Atlas Copco

Raiseboring
in Mining and Construction

Raiseboring in Mining and Construction

Printed matter no. 9851 2575 01

Atlas Copco Rock Drills AB

First edition 2008
2008

www.atlascopco.com www.atlascopco.com
Turning heads and pulling the string

A tough environment demands tough machines.

Machines built for tight places able to squeeze out
the most productivity in the least amount of time.
Machines that are versatile, reliable, cost-efficient and
with the highest rate of penetration and safety on the market.
No other company has the experience, the innovation and
the commitment to the industry like Atlas Copco.
Whatever the rock, wherever you are. Weve got the
raiseborer to fit your application. Count on Atlas Copco,
(We wont string you along)

Committed to your superior productivity.

Atlas Copco Rock Drills AB

www.atlascopco.com
Contents
Foreword
2 Foreword by Marcus Eklind, Product Line Manager,
Raiseboring, Atlas Copco Rock Drills AB

Talking technically
3 Rock drillability
7 History of raiseboring
10 The raiseboring concept
13 The raiseboring machine
20 Computer based training for raiseboring
22 Horizontal and low angle boring
25 Development of boxhole boring
29 Down reaming Product specifications
33 Modern boxhole boring with BorPak
36 Selection of raiseborer drive system 82 Robbins raiseboring machines
38 Computers improve rock excavation productivity 91 Pilot bits from Atlas Copco Secoroc
40 Site preparation 96 Drill string components
47 Operating the raiseborer 99 Power packs
51 Bailing considerations 101 Drill pipe handling equipment
56 Cutter and reamer design 102 Transporters
64 Raiseboring drillstring components 103 Tools
104 Raiseborer system upgrade kits
108 Conversion table
Case studies
67 Boxhole boring at El Teniente
73 Raiseboring for production at McArthur River Front cover: Robbins 34RH C at the Kvarntorp
78 Replacing Norways Tyin hydropower plant test mine in Sweden

Produced by Atlas Copco Rock Drills AB, SE-701 91 rebro, Sweden, tel +46 19 670 70 00, fax 019-670 73 93.
Publisher: Marcus Eklind, marcus.eklind@se.atlascopco.com Production Manager: Elisabeth Nilsson, elisabeth.nilsson@se.atlascopco.com
Editor: Mike Smith, mike@tunnelbuilder.com Senior Adviser: Hans Fernberg, hans.fernberg@se.atlascopco.com
Contributors: Bjrn Samuelsson, Jan Forsberg, Johnny Lyly, Mikael Bergman, Rikard Erlandsson, Roberto Lopez, Sverker Hartwig
all name.surname@se.atlascopco.com, Steve Brooke, steve.brooke@us.atlascopco.com
Digital copies of all Atlas Copco reference editions can be ordered from the publisher, address above, or online at www.atlascopco.com/rock.
Reproduction of individual articles only by agreement with the publisher.
Edited by Mike Smith, tunnelbuilder ltd, United Kingdom. Designed and typeset by ahrt, rebro, Sweden. Printed by Welins Tryckeri AB, rebro, Sweden.

Legal notice
Copyright 2008, Atlas Copco Rock Drills AB, rebro, Sweden. All product names in this publication are trademarks of Atlas Copco.
Any unauthorized use or copying of the contents or any part thereof is prohibited. This applies in particular to trademarks, model denominations,
part numbers and drawings. Information in this publication is provided as is. Atlas Copco Rock Drills AB disclaims any representation or warranties
of any kind including without limitation warranties of merchantability or fitness for a particular purpose, non-infringement or content. In no event
will Atlas Copco Rock Drills AB be liable to any party or any damages for any use of this publication. The contents, including illustrations and photos,
in this publication may describe or show equipment with optional extras. It may also contain references to products or services that are not available
in your country. This publication, as well as specifications and equipment, is subject to change without notice. Consult your Atlas Copco Customer
Center for specific information.

raISEBORING 1
Foreword
Ageneration ago, excavating raises was hard and dangerous
manual work, carried out by only the most experienced miners.
Mines needed ore passes and ventilation raises, and there
was only one way to excavate them, using drill/blast. When
James Robbins built the prototype Robbins 41R raise drill in
1962, it was the beginning of a new era. Boring of raises was
far more attractive than traditional methods. It was faster,
cleaner, and, above all, took the operators out of the raises
and placed them in accessible, well ventilated, and safe
positions.
From the Robbins 41R to the current model 191RH, the
Robbins raise drill has come a long way. Both in the capa-
bilities of the machine, and in the technology behind it. Our
raise drills are now capable of boring holes 1,000 m-long,
and up to 6 m-diameter. As a result, raiseboring is now the
preferred, and most cost-effective, means of excavating
openings in underground projects.
Increased automation is a continuous trend in the business
of raise drilling. The reasons for this are simple, and can be
summarized as: reduced labour; faster and smoother operation;
quicker response to blocky ground; and data logging and
diagnostics. New control systems ensure that the operator
can select the optimal running parameters to get the most
out of the raise drill, both in performance and economy.
Functions such as automatic shutdown and anti-jamming
make it possible to carry on drilling between shift changes,
without worrying about spin backs or losing the drill string.
As the hydraulic drives have developed and become more
efficient, the improved control accuracy has made them the
first choice for most customers. Hydraulic drives offer good
reaming characteristics and are very soft on the drill string.
Combined with the new reliable control system, this is prov-
ing to be the way forward in most operating environments.
This book is designed as a reference for all raise drillers,
describing the methodology in detail, and giving an insight
into the current equipment offering from Atlas Copco. We
hope you find it useful, and we are available to discuss the
finer points with you at any time.

Marcus Eklind
Product Line Manager, Raiseboring
Atlas Copco Rock Drills AB

marcus.eklind@se.atlascopco.com

2 raISEBORING
 Talking Technically

Rock drillability
Fracturing rock Zone of triaxial
crushing Radial
Drillability is the ability to frac- cracks
ture or drill rock using mechanical
means, and is governed by a num-
ber of factors. Some of these are
related to the rock formation, and
others to the forces applied, and
the geometry of the drilling equip-
ment. Rock properties, rock fail-
ure mechanisms, and drilling para-
meters all relate to drillability, and
are helpful in evaluating drilling
efficiency, trouble shooting pro-
blems, and estimating cutter per-
formance.
General rock boring principles
and their practical application are
the basis of modern raiseboring.
Two basic principles are used to-
gether in full face boring - these
are cratering and kerf breaking.
The objective when boring is to
crush the rock until tensile crack-
ing occurs, causing chips to break
away. The art is in the design of
the cutters and the pressure with
which they are kept in contact
with the rock. This is where ex-
perience counts, and nobody has
more knowledge about raise bor-
ing than Atlas Copco Robbins.

Figure 1: Cratering is the first stage of kerf breaking.

Rock properties
Data on unconfined compressive strength
(UCS) is the most commonly available
rock property. However, it is difficult to
use UCS to predict drilling perfor-
mance without additional information.
The average UCS for selected forma-
tions is shown in Table 1 (next page).
One simple method to determine the
approximate hardness of a formation is
the Moh scale, if UCS information is
unavailable. The Moh scale is used to
classify the relative hardness between
different minerals. Diamond is at the top
of the hardness scale, rating a 10, and
talc is at the opposite end, rating a 1.
In general, the minerals at the high end
of the scale are harder than those on the
low end of the scale. Scratch testing can
be used to estimate the hardness: a fin-
gernail can scratch up to about 2 Mohs,
a copper coin up to about 3 Mohs, and
glass up to 6 Mohs. However, care must
be taken to ensure that the scratch is
not a powder residue left from the item
being used to scratch. Some common
minerals and rocks are shown with their
corresponding Moh Hardness number
in table 2 (next page).
Other factors that influence drilla-
bility are:
Abrasiveness abrasiveness of a for-
mation is usually indicated by its silica
content. Abrasive formations accelerate
cutting structure wear, causing slower
drilling rates as the carbide becomes
blunter, and sometimes cone shell ero-
sion, which can ultimately lead to lost
inserts.
Jointing and bedding formations
with joints or layers are easier to drill
than massive unfractured formations,
since the anomalies provide free faces
which make failure easier.
Schistocity schists have layers of
mica interbedded with harder, more
brittle rock. These mica layers absorb
the energy of the drilling process, with
the rock acting as a plastic, rather than
a brittle material.
Rock failure
The primary failure mode employed by
the rotary drilling method is the tensile
failure of the rock under a compressive
load to form rock chips. In weaker,
more ductile formations this primary
method of failure may be replaced or
augmented by the gouging and scraping
action of the cutter. Studies have shown
that the action of the cutting element is
progressive, as shown in Figure 1.
As force is applied to the cutting
element, the cutter deforms the rock.
As the force increases, a pressure bulb

raISEBORING 3
 Talking Technically

Formation UCS (Psi) Mpa Formation UCS (Psi) Mpa

Berea Sandstone 2,500 17 Limestone 20,000 138

Austin Chalk 3,000 21 Marble 20,000 138

Sandstone 9,000 62 Dolomite 24,000 165

Quartzitic Sandstone 9,000 62 Porphyry 40,000 276

Shale 15,000 104 Pink Quartzite 68,000 469

Table 1: Average UCS for selected formations.

of finely crushed rock forms under the
cutter. The pressure bulb transmits pres-
sure to the surrounding rock, causing
tensile fractures. As these propagate to
the rock surface, chips form, releasing
the pressure of the pressure bulb.
Rock breakage also relies upon the
interaction of several cutting structure
elements and their contact points on
the rock. The placement of the cutting
structure elements is a critical part of
the cutter design.
Cutting structures
Atlas Copco uses three types of cutting
structure geometry for raiseboring appli-
cations: kerfed carbide insert cutters;
rowed cutters; and randomly-placed car-
bide insert cutters.
Table 2: Moh hardness numbers for selected common minerals and rock.
Mineral or Rock Moh Hardness
Amphibolite 6.2
Andalucite 7.5
Andesite 7.2
Basalt 7.0
Kerf, or disc cutters use an extension
of the rock failure mechanism described
above. When properly-spaced discs are
combined with sufficient cutter force,
very efficient drilling results, since the
disc maintains continuous contact with
the formation.
Interaction between adjacent disc
paths produces shear failure of the rock
between these paths. Figure 2 demon-
strates the pattern of a kerf type cutter
on the rock face.
Kerf cutters tend to spall out 10-20 cm
(4 to 8 in) long banana shaped chips and
smaller, almost circular chips depen-
ding on the formation and the loading.
Compared to randomly placed carbide
insert cutters, kerf cutters tend to require
higher thrust and torque to spall out
chips, but are more efficient if sufficient
Mineral or Rock Moh Hardness
Gypsum 1.5
Limestone 3.3
Magnesite 3.5
Magnetite 4.2
Figure 2: Kerfs on the rock face.
load and torque are available. The kerf
cutter concept is shown in Figure 4.
Carbide rowed cutters perform some-
where between the kerf-type cutter and
the random insert-type cutter. The rowed
cutter design has multiple rows of in-
serts, but no steel kerfs in which the
inserts are located. The lack of kerfs
allows more room for cuttings removal,
less opportunity for abrasive formations
to wear away the cutter shell, and greater
penetration of the inserts into the for-
mation with less power consumption.
The staggered insert location and mul-
tiple rows tend to decrease the torque
requirements, somewhat similar to the
random cutting structure, and the rows
of inserts allow for rock kerfs to spall
out of the formation, although generally
smaller than a pure kerf cutter design.
The patented design of random in-
sert cutters employs a random pattern
of inserts on the cutter shell to provide
Figure 3: Random pattern on rock face.

