duty. Because the ring bit is collected from the receiving pit, there is no requirement for drill through and thus there is no limit to the contact surface size and the striking surfaces can be made thick and strong. Designed for long horizontal holes when casing is left permanently in the hole (or for very deep vertical holes) Strong ring bit and casing shoe to guarantee long borings in any soil or rock conditions

Symmetrix Horizon Principle

The casing is drilled through the overburden with HZ version pilot bit and separate reamer with several striking shoulders for extra strength. Typical work for Symmetrix Horizon is for horizontal underpasses (i.e. for utility conduits), which may 200 meters or more in length. The reamer and casing shoe are recovered from the receiving pit. Although the HZ system is designed for break through drilling it can also be used for drilling extremely deep or difficult holes where the ring bit is left in the hole.

HZ type pilot bit used for deep vertical holes

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THE SOLUTION IN OVERBURDEN DRILLING

In horizontal drilling, the casing may require pushing in addition to the pulling action of the casing shoe in order to overcome the tremendous friction. Flushing is therefore critical and the use of augers may be necessary to bring out cuttings from the casing.

A horizontal drilling rig ready for action

Horizontal Drilling for Utility Lines

Horizontal drilling is a common practice for locating utility lines under active roads and railways. Today trenching activities are becoming increasingly unpopular even though improvements to infrastructure require the addition or relocation of new water mains, sewer lines, electrical or telephone conduits. With Symmetrix HZ horizontal drilling system a passage up to 1 meter in diameter can be drilled regardless of the geological conditions faced.

609mm drill bit and casing breaking through after 240 meters of drilling in Italy

44 meters of horizontal drilling, Sweden

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

23

Horizontal Drilling for Pipe Roofs

Pipe roofs are a method of building tunnels through overburden or weak rock formations where a cut and cover method would not be suitable due to existing buildings, roadways or other obstacles.

Pipe roof constructed for a metro line in Hong Kong (preserving park and trees)

Examples of Pipe Roof Designs

Sometimes interlocked casings are used to allow the casings to form an ideal shape. The example in Hong Kong on the right shows where not only the roof but also the walls were constructed using drilled casings interlocked to keep the structure aligned and deviation to a minimum.

Construction of pipe roof for a horizontal underpass, Hong Kong

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THE SOLUTION IN OVERBURDEN DRILLING

7. Symmetrix T-System
The Symmetrix T-system is designed for small diameter casings used with both top hammer (drifter) and DTH hammer use. The driving shoulders are designed very strong which means a long pilot bit lifetime even through difficult conditions. The drill through passage is small however these bits were not designed to be drilled beyond the casing tip. A standard Symmetrix design ensures that only a small amount of torque is needed allowing these bits to be used with standard tunneling jumbos which have very limited torque. Primarily designed for forepoling in tunnel construction Robust, concentric construction for drilling in fractured and variable hard rock formations Available for both top-hammer and DTH drilling

Symmetrix T-System Principle

The Symmetrix T-system was made for forepoling with injection casings. The casings are drilling into the required penetration; the drill rod and pilot bit are withdrawn and injection material is pumped into the casing allowing it to flow out through the casing holes. The ground immediately around the casing becomes permeated with the injected substance as the material is packed in causing it to become more stable. Both cement slurries and chemicals are used depending on the nature of the ground.

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

25

Symmetrix T-Version in Tunneling

For underground infrastructure construction in urban areas, which have typically poor ground conditions or for any underground construction in weak or disturbed soils, modern tunneling engineers have developed a face stabilization and protection system called Forepoling. This method is based on the use of drilled poles (casings) in advance of the tunnel excavation. Rotex was one of the first to develop Symmetrix drilling accessories for this type of work. Symmetrix product ranges cover all forepoling and roof piping application wherever drilling is required.

Forepoling is constructed either with standard tunneling jumbos with short 3~4 meter feeds and threaded casings or as a single pass drilling operation with specialty forepoling rigs with long feeds. Forepoling is a ground stabilization technique where the support structure of a tunnel sector is placed ahead of the excavation. The supporting mechanism provided by the forepoling technique stabilizes the tunnel face area in both transverse and longitudinal directions by an arch-like reinforced zone. The Spiling method consists of four different parts: Drilled steel pipe Grout inside the pipes and in voids outside Treated ground by permeation or fracture grouting Steel arch supports (with foot piles when necessary)

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THE SOLUTION IN OVERBURDEN DRILLING

Injection is the crucial part of this system in order to form the arch-like structure. For cement or chemical grouting, perforated casings are used; holes are either open or fitted with oneway valves for double packer grouting.

Casing shoe and thread

Fiberglass system

Weak and/or wet conditions may require fiberglass casings at the face of the tunnel for stabilization and longer drainage casings with Sidra/Sidrex systems.

Sidrex Simultaneous Drainage

In forepoling, the ground around the casings is treated by permeation or compaction grouting through the casing holes with packers. A high water content will complicate the work resulting in the need to have special drainage casings drilled in for dewatering. Standard forepoling casings can now be utilized for simultaneous drainage with the new Sidrex System. Some forepoling casings have an added 1.5 to 6 meter element with slots for draining water. The slots open automatically after drilling. The outside packer prevents the grout from blocking the slots.

Dewatering slots are protected with a water soluble material and they open automatically within 12 hours after drilling. A patented packing seal located on the outer surface of the drainage element prevents grout from blocking the slots. Symmetrix and Sidra are patented trademarks.