Bituminous Coal 2.5 Marble 3.0

Chert 6.5 Potash 2.2
Cryolite 2.5 Pyrite 6.2
Diabase 7.8 Quartz 7.0
Diamond 10.0 Quartzite 7.0
Dolomite 3.7 Ryolite 7.2
Emery 8.3 Salt 2.5
Feldspar 6.2 Sandstone 3.8
Gabbro 5.4 Slate 3.1
Gneiss 5.2 Soapstone 1.0
Granite 4.2 Sulphur 2.0
Graphite 1.0 Zircon 7.5

4 raISEBORING

Figure 4: Rock failure occurs between insert pressure bulbs.
a fairly dense axial coverage in a com-
plete revolution of the cutter. This design
has shown significant increases in drill-
ing rates, while reducing drilling torque,
which has proven beneficial for situa-
tions where the length of the raise, and
the formation characteristics, have pro-
ven equal or greater than a machines
capabilities. The random insert cutter
tends to spall out circular chips of approx-
imately 1.5 in-diameter or smaller.
An example of the random insert
pattern produced on the rock face is
shown in Figure 3. Multiple passes of
the cutter can provide a wide range of
insert spacing on the formation. Rock
failure occurs when sufficient passes
have been made to achieve the shear
failure between insert pressure bulbs,
as illustrated in Figure 4.
An additional benefit of the random
insert location is a reduction in the phe-
nomenon known as tracking. Tracking
occurs when the insert slips into an ex-
isting pressure bulb crater created by
the last pass of the cutter. Tracking can
wear the edge of the insert prematurely
and result in shear failure of the carbide,
thereby reducing the penetration rate
over time. Tracking can also be reduced
in non-random cutters through varying
raISEBORING 5
Zone of tensile failure
Rock chip
the angles between the inserts in a
given row. The random location of the
inserts helps produce a new pattern
with every pass of the cutter.
As a result of this design, efficient
drilling can be achieved over a wide
range of rock conditions, and is inde-
pendent of kerf spacing.
Drilling parameters
Three drilling parameters have a signi-
ficant effect on performance. These are
cuttings removal, force on the cutter,
and rotary speed. A fourth parameter,
drilling torque, is also of interest, since
it sets limits on the other operating para-
meters.
Cuttings removal can have a signi-
ficant effect in down reaming opera-
tions, since cuttings on the bottom of
the hole are being reground and limit
the effectiveness of the cutting process.
Extended nozzles directed towards the
wall of the hole can help sweep the
cuttings towards the pilot hole. The pro-
file of the cutting structure in conjunc-
tion with the angle being drilled can
also aid or deter the cuttings removal.
For raise drilling, cuttings fall away from
the drilling face, so their removal is not
Talking Technically
a problem. However, rock accumulation
on the cutter head can affect drilling
performance.
Thrust force on the cutter is the para-
meter that can have the most dramatic
effect on drilling rate. The graph in
Figure 5 (next page) shows the typical
response of a cutter to applied force.
This chart is for several different
strengths of rock drilled with a disc
cutter. The spacing between cutters will
affect the location of the curve, but will
not change its shape. At lower cutter
loads, the response of drilling rate to
load is approximately linear. However,
above the threshold loading, drill rate
increases dramatically with increasing
loads. This increase follows the rela-
tionship Drill Rate = Function (force
to the power of n) where n varies from
1.2 for low-strength rock, to approxi-
mately 1.8 for hard rock.
As an example, if a hard rock is dril-
ling at 2 ft/hr at 18.2 t/cutter (40,000 lb),
an increase to 22.7 t/cutter (50,000 lb)
would produce 2 ft/hr x (50,000/40,000)
1.8 = 2.99 ft/hr.
In recommending higher drilling
loads, another relationship needs to be
kept in mind regarding the bearing life
of the cutter, which is Cutter Bearing
 Talking Technically
Penetration Rate Vs. UCS
4 drilling machine, with the consequence
Penetration Rate
3 n = 1.6
2 dictate the load that can be applied to the
1
0
0 10000 20000 30000
UCS
Figure 5: Random pattern on rock face.
Life = Function (force to the power
of 3.33). In the previous example, if
the 40,000 lb cutter load results in a
1,000 hr bearing life, then the 50,000
lb force would result in 1,000 hours x
(40,000/50,000) 3.33 = 475.7 hr.
The actual load applied to each cutter
must be used for this application, and
the load must be broken down into axial
and radial load in the bearing, for a clo-
ser estimate.
The reduced life is even more pro-
nounced when the cutters are consid-
ered as a system. For example, the above
calculation may be accurate when one
cutter is considered, but what if there
are 10 cutters in the system? If the odds
are that there will be one failure in 100,
or 1%, in that period of time, the chances
of failure increase as the number of cut-
ters increases.
In addition, too little force may also
be detrimental to the life of the cutting
structure on the cutter. If the applied
load is insufficient to fracture the for-
mation (minimum of 80% of the UCS
assuming a 1 square inch contact area
per cutter), the inserts will wear rapidly.
This failure is enhanced in abrasive
formations.
Rotary speed and torque
Rotary speed generally affects drilling ra-
tes linearly. For example, a 10% increase
in rotary speed should produce a 10%
increase in drilling rate. The traditional
approach to rotary speed recommen-
dations has been to limit the peripheral
6 raISEBORING
n = 1.8
n = 1.4
n = 1.2
40000 50000 60000
speed of the head to under 350 ft/min.
These limitations have been set due to
concerns over gauge wear on the head,
drill string wear, and drill string failure,
all of which have occurred at high peri-
pheral speeds. Higher rotational speeds
are incorporated into smaller raiseboring
machines, but caution must be exercised
when using high rotational speeds on
large diameters.
The relationship between rotary speed
and bearing life is also linear, but is
negative, leading to a 10% decrease in
bearing life as a consequence of a 10%
increase in rotational speed.
Increases in penetration rate due to
increases in rotational speed are not as
Cratering
Cratering is the term used to describe
the crushing action in the rock di-
rectly beneath the contact area of the
cutter edge, which is usually a chisel
shaped tungsten carbide insert. As in-
creased loading is reacted into the rock
by the cutter, it is crushed to a fine
powder and compressed. The induced
stresses initiate radial tensile cracks
in the rock mass, which break back
to the free surface. As penetration of
the cutter edge into the rock continues,
the cracks expand, and chips split
away. This allows the crushed fines to
escape and new tensile cracks to form.
In this way, continuous production is
possible by simply keeping the rotating
bit pressed against the face.
dramatic as penetration rate increases
due to increased cutter load, but should
not be discounted. Often, the increased
speed is within the capability of the
being increased power consumption.
Insofar as drilling torque is con-
cerned, capacities of equipment often
cutters. Several factors influence torque
requirements, such as load per cutter,
reamed diameter, formation, and angle
of the raise. Additionally, the torque re-
quirements tend to fluctuate radically,
with peak torque more important than
average torque.
All things being equal, the torque re-
quired increases as the load per cutter
increases, as the diameter of the raise
increases, and as the angle of the raise
increases away from vertical.
Formation can be more difficult to
classify in regards to torque require-
ments. However, in general, the softer
the formation, the deeper the insert pe-
netrates, and the higher the torque re-
quirement. This relationship can be
altered considerably if the rock fails
readily through shear, as in some verti-
cally jointed formations. Broken and
blocky formations can also produce
large spikes in the required torque as
the formation tries to unravel.
Steve Brooke
Kerf breaking
Kerf breaking occurs when radiating
cracks beneath the cutter edge reach
an adjacent kerf and form a chip be-
tween the two cutter kerfs. Kerf brea-
king is applied to the entire rock face
by a reamer dressed with either single
row disc cutters or multi-row button
cutters. These are mounted on the rea-
mer at spaced intervals outward from
its centre. As it rotates and is thrust
forward into the rock face, the cutters
roll against the surface of the rock and
crush kerfs in concentric paths. Once
the critical depth of penetration to spa-
cing ratio is reached for the particular
rock type being bored, chipping occurs
between the kerfs, and the rock face
can be systematically excavated.
 Talking Technically

History of raiseboring
Forty five years on
It is now 45 years since Atlas Cop-
co Robbins built the worlds first
successful raiseboring machine,
and launched a worldwide revo-
lution in underground mining and
construction that is still gaining
momentum.
New products, concepts and
techniques, such as automation,
computerization and horizontal
reaming are creating exciting new
opportunities for the user under-
ground.
The latest innovation is the ap-
plication of Atlas Copcos CAN-bus
control technology to raiseborers,
using components that are com-
mon to other new generation pro-
ducts such as Rocket Boomer and
Simba drill rigs that may already
be at work on the mine.
In this way, mechanization for
one-man operation is facilitated
without having large inventories
of spares, and with very short lear-
ning curves for all concerned.

Market share
The history of raiseboring is really
the history of Robbins raise drills. As
the industry pioneer, the company has
manufactured 350 raise drills of the
approximate 600 that have been pro-
duced in total to date, giving it a +60%
market share.
In all, some 35 models have been
introduced, with reaming diameters of
Figure 1: The Robbins 41R, first of a long line of raise drills.
0.6 m to 6.0 m.
Of the models produced, the 73RM
is the most sold, with a reaming diameter Built for life standards for tungsten carbide cutters,
of 1.8 m-3.1 m. and a float box to reduce stresses in
Nearly all of these Robbins raise When James Robbins built the first raise the main bearing and drill string of the
drills are still available for work. So, borer in 1962, little would he have raiseboring machine. Connectors using
despite always requiring high capital thought that it would still be working API-standard 7-inch tapered threads
investment, raise drills have given an 45 years later. However, the fact is that were introduced to connect the drill
exceptional return to their owners while the very same 4 ft-diameter machine, tubes on the second machine built by
retaining solid residual value. This sums the original Robbins 41R as shown in Robbins and was in use in various sizes
up the raiseboring story. Figure 1 with pinned drill tubes and until the DI-22 thread was invented in
Apart from mechanizing the singu- steel cutters, was recently reported as 1969. This proved to be a well func-
larly most dangerous job in mining, working in Morocco. tioning and reliable connection.
these machines have proved to be a By 1966, rapid development on the In 1967, Robbins upped its game
wise investment all round. part of Robbins had established industry with the introduction of the Robbins

raiseboring 7
 Talking Technically
Figure 2: Robbins 63RM was predecessor to the worlds most sold raise drill, the Robbins 73RM .
61R, capable of reaming a 6 ft-diameter
hole. This became the most-sold ma-
chine in the world, reaching volumes
of 50-60/year in the early-1970s. The
61R became the 63R, as shown in Figure
2, and is now the 73RM and the current
market leader with the biggest volume
sales to date.
From 1971-73, larger machines such
as the Robbins 83R were developed to
satisfy a demand for bigger diameter
boreholes. All machines built before
1973 were equipped with two-speed AC
motors, but from then onwards, DC
drive and hydraulic drive became the
natural choice.
The first boxhole borer appeared in
1974, giving miners the option of exca-
vating raises where there is limited or
no access to the upper level. The raise-
borer is set up at the haulage level and
a full-diameter raise is bored upward,
8 raiseboring
boring machines achieved milestones
by reaming 150 ft (46 m) raises in soft
granite at two-week intervals. These had
previously taken several months using
the older methods.
Before long, bored raises exceeding
1,000 ft (305 m) became common. Raise
diameters of over 20 ft (6 m) have now
been bored in medium to soft rock.
Single passes in hard rock are ap-
proaching 3,280 ft (1,000 m) in length.
Raiseboring machines have proved su-
perior and more economical when com-
pared to the drill and blast methods of
raise excavation. They have also opened
new opportunities for mine planning,
offering more opportunities for less
development investment and earlier
production.
Another advantage is that, because
there is no blasting, the rock is not shat-
tered. The result is a smooth interior
raise surface, which allows for more
efficient movement of ore and air, and
provides maximum wall stability.
Finally, mechanization with raise bo-
ring machines requires less manpower
overall. Skilled conventional miners,
always in short supply, are not needed
to operate a raiseboring machine. Less
total manpower, less rock to handle,
less construction time, and increased
safety all add up to earlier profits.
Figure 3: Atlas Copco Jarva raiseborer.
with the cuttings gravitating down the
hole for removal. Within ten years, the
Robbins BorPak was launched, facili-
tating boxhole boring without a drill
string, making the operation vastly more
efficient and easy to set up.
Improved methodology
Since Robbins introduced to the mi-
ning industry the first machine built
exclusively for raiseboring, the advan-
tages over older methods have become
increasingly evident.
Foremost among these is safety, as
workers are not required to be in the
raise during the excavation process. The
inherent dangers of rock falls, fumes,
and the handling of explosives are
eliminated.
The second advantage is speed of
operation. Even early on, Robbins raise

Figure 4: The control console of the Atlas Copco Jarva raiseborer.
Acquisitions
In the late 1970s, Robbins bought
Ingersoll Rands raiseborer division,
with its well-regarded tungsten insert
cutters, which to this day are acknow-
ledged as the best available. Robbins
immediately switched from Reed cut-
ting tools to those of its own manufac-
ture, and has since supplied them with
every raiseborer produced. Ingersoll
Rand had itself built some 30 raise bo-
ring machines prior to the takeover by
Robbins. Another acquisition by Robbins
was that of Drillco Texas when it was
under Chapter 11 administration.
In 1980, Atlas Copco bought the
Jarva Company, based in Solon, Ohio.
Four very advanced raiseboring ma-
chines were built in 1982-1983 as shown
raiseboring 9
in Figure 3, with variable speed drives
and computer control as shown in Fi-
gure 4. These machines are today ope-
rated by Dynatec in North America.
Future trends
The current trend is towards compute-
rization of the raiseboring operation
using Atlas Copcos patented Rig Con-
trol System (RCS). This is CAN-bus
based, with a single power cable
servicing all of the electric units, and
analog or digital switches controlling
the use of the electrical power. The
digital signal is superimposed on the
powerline, and a computer listens to
this, and sends out instructions in the
same manner. Two tiny wires have been
added to cope with the signalling, and
Talking Technically
sometimes two powerlines are required.
The CAN-bus system is very reliable,
flexible and easily expandable. New
units can be added anywhere on the
machine, without adding another cable.
It has become very popular in the forest
and textile machine industries, and most
cars, trucks and construction vehicles
are, or will be, equipped with this system
in the future.
RCS gives the operator greater con-
trol over the machine, with some of the
more mundane aspects of the boring
process computerized, leaving him free
to concentrate on the more complex
aspects. The result is that a single ope-
rator can now control all functions on a
raiseborer, including rod changing.
Marcus Eklind
 Talking Technically

The raiseboring concept

Particular
terminology
The raiseboring concept involves
terminology that is a little diffe-
rent from normal mining language.
Raiseboring, also called raise dril-
ling, is the process of mechanically
boring, drilling, or reaming a ver-
tical or inclined shaft or raise be-
tween two or more levels. All le-
vels may be underground, or one
level may be at the surface.
During the early development
of mechanical raise excavation,
different approaches were pursued
and, in several cases, systems
were developed. The most suc-
cessful method became known as
raiseboring.
Today, raiseboring is accepted Figure 1: Raiseboring process.
as the world standard for mecha-
nical raise excavation, and the
name of Atlas Copco Robbins is string at the lower level. Using the rea- Civil: hydro penstocks and surge cham-
synonymous with the technique.
mer, the small pilot hole is reamed back bers; redirection and retrieval of hydro
to the machine on the upper level. The water; petroleum, pressurized gas, and
cuttings excavated by the reamer fall nuclear waste storage; road and rail tun-
Raiseboring process to the lower level and are removed by nel ventilation; stormwater storage and
any convenient method. drainage; access for pipes, hoses, and
In raiseboring, the machine is set up at cables; water inlets and outlets for fish
the surface or upper level of the two Applications farms.
levels to be connected as shown in Fi-
gure 1. A small pilot hole is then dril- Raiseboring machines have been used Horizontal and low angle
led down to the lower level using a drill in both mining and civil projects for raiseboring
bit attached to a series of cylindrical holes in the range 0.6-6.0 m-diameter
drill pipe pieces, which form the drill and up to 1,000 m-long. Some specific Standard raiseboring machines are ca-
string. Upon completion of the pilot hole, applications of bored raises are: pable of boring raises at angles from
a reamer with a diameter larger than Mining: materials transport; ventilation; vertical to 45 degrees from horizontal.
the pilot hole is attached to the drill manriding; mineral production. Raises from 45 degrees to horizontal

Figure 2: Low angle raiseboring.

10 raiseboring
 Talking Technically

have been completed with the addition Figure 3:

of only a few accessories and minor Boxhole boring.
adjustment of the standard machine as
shown in Figure 2.

Other methods of vertical

boring
Other methods of mechanical raise and
shaft excavation have been developed in
addition to raiseboring. These methods
are described in the sections below and
are as follows: boxhole boring; blind
shaft boring; down reaming; pilot down
- ream down; hole opening; BorPak.

Boxhole boring
Boxhole boring is used to excavate rai-
ses where there is limited or no access
to the upper level. Here, the machine
is set up at the lower level and a full
diameter raise is bored upward.
While boring upward, stabilizers are
periodically added to the drill string to
reduce oscillation and bending stresses.
The cuttings are carried by gravity down
the hole, and are def lected from the
machine and removed at the lower level.
Boxhole boring can be completed with
or without a pre-drilled pilot hole, as
shown in Figure 3.

Blind shaft boring

Blind shaft boring is used where there
is access to the upper level of the pro-
posed raise, but limited or no access to
the lower level. With this method, the
raise is excavated from the upper level
downward using a down reaming sy-
stem connected by a drill string to the
machine above. Weights are added to the
reamer mandrel as shown in Figure 4.
Stabilizers are located above and
below the weight stack to ensure verti-
cal boring. A reverse circulation sy-
stem, or a vacuum system, is typically
used to remove the cuttings out of the
shaft.

Down reaming
Down reaming begins by drilling a
conventional pilot hole, and then en-
larging it to the final raise diameter by
reaming from the upper level to the lo-
wer level as shown in Figure 5. Larger

raiseboring 11
 Talking Technically

diameters can be achieved by conven-

tionally reaming a pilot raise, and then
enlarging it by down reaming.
During reaming, the cuttings gravi-
tate down the pilot hole, or reamed hole,
and are removed at the lower level. To
ensure sufficient down reaming thrust
and torque, the down reamer is fitted
with a non-rotating gripper and thrust
system, and a torque-multiplying gear-
box driven by the drill string. Upper and
lower stabilizers ensure proper kerf cut-
ting, and reduce drill string oscilla-
tions.

Pilot down, ream down

This method, also known as hole open-
ing, is used to enlarge an existing pilot
hole with a small-diameter reamer. The
operation is similar to pilot hole drill-
ing, the only difference being that a small
reamer is used instead of a pilot bit.
The small reamer is designed to use the
existing pilot hole to guide the drilling.
Stabilizers are used in the drill string
behind the reamer to prevent it from
Figure 5: Down reaming.
bending. Pilot down, ream down hole
opening is only used when a standard
reaming system is either impractical
or impossible, as shown in Figure 6.
Figure 6: Pilot down, ream down.
BorPak
The BorPak system is used for blind hole
boring. It comprises a guided boring
machine, a power unit, a launch tube/
transporter assembly, a conveyor, and an
operator's console. The BorPak operates
like a microtunnelling machine, climb-
ing up the raise as it bores. Cuttings pass
through the centre of the machine, fal-
ling down the raise and launch tube
onto a conveyor. This revolutionary ma-
chine has the potential to bore from 3.9
to 6.6 ft (1.2 - 2.0 m) diameter holes
at angles as low as 30 degrees. Like a
raiseboring machine, the BorPak offers
high speed drilling, but eliminates the
need for a drill string. It also pro-
vides the steering flexibility of a raise
climber. BorPak is especially attractive
when flexibility and mobility are at
a premium, or when the job requires
drilling a series of short raises.

Roberto Lopez
Figure 4: Blind shaft boring.

12 raiseboring
 Talking Technically

The raiseboring machine

Thrust and rotation
The raiseboring machine (RBM)
provides the thrust and rotational
forces necessary for raiseboring
as well as the equipment and in-
struments used to control and mo-
nitor the raiseboring process.
The RBM is composed of five
major assemblies described in the
sections below. These are: derrick;
hydraulic system; lubrication sy-
stem; electrical system; and con-
trol console supplied with each
machine.

Derrick assembly
The derrick assembly supplies the ro-
tational and thrust forces necessary to
turn the pilot bit and reamer as well as
to raise and lower the drill string. This
assembly consists of several major com-
ponents. These are: base plates; main-
frame; columns; headframe; hydraulic
cylinders; and drive train assembly.

Base plates
The base plates, left-hand and right-
hand, provide the structure for suppor-
ting the weight of the derrick assembly
as well as for positively transferring the
forces required for raiseboring into the
derrick mounting system.
The base plates are normally set on
a level concrete foundation pad and an-
chored by rock bolts passing through
the pad into the rock formation below.
In some instances, the base plates are
mounted to a steel beam system, which
in turn is secured to concrete founda-
tion pads and the rock formation.
Mainframe
The mainframe is the major load bear-
ing structure of the derrick assembly.
It is mounted and secured on the base
plates with removable turnbuckles and
expansion pins. Each turnbuckle con-
sists of two threaded eyes screwed into
a turnbuckle body. The turnbuckles
Figure 1: Derrick assembly layout .
establish and maintain the required
boring dip angle. After the boring angle
is confirmed, the expansion pins are
tightened to provide linkage between the
mainframe and turnbuckles, and the base
plates and turnbuckles, for the positive
transfer of boring forces.
Removable pivot brackets mounted
at the rear of the mainframe allow the
hydraulic cylinders of the transporter
system to be attached to the mainframe
for derrick erection and takedown.
These brackets also serve as rests for
the derrick assembly when loaded on
the transporter. The mainframe is equip-
ped with a worktable. This is designed
with a hollow centre to allow passage
of drill string components from the drive
train assembly into the pilot hole. The
plane of the worktable top surface re-
mains perpendicular to the axis of the
drill string at all dip angles.
All worktables are equipped with, or
are used in conjunction with, a work-
table wrenching system. This reacts the
machine torque into the mainframe for
threaded connection makeup and break-
out. The wrenching system is also used
to hold the drill string and the cutting
components securely in the hole when
adding or removing parts.
The worktable also provides moun-
ting for various accessories necessary
for raiseboring machine setup and

raiseboring 13
 Talking Technically
Headframe
Hydraulic
cylinder
Mainframe
Machine
worktable
Turnbuckles
Expansion pins
Figure 2: Exploded view of derrick assembly.
operation, such as the pilot hole starter
bushing, the outlet housing of the blo-
oie system, the drivehead installation
and removal tools, and the ram assem-
bly, if fitted.
Columns
Chrome plated cylindrical columns pro-
vide torque transfer from the drive train
assembly into the mainframe. These co-
lumns are connected at their bottom to
the mainframe, and at their top to the
headframe. They pass through machined
bushings in the crosshead, and guide
the crosshead as it travels up and down.
Headframe
The headframe is mounted atop the
derrick assembly columns, linking them
together. This dampens column vibration,
14 raiseboring
Main Drive
DC Hydraulic AC
Crosshead
Hydraulic cylinders
Drivehead
Turnbuckles
Baseplates
and shares the boring torque between
columns. The headframe is most com-
monly secured to the columns by use of
a bolted crown gear coupling system.
Hydraulic cylinders
The hydraulic cylinders supply the thrust
required for raising and lowering the
drill string in relation to the raise bo-
ring machine. These same cylinders also
supply the thrust necessary for both
pilot hole drilling and raise reaming.
Extra thrust capacity is often provided
in the design of these cylinders to deal
with special circumstances.
Drive train assembly
The drive train assembly supplies to the
drill string and cutting components
the rotational power necessary for raise
Gearbox
Columns
Expansion pins
boring. General descriptions of the three
major components making up the drive
train assembly are given below. These
are: crosshead; main drive motor; and
gearbox.
Crosshead
The crosshead is a moving platform to
which the main drive motor system and
gearbox are mounted.
Driven by the hydraulic cylinders and
guided by the columns, the crosshead
raises and lowers the drill string and
transfers torsional forces into the raise-
borer columns.
Most Atlas Copco Robbins raise bo-
ring systems utilize the crosshead as a
reservoir for the gearbox lubrication oil.
Other lubrication system components,
such as the lubrication motor and pump,
can also be housed in the crosshead.
 Talking Technically

Main drive motor system

Drivehead
The main drive motor system of the capscrew
derrick assembly supplies the rotational Splined
power necessary for raiseboring. Four connection
types of main drive motor systems can
be used with Atlas Copco raiseboring
machines. These systems are: AC, DC,
hydraulic and VF.
The AC system has the simplest de-
sign, lowest cost, and highest reliability
of all raise drill drive motor systems.
It features fixed speed and fixed tor-
que, and is best suited to competent
ground, where minimum motor stalling
will be encountered.
DC drive is variable speed and va-
riable torque, and is best suited for lar-
ger raise diameters in mixed ground
Axial
conditions.
float
Hydraulic drive, employing variable
speed and good torque limiting control,
is suited for use in all ground condi- Floating box with
tions and has high reliability. patented spherical Swiveling
The VF drive system, developed in- design and replaceable action
house by Atlas Copco, combines the threaded insert
simplicity of the AC drive motor sy-
stem with exact motor speed, torque,
Figure 3: Cross-sectional view of the drivehead.
and positioning control.
The VF system circuitry controls the
speed, torque, and position of its AC AC mine power to DC, and then con- frequency and voltage of the AC signal
motor by first converting the incoming verting it back to an AC signal. The outgoing to the AC motor can be ad-
justed, enabling precise speed, torque,
Figure 4: Pilot drilling and reaming. and positioning control.