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THE SOLUTION IN OVERBURDEN DRILLING

27

8. Special Symmetrix Systems Enhanced flushing by Symmetrix RC

Reverse circulation drilling was originally designed to collect chip samplings for geological exploration. This required the use of special two stage (or two way) drill rods and an RC hammer with a collection inlet. Later, RC hammers were also used in the construction industry to drill in locations where exhaust air escape through the collection inlet helped to cope with high backpressures. This assisted in reducing the worry of volumes of air being introduced to the ground and a control of the material washed out. To overcome the most common problems experienced with this method, Rotex developed a new pilot bit. The new RC bit does not require the use of double wall or two stage drill rods or a special RC hammer yet it allows proper flushing without risk of over-flushing to be gained through the superior design: Air flushing (water and foam if added) cleans the bit face and directs the flow back inside the casing through the center holes The amount of face cleaning air is controlled through a nozzle in the other air passage opening in the casing By controlling the second passage we can balance the flushing without over flushing

The RC design is available for all Symmetrix Systems

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Rotex DRC Systems

Rotex Oy has developed a system with fluid flushing. This system is based on the Symmetrix RC version bit and the use of a RC hammer where the collection tube is used as a conduit for the flushing media, normally water or water/bentonite slurry.

Ports Open

Ports Closed

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THE SOLUTION IN OVERBURDEN DRILLING

29

SimGrout Simultaneous Grouting Method

Sometimes simultaneous grouting is a requirement either in rock sockets for a solid anchor or along the whole casing before the drilled casing can be accepted as a permanent pile. All Symmetrix STD bits can be used with the new SimGrout system developed by Rotex Oy.

SimGrout Simultaneous grout injection Available for all Symmetrix STD pilot bits Three injection holes Grout volume and pressure selected according to the application and available grouting equipment Modifications to adopt the method can be made at the work site

Grouting is done either through standard plastic grouting hoses (if double wall drill rods are used) or through steel hosing (water pipes) with simple overlapping joints. Centralizers are not rotating but fixed to the casing and retrieved when the hammer and pilot bit are extracted.

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Drilling with Water Hammer

Rotex Oy is the supplier of Wassaras W-Rex casing drilling product line.

W-Rex casing advancing systems

The Wassara water hammer has many advantages over standard air powered hammers. They can be used in areas with a high ground water pressure; they keep their efficiency in long holes; and drilling with water consumes only 1/3 the energy used in standard DTH drilling.

Drilling with Rotary and DTH in the Same Hole

Due to Symmetrixs unique locking system it is possible to drill with a tri-cone bit or drag bit and with a DTH hammer in the same hole. A special ring bit adapter is used when drilling with the tri-cone or drag bit in order to rotate the ring bit. When DTH drilling is required, the drill string is lifted out and the DTH hammer with Symmetrix pilot bit is locked into the ring bit.

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THE SOLUTION IN OVERBURDEN DRILLING

31

9. System Requirements
Drilling requires: a suitable DTH hammer applicable to the task at hand: compressors to run the hammer; drill rods; and a Symmetrix pilot bit with sets of reamers

Hexagonal joint drill rod for 610mm casing

Drill String Principle

Drill rods conduct the air required by the DTH hammer downward; exhaust air and the cuttings return between the drill rod and the casing wall. The bailing velocity depends on the compressor used and the annulus area between the rod and casing. Air speed should exceed 15 m/sec (3000 fpm). With large casing sizes this typically means drill rods that are about 60~80mm (2~3 inches) smaller in diameter than the casing size. If hexagonal joint rods are used, a man cage or mast lift will be required to assemble and disassemble the locking pins on the drill head spindle. The DTH hammer requires a certain feed force to work properly. Ensure that you have a feed force between 8~10 kg/mm of bit diameter (450~560 lb/inch). DTH hammers require lubrication. An adjustable positive replacement pump ensures adequate lubrication at all times.

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Another possibility is to utilize the reverse circulation principle with dual wall drill pipes. Two swivels, one for compressed air and the other for exhaust air with cuttings and soil need to be installed. One must ensure that the hollow spindle of the rotary head has a passage equal to the inner diameter of the RC pipe. Reverse Circulation Drilling Principle: Cuttings are collected; same rod can be used for several different casing sizes by only changing the rubber liner seal; suitable for sensitive drilling conditions.

Rubber liner keeps cuttings from traveling up the casing

The diverter directs the return flushing air into the inner pipe of the dual wall drill rod and up through the rotary head into the collection pit.

In all DTH drilling remember: Grind the casing shoe and casing surfaces before welding Use a proper root weld Ensure you have enough flushing velocity; especially in deep holes (over 30 m) slow flushing increases back pressure thus causing slow penetration and possible shoe breakage Use stabilizers Use air valve to reduce the stress on casing shoe/reamer shoulders after breaking through boulders Maintain your pilot bits Use foam when necessary

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

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Welding of Reamer Set to the Casing

As the casing shoes conduct the impact energy and pulling force to the casing and must come up with the casing when it is extracted, care should be taken that the weld is competent to take the load.

The casing shoe and casing should have a minimum 2~2.5 mm gap prior to welding to ensure full weld penetration. This also applied to the buttwelded N-version.

When large diameter N versions are welded the first root weld is done from inside with the weld ground smooth from both sides. Subsequently the weld should be inspected and then filled from outside with two or three runs (depending on the type and size of the electrodes and the casing diameter)

Maintenance
When doing repair welds, use hard welding rods and grind the surfaces back to original standards. Keep buttons grinded. Grind them before 1/3 of the button is flat. Especially watch gauge buttons. Good welding rods for hard welding the worn shoulders are: Esab OK 84.58

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10. Exceptional Casing Shoe Designs

Symmetrix STD135 version B will adapt to any casing wall thickness

Symmetrix STD155

Symmetrix STD165

Symmetrix W versions W140 and W153 look today as follows:

Old short shoe sleeve

New design allows plus welding

SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING

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