Gearbox
The gearbox mounts directly to the main
drive motors at its input end, and re-
duces motor input speed to a speed
compatible with raiseboring at its out-
put end.
Most gearboxes use a planetary re-
duction system. This shares the load
among three planetary gears, reducing
the diameters of the individual gears
required, and allowing a more compact
drive train assembly.
Gearbox reductions must include ra-
tios capable of providing high torque
and low speed for raise reaming, and
high speed and low torque for pilot hole
drilling. It is not uncommon to have a
multi-speed gearbox with a variable
speed motor.
The output end of the gearbox is
attached by a splined connection to the
floating box, which connects it to the

raiseboring 15
 Talking Technically
Figure 5: Hydraulic power unit.
drill string. The splined connection,
while enabling the rotational power of
the drive train assembly to be transmitted
into the drill string, also allows the floa-
ting box to drift axially when threading
or unthreading drill string components.
Axial free f loat permits the threa-
ding of the floating box to follow the
threading of the stationary drill string
component, greatly reducing the chances
of thread damage during connection
make-up or breakout. Periodic height
adjustment of the drive train assembly
Figure 6: Electrical power unit.
16 raiseboring
in relation to the drill string component
is necessary, which can be carried out
by the operator.
Spl i n e d c o n n e c t io n f lo a t i n g
boxessupplied with newer raiseboring
machines are equipped with a spheri-
cal design patented by Atlas Copco
Robbins.
This provides a swivelling action in
addition to free float. This prevents
bending, stresses from damaging the
gearbox and accommodates slight drill
string misalignment.
The floating box can be housed in-
ternally within the gearbox, or mounted
to the output end of the gearbox as a
separate component. When mounted se-
parately from the gearbox, the assembly
housing the floating box is referred to as
the drivehead.
The drivehead is connected to the
output end of the gearbox by spindle
bolts or a single threaded capscrew. If
a single capscrew is employed for this
connection, drivehead installation/re-
moval tools are required when instal-
ling or removing the drivehead from
the gearbox.
Hydraulic system assembly
The hydraulic system supplies hydrau-
lic power for raiseboring. This assembly
comprises the hydraulic power unit and
all interconnecting hose assemblies.
The hydraulic power unit is on a
skid-mounted structure containing a hy-
draulic reservoir. These are used as mo-
unting platforms for the majority of the
components making up the hydraulic
system. Included in these components
are the motors and pumps used to po-
wer the hydraulic system along with
various valves, filters, and manifolds.
Lifting eyes are provided on the
hydraulic power unit for hoisting and
positioning.
Design of individual hydraulic sy-
stem assemblies varies according to the
type and size of machine. The service
manual should be consulted for spe-
cific hydraulic system setup, operation,
and maintenance procedures.
Lubrication system
The lubrication system assembly en-
sures proper delivery of lubricating oil
to the high-speed bearings and other
selected components of the drive train
assembly gearbox. This assembly is
commonly made up of the lubricating
oil reservoir, with level gauge, thermo-
meter, and breather; pump drive motor;
and lubricating oil pump, filter, heat
exchanger, and flow meter.
Most Atlas Copco Robbins raise bo-
ring machines employ the crosshead of
the drive train assembly as the lubrica-
tion reservoir, and as the housing for
the lubrication pump drive motor and

Figure 7: Robbins 73RH C with RCS control panel.
pump. Some machines are designed with
the lubrication system reservoir and com-
ponents located separately from the der-
rick assembly, usually to permit the der-
rick to be tilted to bore raises at low
dip angles without affecting the level
of the lubrication oil reservoir and the
functionality of the lubrication system.
Electrical system
The electrical system assembly com-
prises the electrical power unit and all
electrical power and control cables.
The electrical power unit consists of an
enclosed cabinet containing the power
and control distribution hardware and
circuitry for the entire raiseboring sy-
stem. Lifting eyes are provided on this
cabinet for hoisting and positioning.
Power and control cables are inclu-
ded in the electrical system assembly.
Most of these cables are of the quick-
coupler type, with all the plugs and
raiseboring 17
receptacles identified for ease in making
proper connections during system
setup.
Because of varying site power sup-
plies, and differences in main drive
motor systems and machine options, the
design of electrical system assemblies
can be quite diverse from machine to
machine. The service manual supplied
with each raiseboring machine should
be referenced for specific electrical sy-
stem setup, operation, and maintenance
procedures.
Control console
The modern rig control system from
Atlas Copco features a Control Area Net-
work (CAN) for digital communication
between all modules connected to the
Bus wire.
The entire system features various
I/O (In/Out) modules for communi-
cation with all machine sensors and
Talking Technically
meters, a master module for computing
and processing of operational data, and
a display module for presentation of
calculated data.
The I/O modules are positioned in
the thrust pack and the drive pack, as
well as on the derrick assembly. The
computing module is usually placed in
the drive pack, which is located in a
safe, dry place for power supply and
convenience to major components.
The display module is part of the
control panel, itself a robust assembly
enclosed in a waterproof envelope, spe-
cially designed for outdoor and under-
ground use.
Manufactured and delivered to over
400 units since 1998, this proven, stan-
dardized control system is modular, with
all major parts interchangeable with
other similarly-controlled Atlas Copco
products.
Jan Forsberg
 Talking Technically
Side loading pipeloader in operation.
Robbins 73RM-DC under installation.
Reaming the Henty ventilation shaft.
18 raiseboring
Robbins 73RM-DC in Tasmania
Henty Gold Mine, owned by Gold Fields Tasmania Pty,
is located on the west coast of Tasmania, in the middle
of an environmental protection area with many re-
strictions. The mine needed more fresh air, and opted
for a raise bored ventilation shaft from surface.
Pilot and ream
The pilot hole was pre-drilled by a subcontractor in three
stages to HQ 14 in using DTH equipment. A Robbins
73RM-DC raiseborer was then employed by Skanska
Raiseboring of Sweden to develop the 689 m-long,
2.44 m-diameter vertical ventilation shaft.
Crawler transporter
Some ten 20 ft containers were used for transportation
of the equipment to site.
The rig was mounted on an air powered crawler tran-
sporter capable of 1.5 km/h and positioned on a specially-
designed steel frame over a 10 m-deep concrete lined
pre-sink of 4.5 m-diameter. All drill tubes were inspected
with a magnetic particle inspection kit before the project
started.
One month of boring
Skanska had three operators and one supervisor on site.
Set up took seven days, and take down five days. Drill
pipe was high strength, with 10 in outside diameter in 5
ft lengths. Thread lubrication was Best o Life 3010 from
Dallas, Texas, US. Pipe changes took 5-6 minutes, using
a side loading pipeloader and crane.
Boring took place over a 31-day period, during which
average penetration rate was more than 22 m/day. The
2.44 m (8 ft) reamer was dressed with 14 cutters, 7 four-
row and 7 five-row. The raiseborer developed thrust of
100 - 280 t, the equivalent of 7-20 t on each cutter, with
a torque of 350 and 7-8 rev/min. The drillstring was
stabilized using a stinger and two 13.625-in stabilizers,
and no cutter changes were necessary during the boring
operation.
Satisfied customer
The machine gave close to 100% mechanical availability,
delivering the raise in half the expected time, allowing
ventilation the equipment to be installed earlier than
expected.
The mine had to bring forward extra resources for
mucking, in order to keep pace with the raise drilling.
There were no accidents or incidents, and no reportable
environmental impacts, such as oil leakage, and the cus-
tomer expressed satisfaction with the project.

Variable frequency drive for Norilsk
One of two Robbins 73RM-VF machines delivered to Norilsk Mine, Russia..
Most popular model
With 35 units delivered worldwide since 1980, the Rob-
bins 73RM has become the most popular raiseboring
model today. The 73RM is used to develop raises and
shafts in the crucial 1.8 m to 3.1 m-diameter (6-10 ft)
range.
The two medium-sized Robbins 73RM-VF raise bo-
rers now at work developing ventilation shafts in the ar-
duous conditions at Norilsk, Russia are an example. The
Variable Frequency drive governs the speed of the main
motors, and consequently the speed of the pilot bit and
the reaming head, by means of frequency conversion of
motor current.
Variable frequency
With VF control, the machine and the drill string are
automatically protected from over-torque. Using full tor-
que at minimum current and low speed gives smooth
start-up and stop procedures at constant torque, with
reaming performed in the 0 8 rev/min range (0 50 Hz),
raiseboring 19
Talking Technically
and pilot hole drilling in the 0 30 rev/min range. At con-
stant power, reaming is performed in the 8 16 rev/min
range (50 100 Hz), and drilling in the 30 60 rev/min
range, where the torque drops as the speed increases.
Overcoming geology
The ability to vary the reamer head speed is particularly
beneficial for operation under widely varying geological
conditions, whether working in hard or soft rock, or solid to
fractured.
Also, the reaming head speed can readily be adapted
to various reaming head diameters.
Variable speed control was previously achieved by
either a hydraulic or DC electrical motor drive. The
advantages of the Atlas Copco Robbins AC drive, which
is fully torque vector controlled, are superior efficiency,
reliability and reduced operational costs.
In all, the final outcome is higher productivity and
better cutter economy.
 Talking Technically

Computer based training

for raiseboring
Latest version
Atlas Copco Secoroc recently in-
troduced version 4.0 of its Com-
puter-Based Training (CBT) pack-
age as being of paramount im-
portance in achieving the highest
level of competence in rock dril-
ling tools among distributors and
customers, as well as its own sales
force. Correct understanding of
how to choose, use and maintain
the rock drilling tools affects profi-
tability for all, and adds to com-
petitiveness. Atlas Copco Seco-
roc believes that the CBT package
for rock drilling tools is the most
comprehensive interactive train-
ing tool available in the industry
today.

Main menu. This is the first picture shown when you start the CBT. From this main
Expert knowledge menu you can choose which of the courses you would like to enter.

The course is based on the skills and

experience gained by key Atlas Copco CBT Rock Drilling Tools version 4.0 and drill string products, and their use,
Secoroc personnel over many years and was released after six years of patient in a simple and efficient way.
conveys expert knowledge in the use development. Computer based training Aided by 3-dimensional animations,
of modern rock drilling products. transfers knowledge about raiseboring photographs, film sequences and inter-
active lessons, the training course ex-
Course menu. View picture for the course Raiseboring. Under the text Introduction you find two plains how the markets leading raise
buttons, Learning objectives will explain what you are expected to learn. Introduction will give boring and drill string products can
you an overview by running pictures and a speaker talking. Under Lessons you choose chapters. increase both productivity and profit.
With version 4.0, CBT now includes
training on all Atlas Copco Secoroc
products, with:

1. Three separate packages divided into

Tophammer, DTH and Raiseboring.
2. Separate libraries for drilling equip-
ment and applications in all packages;
3. Updated product training section on
tophammer equipment including
troubleshooting, bit grinding and care
and maintenance;
4. Product training section on in-the-
hole equipment including trouble-
shooting, bit grinding and care and
maintenance;
5. Product training section on consum-
ables for raiseboring equipment, in-
cluding care and maintenance;
6. Focus tests on each lesson;

20 raiseboring
 Talking Technically

Chapter. In this section you choose the lesson you want. In the lower right Lesson. There are three buttons for presentations. Video camera
corner you find four buttons. X will finish the actual step. Number two will button: running pictures and speaker text. Photo camera button: pictures
take you back one step. The third button allows you to scroll through the course. from more important or difficult parts. Text button: pictures and text.

Step player. When pressing the step player button you will find film Product selection exercises. At the end you also have the possibility
sequences or animations. At the end of every lesson you can also go through to go through some real exercises, where you will have the background for a
a test, Focus test, to check your knowledge. specific rock excavation and from that choose the suitable equipment to do the job.

7. a new section of product selection
exercises.
Complete training
The whole Secoroc CBT Rock Drilling
Tools package comprises approximately
50 hours of lessons and tests. With a
recommended maximum of four hours
of lectures per day, the total length of a
complete training course on rock dril-
ling tools can be estimated at three
weeks.
CBT enables efficient training when-
ever the need arises. For instance, a new
employee can start the learning process
right away, and learn about how the pro-
duct is manufactured, its characteristics,
wear limits and much more.
A modular structure enables users
to study lesson by lesson, or in a se-
lective way at their own pace.
With personal computers, learning
can take place whenever and wherever
the individual chooses, including in
the field. The training package tea-
ches you to find the right tool for any
given rock drilling application at any
time of the day. Similar to its experi-
ence with CBT version 2.0, Atlas Copco
Secoroc has found good market accep-
tance of version 3.0, which has been ad-
vising key customers and technical
schools on its use, as well as its own
sales team.
The new version of CBT 4.0 is ex-
pected to even further contribute to
the added value in Atlas Copco Secoroc
sales service, inproving profitability
and competitiveness for all involved in
raiseboring and rock drilling.
Bjrn Samuelsson

raiseboring 21
 Talking Technically

Horizontal and low angle boring

New applications
Raiseborers have been adapted to
some unusual situations where
horizontal or low angle holes have
been required. These have been
well documented at projects where
raise bored holes were planned,
such as at Venda Nova in Portu-
gal. However, recent legislation
following a tunnel fire at Guadar-
rama in Spain completely changes
the picture. At the Guadarrama
twin railway tunnels, the TBMs
were well ahead of the cross pas-
sage development when a fire oc-
curred near the face. As a result,
the fire crews were denied access
to the face along the parallel tun-
nel, and had to stand off. All fu-
ture twin tunnels in Spain will now
have to develop cross passages Robbins raise drill in front of the face.
close to the face. Because these
tunnels are mainly TBM-driven,
and blasting would be risky to hu- projects, and service drifts in mines are vertical raiseboring application, be-
gely expensive equipment, the a few examples where horizontal raise- cause of the downward pull of the drill
cross passages will have to be de- boring has advantages over drill/blast string.
veloped mechanically. Horizontal
raiseboring is possibly the only methods. The latter methods are not However, most types of raiseboring
currently available alternative. even an option in the 0.7-1.2 m-diameter machines can be modified to pull hori-
range, because men and equipment are zontal and low angle raises. These modi-
simply not available to safely work such fications generally include an altered
Modifications small openings. gearbox lubrication routing, a modi-
The raiseboring method does not fied base plate, and the addition of a
There are many different applications change when the angle is lowered to rear support for the guide columns.
that require horizontal or low angle horizontal. However, transporting the
drifts. Raiseboring is a non-explosive rock cuttings from the face becomes Handling rock cuttings
method, so the vibration effect on sur- a challenge, because gravity does not
rounding rock, and on buildings close help in the same way as for steeper A reamer used in a horizontal applica-
to the drill site, are kept to a minimum. holes. Hitting the target with the pilot tion employs scrapers to remove cut-
Hydropower projects, urban sewerage bit also requires more skills than in a tings from the rock face. These clean

Low angle raiseboring.

22 raiseboring

Collaring of the reamer showing the scrapers.
the lowest point on the face prior to
each gauge cutter passing through, so
that the reamer is not forced upwards by
the cuttings. This will avoid unwanted
bending stress in the drill string.
A large volume of water is also re-
quired to keep the rock face clean and
free of cuttings. This can be introduced
through the drill string, and either piped
from the back of the reamer, or through
holes drilled in the stem directed at the
gauge cutters.
Additional f lushing water can be
pumped from the machine to the face
on the outside of the drill string. A sea-
ling system around the drill string, eq-
uipped with an intake valve, is neces-
sary with this method. This is similar
to the blooie system, which uses air as
the flushing medium for pilot hole dril-
ling. On raises with angles steeper
than 3 degrees from horizontal, large
volumes of flushing water, up to 3,000
lit/min, should be sufficient to remove
the cuttings.
Raises larger than 1.8 m-diameter
can generally be mucked using a small
loader, while short holes can be mucked
by hand. Water and scrapers are nee-
ded to keep the rock face clean.
For smaller diameter raises close to
horizontal, mucking methods are more
raiseboring 23
Steel container collects cuttings behind the reamer.
innovative. The following methods
have been used successfully on recent
projects.
A pulley with steel cable is attached
on a swivel on the back of the reamer.
The cable passes through the reamer,
and a pair of air-powered winches is
used alternately to pull out a scraper,
which cleans the cuttings from the raise.
Water and scrapers are needed to keep
the rock face clean.
Alternatively, a steel container is at-
tached to the back of the reamer with a
swivel. The scrapers on the reamer lift
the cuttings into the container, from
where a slurry pump and pipeline con-
vey the cuttings out of the raise. This
method occasionally requires people in-
side the raise to extend pipe, route po-
wer to the pump, and remove any over-
size cuttings.
Another method is to use a non-
rotating sealed plate pulled on a swivel
behind the reamer. A pipe is connected
to the sealed plate, and a pan is mounted
just below the pipe connector on the
reamer side. The reamer scrapers lift
the cuttings onto the pan, and a mix-
ture of air and water supplied through
the drill string cleans the face. The in-
creased pressure inside the sealed area
ensures that cuttings are blown out
Talking Technically
through the pipe, which has to be ex-
tended as reaming progresses. A cable
that attaches to the back of the sealed
plate is used to winch the reamer out
of the raise when necessary.
Horizontal piloting
The weight of the drill string causes de-
viation of the pilot hole in a horizon-
tal application, so great care has to be
taken throughout the piloting sequence.
If the thrust is too high on the pilot bit,
it will divert the pilot hole upward. If
too low, it will divert the pilot hole
downward.
Stabilizers installed along the pilot
hole will counteract some of the drill
string weight, as will a balanced amount
of bailing medium, although too little
bailing may cause the drill string to
stick.
The accuracy of the pilot hole is
most affected by the machine set-up
and collaring, for which an experienced
operator is a necessity. An accurate, but
more expensive and time consuming,
approach to a horizontal pilot hole is
to drill it in three stages. First, a guided
coredrilling machine drills an accurate
small-diameter hole. This is reamed
by DTH to pilot hole size, following
 Talking Technically
Venda Nova
Dam worksite
Location map for Venda Nova Dam worksite.
which the raiseboring drill string is
installed.
Challenge at Venda Nova
A consortium of three Portuguese com-
panies, Somague, Moniz da Maia Serra
& Fortunato (MSF) and Mota, was for-
med to complete the civil works of the
Checking the raiseborer drillstring in the 110 m shaft.
24 raiseboring
Venda Nova project situated on the ri-
ver Cavado in Ruives-Vieira do Minho,
in north Portugal as shown in the map
alongside.
The project required the drill/blast
excavation of 300,000 cu m of rock to
provide a 2.8 km inlet tunnel, a 1.4 km
discharge tunnel, a powerhouse cavern,
a 625 m-long ventilation tunnel, a
1,210 m access tunnel, and a 130 m
water intake. There are also two raise-
bored shafts of 415 m and 110 m.
The consortium chose Atlas Copco
equipment for the main operations using
Rocket Boomer drill rigs, Secoroc rock
tools, Swellex rock reinforcement, and
a Robbins raiseborer.
Somague is the leading company in
Portugal for drilling, mining and civil
works, and its relationship with Atlas
Copco goes back some 40 years.
Rock conditions at the Venda Nova
site are mainly favourable. The host rock
is granite, with some areas of schist and
zones with fractures and faults.
One of the most challenging aspects
of the project was the development of
the shorter of the two raise bored shafts.
The 110 m escape and ventilation shaft
has a decline of only 26 degrees, from
the turbine hall to the existing ventila-
tion and escape system.
Drillcon Iberia Lda, a subsidiary of
Drillcon AB of Sweden, used an Atlas
Copco Robbins 73R raiseboring ma-
chine to develop the shaft in fairly hard
granite of 170 MPa. The raiseborer was
mounted on a concrete platform in the
escape tunnel, from where the pilot hole
was drilled down to the turbine hall.
The tunnel was then reamed upwards,
back to the escape tunnel.
A Secoroc RRL 3.5 m reamer was
flown in from Australia specially for the
project, as pictured below. The cutters
performed perfectly, and the mucking
was very easy, using water pressure to
assist with flushing the muck out during
reaming. A total of 18 new cutters were
used on the reamer: nine 5-row cutters,
and nine 4-row cutters.
The deviation on the finished hole
was 40 cm, which is less than 0.5 %.
Atlas Copco assisted the contractors
with every step of the raiseboring pro-
cess, from training drillers on the Rob-
bins unit, to helping install new cutters
on the reamer. When the hole was fin-
ished, Atlas Copco personnel were on
hand to demonstrate servicing of the
reamer, maintenance of the cutters, and
regreasing.
Drillcon have another two Robbins
raiseborers in Portugal, stationed at
Neves-Corvo copper-zinc mine, where
they drill approximately 2,500 m/
year.
The new Venda Nova plant and tun-
nel system came into operation in 2004
to provide much needed generating ca-
pacity for the national grid. Venda Nova
will also act as a pumped storage sta-
tion serving its companion dam Para-
dela further downstream. When elec-
tricity demand is low, water that has
passed through the powerhouse for stor-
age at Paradela can be pumped back
through 4 km of tunnels to the Venda
Nova Lake, to provide extra power at
peak periods.
Mikael Bergman
Secoroc RRL 3.5 m reamer as supplied to
Venda Nova in Portugal.
 Talking Technically

Development of boxhole boring

Safe and efficient
The boxhole borer concept emer-
ged in the early 1970s, and the
current models of dual-purpose
raiseborers are a combination of
the engineering skills and experi-
ence gained since then. Boxhole
boring has come a long way since
the early machines employed on
the South African gold mines,
and creditable advances are being
consistently achieved at mines
around the world, without pilot
holes and with minimum site pre-
paration and setup time. Most of
the machines ever built are still
working, releasing miners from
the thankless task of manual rais-
ing, to the benefit of all. Boxhole
boring has contributed greatly
to improved safety underground
while providing a far superior
raise at less cost.

Four decades of evolution

Raiseboring started in Germany, prima-
rily in the Ruhr coalmines, where they
piloted from a lower level to a higher
level and reamed down with successively
bigger reamers. The first machine to drill
down and ream up using the technique
that is now known as conventional raise
drilling, was the Robbins 41R-1101 built
in 1962 for the Homer Wauseca Mine.
The raise was 40 in-diameter and 200
ft-long. The drill pipe was 5 in-diameter
and 4 ft-long, with oil drilling standard
API tapered thread. This pipe was torq-
ued up so much during reaming that it
belled on the box ends and welded at the
Figure 1: The Robbins 34R raiseboring machine was the predecessor to the versatile Robbins 34R.
shoulder, and each length had to be cut
off as it was removed. The pilot hole was
drilled using a Mission DTH hammer, and The mine uses the machines to bore variable speed control which helps the
Security designed and built the reamer. 1.2 m-diameter slot raises, and for down- operator to maximize machine per-
Since those early days, some 600 raise- reaming 710 mm-diameter holes, which formance in varying rock conditions.
boring machines have been sold world- are used for dumping backfill into empty In addition, with a number of auto-
wide. stopes. matic features, the Robbins 34R can be
The first Robbins 34R units were The Robbins 34R has a number of operated by one person. These features
made for Falconbridges Kidd Creek special advantages: it is small, compact include a sensor that automatically shuts
mine in Timmins, Ontario, Canada, and powerful; it can operate with as little down the boring cycle at the end of a
and have been in continuous use since clearance as 3.4 m while drilling or rea- cylinder stroke, or at a pre-determined
they were commissioned. ming; and the hydraulic drive provides level of torque.

raiseboring 25
 Talking Technically

Figure 2: The Robbins 34RH raiseboring machine has demonstrated its versatility at projects around the world for more than 25 years.

Since those first two machines, the
Robbins 34R torque and thrust has been
increased, and the model renamed the
34RH-HT (High Thrust).
It used to be necessary to bolt such
machines down securely on a concrete
pad, to cope with their high torque and
thrust. Such pads were costly and time-
consuming to install, and have since
been replaced by a drilling platform that
uses leveling jacks combined with stinger
cylinders in the derrick columns, elimi-
nating the need for pads.
From raiseboring to
boxholing
The advantages of raiseboring are: more
economical and much faster advance
rates than drill/blast; more stable exca-
vation and considerably safer and better
work environment; smooth wall need-
ing 300% less power for air ventilation;
cost/metre decreases as raise length
increases, allowing more flexibility in
mine design and planning; and a signi-
ficant reduction in labour requirements.
The common boxhole raise is an ore
pass raise driven from the haulage way
below to the ore body above. At the
bottom of the raise, in the haulage, is a
chute base with guillotine gate to con-
trol feeding of ore by gravity into haul-
age cars. The raise going up from this
chute box or base is therefore known
as a boxhole.
The Robbins 34RH-HT can drill box-
holes, for which the machine is set up
at the lower level and a full-diameter
raise is bored upward. During boring,

Figure 3: Boxhole boring can be carried out with or without a predrilled pilot hole, or in a combination of both.

26 raiseboring
 Talking Technically

stabilizers are periodically added to the

drill string to reduce any oscillation and
bending stresses. The cuttings are car-
ried by gravity down the hole, and de-
flected from the machine for removal at
the lower level. Boxhole boring can be
carried out with or without a predrilled
pilot hole, or in a combination of both,
where a shorter pilot hole is predrilled
to ensure straightness and orientation,
followed by single pass/blind reaming
and piloting in one step.

Boxhole borer development

Originally, the South African gold mines
utilized drill and blast techniques for
the 8-10 boxholes needed in each stope.
In the highly stressed footwall of these
very deep mines, this proved dangerous.
In 1972, the West Driefontein Gold
Mine asked the Robbins Company and
Calweld Corporation to develop a box-
hole borer. The raises were to be 90 m-
long, 5 ft-diameter, and from vertical to
60 degrees inclination. The result was
the Robbins 51R, first produced in 1973,
featuring 24 in non-rotating drill string
and in-the-hole motor and drive system.
The thrust was 350,000 lb and the tor-
que was 95,000 ft lb. The drill pipe was
4 ft-long with 3 radial fins for stabi-
lization. The rig weighed only 28,000
lbs and could be transported through a
Figure 4: The Robbins 51R raiseboring machine, first produced in 1973.
2 m x 2 m drift.
The 51R was later rebuilt as a 55R,
which was the prototype of the 52R. rates of 2 m/hr to 2.5 m/hr with a 5 ft- An important advantage with the
The 52R was more compact, used 24 in- diameter head, which in 25,000 psi dual-purpose machine is that both
diameter flanged pipe, had many hy- quartzites was considered excellent. As boxhole boring and raiseboring can be
draulic and drive train improvements, a a result, the Robbins 53R became popu- carried out. The conversion between
built-in water spray, and non-rotary drill lar in the South African gold fields. The drilling modes is relatively quick and
string with in-hole cutterhead drive. muck chute was improved, and further easy. The 34R is turned upside down
Some 22 units of 52R with hydraulic and work was done on stabilizers. and a float box spring is added, whereas
electric drive were built, many of which
are still operating. Dual purpose machines Figure 5: Robbins 53RH set up underground.
In 1982, Robbins launched a project
to design a new machine, the 53R with The Dual Purpose 34R is a low profile,
derrick drive and rotary drill string. The small diameter machine developed on
machine was designed so that site pre- the basis of the 32R. The High Thrust
paration work was limited to only a basic HT version was developed in the 1980s
pad. The reaming torque was 80,000 with 47,500 ft lbs torque and 289,000
lbs ft and thrust was 620,000 lbs. lbs thrust. It allows quick conversion
The Robbins 53R was ready for from raiseborer to boxholer. It is also
South African gold mining, and the first used around the world at places such
machine went to Vaal Reefs 8 Shaft in as: Brunswick Mine, Canada; Toyoha
1984, where the first 42 m-long hole was Mine, Japan; Leinster Mine, Australia;
pre-piloted. All subsequent holes were Western Metals (ARD), Australia; and
drilled blind, achieving penetration EI Teniente Mine, Chile.

raiseboring 27
 Talking Technically

the 53R has top and bottom chucks into

which the swivel is attached.
Dual-purpose machines are espe-
cially useful in South African boxhole
situations where mine layout allows
boxholing and conventional raise-
boring from the same place, giving
multiple holes from one location.
Standardization on one machine type
results in significant savings in ma-
chines, parts inventory, operator train-
ing, maintenance training, procedures
and documentation.

Boxhole reaming
Initially, the reamer for boxhole boring
machines was installed overhead, a cum-
bersome procedure which also entailed
extra time and expense for the prepara-
tion of each drilling site.
Accordingly, it was decided to extend
the width and depth of the machine to
accommodate the reamer and stabilizers.
The drill pipe wrenching system was
integrated in the machines worktable,
and was split into two halves, so that hy-
draulic cylinders opened it wide enough
to allow the passage of the reamer. This
feature increases the footprint of the ma-
chine, but does not increase its height,
Figure 6: The remote controlled and hydraulically operated muck collector is fully integrated into the
and produces a more functional system.
derrick assembly, and remains on the machine even during transportation.
The remote controlled, hydraulically
operated slide-opening worktable ena-
bles the entire drill string, including drill pipe, to better stabilize the reamer, from entering the drive box area of the
boxhole stabilizers and reamer, to pass and to transmit the full torque and thrust machine.
through the worktable of the machine. of the machine. The collector also incorporates a
Depending on model and frame width muck chute, which deflects the muck
of the 34RH-HT, reamers of diameters Muck collection away from the machine to the rear end
from 692 mm to 1,060 mm can pass in a 90-degree working range. Further-
through the worktable. To prevent the cuttings from covering the more, this remote controlled and hy-
Over the years, Atlas Copco engi- machine as they fall down the bored raise, draulically operated muck collector is
neers have designed many reamers, a muck collector is installed between fully integrated into the derrick assem-
both standard and specialized. Concern the bored hole and the machine. bly, and remains on the machine, even
about the possibility of ground squeez- Atlas Copco have designed a muck during transportation.
ing during boxhole boring was over- collector that connects to the head frame The design of the 34RH-HT conti-
come by fitting a set of gauge housings of the Robbins 34RH HT, with exten- nues to evolve, as customer require-
and cutters, which are installed on the sion bars that can be adjusted to raise ments change, resulting in 360-degree
underside of the reamer. In the event of or lower the muck collector by pushing drilling, no concrete pad requirement,
the ground squeezing during boring it with the drive head. reamer and stabilizer installation under
operations, the RCC Duro cutters would The muck collector unit is fitted with the head frame, and an integral muck
cut their way out as the reamer is with- a rubber seal, which assists in contain- collector.
drawn from the completed boxhole. ing muck and dust. This is designed in Close cooperation between Atlas
All Robbins 34R units are designed two halves, to be opened by remote- Copco engineers and customers is re-
so that the machines full torque and controlled hydraulic cylinders for the sulting in the continued development of
thrust are available in either the push- reamer and stabilizers to pass. It also fea- this most versatile raise drill.
ing or pulling mode. The 34RH-HT was tures a cone-shaped seal to clamp around
modified to use stronger 10 in (254 mm) the drill pipe to prevent muck and water Roberto Lopez

28 raiseboring
 Talking Technically

Down reaming
Increased safety
Down reaming is a type of raise
boring where a pilot hole is rea-
med from the machine to a lower
level. This can be done in one or
several steps to final diameter. The
cuttings are transported through
the pilot hole to a lower level. This
method is mainly used for small-
diameter slot-raises and backfill
drifts. Very occasionally the down
reaming method is used for large
diameter raises, usually in steps.
Down reaming is more complex
and more costly than raise rea-
ming due to the necessity to sta-
bilize the reamer and drill string
when reaming. Removing cuttings
from the face requires more effort Figure 1: Part of the down reamer used on the San Giacomo project in Italy.
than a standard raisebored shaft.
Down reaming is mainly used as described above. When the first reamer in the raise using drill string stabilizers
when the lower level is unsafe or completes and is removed from the of the same diameter. Weight stacks have
if access to the lower level is fi-
nancially not viable. One advan- raise, the second, larger reamer is col- historically been used on the reamer to
tage for the down reaming me- lared into the top of the hole. The front increase the thrust capacity in the down-
thod is that all work is done at of this reamer follows, and is stabilized reaming system, as shown in Figure 3.
machine level further increasing
safety over competing methods.
Figure 2: Down reaming, one step.

Down reaming, one step

In the working sequence below, the rea-
mer needs to either pass through the
machine work table or be assembled to
the drill string in a pit underneath the Pilot down Ream down
raiseborer.
The raise is piloted
Drill string is pulled
The reamer is attached and collared
As the raise advances, stabilizers are
attached to the drill string, usually in
a pre-determined pattern
After breakthrough the drill string is
pulled
The diameter limitations on the above
method are set by the raiseborer thrust
bearing load limit, the pilot hole size,
and the chosen reamer connecting pro-
cedure as shown in Figure 2.

Down reaming, two or

more steps
The down reaming sequence, when the
raise is done in several steps, is the same

raiseboring 29
 Talking Technically

Reamer, guide and

stabilizer design
Down reamers should be equipped with
a front guide. It should stabilize the
reamer in the pilot hole while allowing
the cuttings to pass through into the
pilot hole. Cuttings pass the front guide
between the wear ribs. Some designs
lead the cuttings from the face through
the centre of the guide.
In raise reaming, a flat reamer pro-
file is best. This is not the case in down
reaming. The cutters should be on an
angle towards the pilot hole, so that
gravity can help the cuttings flow down-
wards. To prevent recutting, raises with
lower angle than the reamer profile
should be avoided. If the down-reamed
hole has a lower angle than the reamer
profile, than the cuttings have to be
scraped, flushed or lifted into the pilot
hole, since the lowest point of the face is
not the pilot hole. The cuttings are flu-
shed into the pilot hole by water piped
down the drill string to the reamer, and
out to the reamer gauge. A rear guide
ring will further stabilize the reamer
action, keeping carbide breakage to a
minimum.
To centre and prevent side loading
of the drill string, rotating or non-
rotating stabilizers are installed on even
spacing. The rotating stabilizer is of a
simple design that works well in low
load applications. It is bolted onto the
wrench flats on the drill string. The non-
rotating stabilizer consists of a special
drill pipe with four arms mounted on a
bearing bushing. This design runs qui-
eter, and can be more heavily loaded.

Raiseboring machines to
be used for down reaming
Most standard raiseboring machines
are equipped with a smaller bearing on
the pushing (pilot) side compared with
the main bearing on the pulling side
(reaming).
Exceptions are the Atlas Copco Rob-
bins 34RH and 53RH Raiseborers.
These machines are designed for raise
reaming, down reaming and boxhole
boring.

Roberto Lopez and

Figure 3: Down reaming, large diameter.
Mikael Bergman

30 raiseboring

Robbins 34RH set up for down reaming at Brunswick Mine.
Secoroc RDI 720 reamer in the hole.
raiseboring 31
Talking Technically
Brunswick Mine has a partnership with Atlas Copco
Construction & Mining Canada that encourages
new product testing and innovative change. For the
Brunswick operation, the change from 2-cutter to
3-cutter RDI 720 down reamer in their slot reaming
programme has been a great success.
Falconbridge Limited Brunswick Mine has extracted and
processed ore from the world's largest underground zinc
mine for more than 40 years. Located in northern New
Brunswick, Canada, approximately 30 km southwest of
Bathurst, the mine produces 3.6 million t/y of zinc, lead,
copper and silver ore, and has produced 110 million t of
ore to date.
The Brunswick orebody comprises massive sulphides,
with zinc, lead, copper and silver being the principal
metals produced. The host rocks and the mineralization
have undergone four significant deformation events, re-
sulting in intense folding and faulting.
Production is carried out on five main levels to a depth
of 1,125 m, and two shafts provide access. The mine em-
ploys approximately 800 people.
Regular programme
From the first test run three years ago, the Robbins
34RH has down reamed 3,700 m of slot-raises. The mines
regular programme is 3 to 4 slot raises a month. The
bench height is normally between 20 m and 45 m. The
slots are drilled on a slight angle from vertical.
The down reaming working sequence is as follows: clean
the drill site down to bare rock and pour a concrete
drill pad at the site; erect, anchor and align the machine
on the drill pad at the required angle; drill the 9 in-
diameter pilot hole to break through, and retract the
drill string; install the down reamer through the drill
table, and down ream the hole to break through; attach
rotating stabilizers to the wrench flats on the first rod
above the down reamer and on the wrench f lats of
every fifth rod; pull the drill string and down reamer
out of the hole, once the hole is complete; and move the
equipment to the next prepared drill site.
Viable alternative
Down reaming provides a viable alternative to conven-
tional reaming when the lower level breakthrough site
access is restricted due to the mine planning sequence. At
Brunswick mine, as the advantages of the RDI 720 down
reamer were understood, a large number of the slot raises
that were scheduled for conventional reaming were swit-
ched to down reaming.
Unlike in conventional reaming, the complete down-
reaming operation can be handled at machine level, and
securing of the lower level is no longer necessary.
 Talking Technically
RDI 720 down reamer.
This, of course, is a big advantage in underground benching,
sub level stoping, or any other underground mining method
where an open face needs to be created to safely blast the
initial excavation of a new production area.
Stable reamer action
The RDI 720 down reamer has improved the speed of
the operation in all aspects. Since the three-cutter design
provides more stable reaming action compared to its two-
cutter counterpart, the reamer can be loaded higher, and
rotated faster, without transmitting excessive stress or
32 raiseboring
vibration back into the drill string. At Brunswick, this
more than doubled the penetration rate, while increasing
cutter life and reducing machine down time.
With this higher productivity, the mine has reduced its
need for contracting additional raiseboring services from
external sources to keep up with the ongoing slot raise
demand.
Historical down reaming problems, low cutter life and
low penetration rate virtually disappear with the three-
cutter design, and the customers save money by doing
the work themselves.
RDI 720.
 Talking Technically

Modern boxhole boring with

BorPak
Effective solution
The Robbins BorPak offers a novel
concept in the mechanical exca-
vation of hard rock. A steerable
blind boring machine, it operates
without a pilot hole, without drill
pipe, and, most importantly, with-
out a man inside the excavation.
BorPak is an effective solution for
traditionally difficult areas of mine
excavation or underground con-
struction, particularly where top
access is unavailable. It is suit-
able for a wide variety of mining
and construction projects, such as
drilling from one level to another,
or from tunnel to surface. It is es-
pecially attractive when flexibil-
ity and mobility are at a premium,
or when the job requires drilling
a series of short raises of up to 2
m-diameter. The carrier-mounted,
low-profile BorPak is simple to
position underground for blind BorPak on site.
boring of orepasses, ventilation
drifts, and slot raises. These can
be from 20 m to 200 m-long, as tube housing the cutterhead is braced When the hole is complete, the
low as 30 degrees from horizontal, against the rock face, and drilling can BorPak is automatically retracted and
and up to 90 degrees vertical. commence immediately. Preparation and lowered to its crawler frame, ready to
set-up takes less than two hours under be moved to its next job.
normal conditions. These features of the current Bor-
Innovation at work To begin boring, the machine ex- Pak add up to greater availability, less
tends from its starting tube, which is downtime, and improved production.
BorPak gets its name from the expand- anchored to the rock face by hydraulic
able packer unit that absorbs the torque jacks. The expandable rubber packer Boring unit
and thrust of the rotating cutterhead. holds the machine in position and
Cuttings gravitate down a guidance tube reacts forward thrust and torque during BorPak comprises two major assem-
and onto a conveyor. Operated from a boring. Adjustments by the operator at blies: the boring unit; and the carrier
panel outside the raise, BorPak impro- his console direct steering shoes at the and launcher.
ves worker safety and lowers labour front of the unit, controlling the boring The boring unit has a cutterhead
costs. A hydraulic power system advan- direction. Each time the machine com- at the front, or top. This is supported
ces the cutterhead, and steering is con- pletes its half-metre stroke, the expand- by the body of the machine, with ste-
tinuous, using a laser as a guide. Safety able packer releases, and the operator ering pads for directional control. The
grippers prevent the unit from sliding shifts the steering shoes to hold mode. packer anchors the main body in the
down the raise between strokes or in the The packer is deflated, moved forward raise during boring, while the safety
event of power failure. in the hole, and reinf lated. A new grippers hold the boring unit when the
Atlas Copco engineers will work stroke can then commence, the whole packer is not pressurized. The drive
with clients to design BorPak to spe- regripping process having taken less train for cutterhead rotation is mounted
cific requirements of the job. The sy- than two minutes. This regripping se- within the main body, and a cuttings
stem can be fully automated, and is quence can be computer controlled using outlet is incorporated.
capable of around-the-clock operation. Atlas Copcos well-tried and tested Also within the body are the thrust
Site preparations are minimal, and no Rig Control System, now in its third cylinders, electrical and hydraulic cir-
concrete pad is needed. The launch generation. cuits for powering and controlling the

raiseboring 33
 Talking Technically
BorPak in transport mode.
machine, and water circuits for cooling
and dust control.
These circuits are hooked up to trai-
ling cables and hoses, which connect
the machine to the bottom station, where
the operator's control panel, the electric
power source and the hydraulic power
pack are located,
The cutterhead is equipped with disk
cutters similar to those used on TBMs.
In hard rock, these can be equipped
with multi-row carbide button rings.
For softer rock a steel disk ring is used.
This optimizes the cutterhead design
for the type of rock that is to be bored.
The cutterhead is rotated by a number
of AC electric motors.
A three axis main bearing has been
incorporated to withstand high thrust
loads, and a multiple sealing arrange-
ment is included to ensure long life of
the important drivetrain components.
The hydraulic system supplies suffi-
cient pressure to achieve an average
load of 225 kN per cutter.
The four steering pads in the upper
region of the main body are activated
by differential hydraulic pressure to
move the head sideways during boring,
34 raiseboring
controlling the direction of the bored
raise. The pads also serve to clamp the
front section of the machine in the raise
during regripping for a new stroke, and
to stabilize the cutterhead during bo-
ring.
The rubber packer is a set of wear
resistant rubber pads, expanded against
the bored raise to grip the machine in
the hole, reacting its thrust and torque.
This is a compact arrangement, which
spreads the grip forces evenly over a
large area, and adapts to irregularities
in the rock surface. The packer also
permits steering, while maintaining its
grip.
The safety grippers at the bottom end
of the main body prevent the machine
from sliding backward when the pa-
cker or the steering pads are not pres-
surized because of power cut, or in the
case of a malfunction.
Carrier and launcher
For ease of movement to the under-
ground raise location, the BorPak sy-
stem can be mounted on a diesel-pow-
ered crawler carrier with an integrated
launching tube, or on a sled or a rail
carrier.
The machine is moved on the crawler
to the collaring point, where the out-
riggers are lowered hydraulically to
adjust the base frame into a horizontal
position.
The launching tube is raised to the
proper angle and extended out to the
rock surface by two hydraulic thrust
jacks. The roof jacks then tighten the
tube against the rock. Total set up time
is a few hours, instead of the several
days required for traditional boxhole
drilling equipment.
The packer is inflated for collaring,
and cutterhead rotation and thrust are
engaged. The machine climbs upwards
inside the launching tube, and cuts into
the rock.
The muck produced by the cutter-
head is funnelled by a tube through the
centre of the machine into a hopper
and onto a belt conveyor. This dumps
the rock several metres away, from
where it can be loaded out.
At the end of each stroke, cutter-
head rotation and thrust are halted for
regripping. The thrust cylinders are

Typical operating installation of BorPak machine.
retracted to move the packer forward.
Boring is resumed after reinflating the
packer and returning the steering pads
to the sliding mode. Regripping can be
executed either manually or by auto-
matic control, and takes approximately
two minutes.
A side-tilt feature can be added to
the BorPak collaring system, enabling
the launching tube to be tilted up to 30
degrees to either side.
The entire boring operation is run
by Atlas Copcos patented Rig Control
System (RCS) via a control console.
Applications
The first 1.2 m-diameter BorPak was
put to work at a copper/nickel mine in
Canada, where it encountered 130 Mpa
ore and 310 Mpa granitic gneiss. The
machine was engaged on blind slot rai-
ses of lengths 6.4 m to 32.3 m at angles
from 65 degrees to 90 degrees. Over
the first 17 raises it achieved a typical
boring speed of 1.5 m/h after collar-
ing, with a maximum of 4.8 m/h.
This machine featured four 380 mm-
diameter single disc carbide insert cutters
raiseboring 35
and two 355 mm-diameter tridiscs at the
centre, each loaded to 222 kN to cut
the hardest rock efficiently. An AC drive
system provided 104 kW to the cut-
terhead, which operated at 14 rev/min
at maximum torque of 80,000 Nm.
Auxiliary hydraulics provided 200 bar
system pressure for the BorPak thrust
mechanism.
The second BorPak, a 1.5 m-diam-
eter machine, went to a platinum mine
in Zimbabwe to bore ore passes from
haulage levels up to the reef, a distance
of roughly 15 m. Some 2,000 m/year
of blind raising was scheduled for the
machine.
The third machine went to a copper
mine in Chile for boring ore passes and
muck chutes in block caving develop-
ment. This BorPak has a cutterhead
equipped with four twin-cutter assem-
blies and four single disc cutter assem-
blies, all 15 in-diameter. Rotary power
is supplied by three 52 kW, water-
cooled, three-phase electric motors
through a gearbox and final drive. The
drive system has a closed pumped
lubrication circuit with filter and heat ex-
changer. Four main hydraulic cylinders
Talking Technically
provide the thrust to the cutterhead,
while eight expandable packers grip the
body. The operator can steer the ma-
chine using steering shoes located at
its front end.
BorPak has proved its value in me-
eting the challenges of blind shaft bo-
ring in the mining industry, and is now
ready to take on civil construction,
where it is perfectly suited to accurate
excavation of vertical and high angle
raises for hydro projects.
BorPak also has a future in transport
tunnelling, where horizontal raise drilling
has already been used to excavate cross-
passages on major projects. The compact
dimensions of BorPak, and the nondis-
ruptive nature of its operation, allow it
to be introduced close enough to TBM
tunnel faces to provide early ventilation
between parallel tubes.
The provision of crosspassages close
to the face is a prime safety requirement,
especially for fire fighting.
Marcus Eklind
 Talking Technically

Selection of raiseborer drive

system
Four alternatives
The main drive motor system of
the raiseborer is mounted on the
derrick assembly. It supplies the
rotational power through the drill
string to the pilot bit or reamer.
Four types of main drive motor sy-
stems can be used with Robbins
raiseboring machines, each suited
to different conditions. These sy-
stems are: alternating current (AC),
direct current (DC), hydraulic (H),
and variable frequency (VF). The
correct drive to be selected is a
combination of site availability, en-
vironment, ground conditions, and
Customers capability and avail-
able maintenance and troublesho-
oting skills.
Atlas Copco experts will advise
on the choice of most suitable
drive for specific conditions.
Electrical system assembly.

AC drive DC drive sufficient resources and tecanical know-

The alternating current AC drive motor
system uses a two-speed squirrel cage
induction motor. This type of motor pro-
vides constant power with mine duty
construction. A two-speed gearbox is
used with the AC motor to offer a
choice of four different output speeds.
The AC system has the simplest de-
sign, lowest cost, and highest reliability
of all Robbins drive motor systems. It
is best suited to competent ground where
fixed rev/min and minimum motor stal-
ling will be encountered.
For best performance, the power
source and supply cable to the motor
should be able to handle the locked ro-
tor power demands of the motor, such
as when tightening a threaded connec-
tion, without excessive voltage drop.
State-of-the-art soft start units are used
for bigger models. Considerable deve-
lopments in this field are allowing the
design and manufacturing of simpler
compact units with relatively simple
maintenance requirements.
The direct current DC drive motor sy-
stem uses a variable speed shunt wound
DC motor. This type of motor is open
drip proof with mine duty construction.
It is used with a two-speed gearbox.
The DC drive system has been used
in all types of ground conditions and
on raises in excess of 20 ft (6 m) in
diameter. It has a simple design, lowest
cost, and highest reliability of the vari-
able speed main drive systems. DC drive
has proven performance on larger raises
where low revs/min must be accom-
panied by high torque, and in areas of
broken ground where repeated reamer
stalling occurs. Because of the variable
rev/min and good torque limiting con-
trol, DC drive is best suited for larger
raise diameters in mixed ground con-
ditions. Long manufacturing time and
high cost for specialized design motors
used for raiseboring are the trademark
of this option. Small control units, high
efficiency, and low heat generation are
the top options for the customer with
ledge.
Hydraulic drive
The hydraulic drive motor system con-
sists of one or more hydraulic motors
coupled to a multiple speed gearbox.
Hydraulic power is supplied to the hy-
draulic motors by one or more high-
pressure hydraulic pumps.
Hydraulic drive motor systems are
equipped with variable volume pumps
for infinite boring speed control. The
exact configuration of each hydraulic
drive motor system depends on the par-
ticular raiseboring machine. Latest de-
sign of higher efficiency motors, com-
bined with the use of proportional dis-
placement systems are the preferred
option for raiseboring machines. With
variable speed and good torque limi-
ting control, hydraulic drive can be used
in all ground conditions and has high
reliability when normal hydraulic pre-
ventive maintenance systems are in
place, and heat generation, and space

36 raiseboring
 Talking Technically

for handling of the hydraulic rotation

units is not critical. The hydraulic drive
motor system has the lowest inertia of
all the drives and does not subject the
drill string to high stall torques, such
as happens with electrical drives.

VF drive
The variable frequency VF drive motor
system combines some of the simplic-
ity of the AC drive motor system with
exact motor speed, torque, and positi-
oning control. The VF drive system was
developed in-house by Atlas Copco
Robbins.
The VF system circuitry controls the
exact speed, torque, and position of its
AC motor by first converting the inco-
ming AC mine power to DC and then
converting it back to an AC signal.
The frequency and voltage of the AC
signal outgoing to the AC motor can
be adjusted, enabling precise speed, tor-
que, and positioning control.
The VF drive motor system offers
several advantages over conventional
AC drive as follows:
1. Adjustment of motor speed and Hydraulic system assembly.
torque, automatic motor braking
to prevent thread damage or over-
torque of drill string threaded Control console The latest now-available RCS con-
connections during connection trol console assembly contains all the
starting, and makeup. Controls on the console assembly are controls and readouts necessary for raise
2. System built-in diagnostics and for both electrical and hydraulic func- boring system operation. A modern com-
fault indications, simplifying motor tions. Drive train assembly controls pact rig control system from Atlas Copco
maintenance and troubleshooting. in-clude those for reversing rotation features a Control Area Network (CAN)
3. Lower Costs. The VF system uses and selecting drivehead speed. for digital communication between all
less electrical energy than AC drive Other electrical controls are provided modules connected to the communi-
systems because of its higher power for rapid crosshead traverse, electrical cation wire (bus). The entire system
factor, requires normal mainte- motor starting, and hydraulic cylinder features various I/O modules for com-
nance, and utilizes specially desig- thrust pressure control. Hydraulic con- munication with all sensors and meters
ned and manufactured main drive trols are provided for oil flow rate and involved, and a master module for com-
AC motors. thrust pressure regulation. Controls for puting and processing of operational
4. Conversion of a standard AC drive an optional Pipeloader are commonly data, as well as a display module for
motor system to a VF system. housed in a portable pendant station presenting of calculated data (graphical
This conversion can transform an that is located at the control console user interface). The new control system
older four-speed AC system into a assembly. is the proven Atlas Copco standard
versatile state-of-the-ar t raise Control consoles on more raise bo- CAN-bus control panel, manufactured
borer. ring machines have meter readouts of and delivered to over 140 units since
Inherited into the VF drive techno- main drive motor amperes or main drive 1998. It features a solid shell specially
logy is the considerable amount of space motor pressure, depending on the type designed for outdoor and underground
required to handle heat dissipation. of main drive motor, and drivehead revs/ usage under severe conditions. All com-
Since standard types of AC motors are min. Additionally, actual force applied ponents involved are deve oped and long
not recommended for use in VF drives, to the rock face by the pilot bit or rea- term tested for the same conditions.
a new Atlas Copco Robbins speci- mer is displayed by use of a bit force
fication AC motor should be installed computer. Indicators for various hyd- Roberto Lopez
with every VF drive conversion. raulic pressures are also displayed.

raiseboring 37
 Talking Technically

Computers improve rock

excavation productivity
Rig control
system applied
to raiseboring
Atlas Copco Robbins is applying
its well-established RCS drill rig
computer technology to raise bo-
rers. This represents a quantum
leap forward with respect to drill-
ing accuracy, equipment reliabil-
ity, logging capabilities, reduction
of manpower, and serviceability.
CAN-bus technology, well proven
in the automobile industry, is an
integrated part in the computer-
ization. The new systems are an
option on new raiseborers, and
have already been retrofitted to a
number of older machines.

Introduction
In mines and tunnels, an accurate exca-
vation profile contributes to better rock
stability and overall economy. These
qualities accelerated the acceptance of
computerized rigs underground, giving
Atlas Copco the confidence to apply
the technology to other products, in-
cluding raiseborers.
The latest generation of raiseborers
requires less operators to supervise them,
while offering improved working envi-
ronment and high production with reli-
ability.
Atlas Copco has a great interest in
what raiseboring can do to improve
the rock excavation process as a whole,
and continually monitors the perfor-
mance of machines working for cus-
tomers around the world.
The PLC system, installed on drill
rigs for many years, uses a large radial
network to connect the central com-
puter with the various sensors and pro-
cessors. It handles analog high-speed
signals, while hosting many processors
for advanced digital communication
and man-machine communication. This
RCS is a common platform for all Atlas Copco mining and construction products.
means that all sensors are hooked into
one central computer, which processes
the instructions sequentially.
When automating a raiseborer that
is hosting only a few steps, PLC is pro-
bably still a good solution. However,
as control systems become larger and
more complicated, the mix of high-
precision and high-speed signals be-
comes more difficult to optimize in PLC
systems, and the radial networks in-
volved require intense cabling.
CAN-bus raiseborers
With the introduction of the CAN-bus
system on the new generation of Atlas
Copco Robbins raiseborers, comple-
tely new thinking in the derrick control
and rod changing systems has been
enabled. Two levels of customer access
to the parameters are possible. At the
first level, the operator can change
a few parameters. At the next level
of parameter access, the foreman is
provided with a password. At this
level he can change all of the relevant
para-meters.
Another important feature with the
CAN-bus rigs is that these have a built-
in diagnostic procedure for the elec-
tronic system, making it easy to find
and repair faults. The electronic com-
ponents on the CAN-bus rigs are com-
mon and interchangeable, thus requir-
ing fewer spares at site.
CAN-bus can be adapted to the
type of application, whether surface or

38 raiseboring

Monitoring module condition.
underground, the pilot and reamer sizes,
the level of automation, and the intro-
duction of new functions, without the
need to install a heavy and expensive
computer in the small and less complex
rigs.
Quality drilling
The new raiseborers offer numerous im-
provements in the drilling and quality
of the drilling result, which eventually
will lead to lower overall cost. Some
of the advantages are listed.
Higher availability of the raiseborer
is expected
The running costs are expected to be
lower, as the proper follow-up of the
machine performance and direct fault
finding will improve the availability of
the rig.
Because fault tracing is carried out
by the software, the service organi-
zation does not require a deep know-
ledge of digital or computer technology.
Monitoring of the rock characteris-
tics is possible
Using the MWD (Measuring While
Drilling) function, rock parameters can
be logged during pilot drilling and rea-
ming, without extra input. This is valu-
able in interpreting the results of para-
meter monitoring.
Rod changing is automated
Using radio remote control, the opera-
tor is able to undertake rod changing
without assistance, removing the need
for a second person.
Rod joints are tighter
The RPC-F function keeps rod joints
tight, which ensures efficient energy
transmission.
raiseboring 39
Rig control systems
RCS promotes quieter and more spa-
cious surroundings for the operator,
since there are no longer any hydraulics
or gauges in the cabin. Instead of dials
and switches, the operator has a screen
and joysticks, backed up by a full dia-
gnostic and fault finding facility. Once
he has programmed the hole, the com-
puter takes over, optimizing the pilot
drilling or reaming process, and lea-
ving him free to carry out other duties.
Stress on the operator is reduced, while
his productivity is increased. The result
is quality holes and happier workers.
RCS also provides a gradual ramp-
up of power at the start of pilot drilling
and reaming. Smoother control during
the boring operation then takes the
stress off the drill string, and improves
the penetration rate. When jamming
starts to occur, it is detected by an in-
crease in rotation pressure, which im-
mediately causes boring to stop, avoid-
ing unnecessary torsional stresses in the
machine and drill string.
Future trends
Automation products are already avail-
able to connect a raiseborer to a cus-
tomers communication network.
Once the raiseborer is connected to
the network, the project control and
management systems will receive vital
RCS applied to raiseboring.
Talking Technically
information on drilling data and the
rigs internal condition. The raiseborer
will also be able to load new working
orders and information.The new series
raiseborers are automation-ready and
intelligent, with options such as tele-
remote operation, navigation and auto-
nomous operation. They also have a
customer application interface to stan-
dardize the exchange of data between
machine and jobsite. The connectivity
network offers customers better service
support, with engineers based at the
home factory carrying out remote
troubleshooting. Rigs can repor t
failures, and request servicing, using
either direct modem connection, or via
the Internet.
With the RCS system, and its PC-
based technology, upgrading raiseborers
of all types and manufacture has never
been easier. Atlas Copco Robbins is
now able to provide a full range of
automation options to its computerized
raiseborers, such as:
Automatic collaring
Automatic rod handling
Automatic drill control
Bailing surveillance
Detection of worn out reamer and
pilot drill bits
Lubrication surveillance system
Maintenance logging
Measure While Drilling logging
Rig Remote Access
Johnny Lyly
 Talking Technically

Site preparation
Improved efficiency Clearance for derrick
Overhead
clearance
Correct site preparation elimina- erection from the for complete
tes major delays and adds noti- transporter system derrick
ceable efficiencies to the raisebo- extension
ring operation. The site planner
needs to know the geology and
layout of the hole so that a cor-
rect design can be evolved for the
areas at both top and bottom. It
is necessary to have good access
to both positions, and sufficient
manoeuvring room for tube chan-
ging at the top and clearing away
muck at the bottom. Consideration
also has to be given to the routes
along which all of the equipment
will pass. A well thought-out site
will be of benefit to the operators,
both in time and money.

Site layout
Raiseboring site preparation begins with
a comprehensive plan, for which the site
planner must first receive the following
information well in advance of the sche-
duled boring date:
1. Survey drawings showing the propo-
sed collaring point, proposed break-
through point, and hole axis section.
Dip angle and actual length of the
hole should also be specified.
2. A geological section through the hole
axis including its location and a brief
geological description.
From this information, a site layout plan
is formulated for the surveyors.
Site planning considerations include:
derrick mounting systems
bailing fluid selection
bailing fluid and cuttings discharge
storage and positioning of drill string
components
overhead clearances
floor space and equipment
positioning
compressed air
water
electrical power
lighting
telephones
and ventilation
Overhead clearances.
Derrick mounting systems
The derrick must be positioned and mo-
unted at the site before the raiseboring
operation can begin.
The two most commonly used moun-
ting systems are concrete pad and steel
beam.
When deciding the type of derrick
mounting system, the layout of the site
and availability of construction materials
are factors to consider.
Once the mounting system is decided,
a detailed design specific to the site
layout and raiseboring machine needs
to be put together.
This should be approved by a quali-
fied engineer who has to ensure that
the mounting system is strong enough
to safely react the maximum thrust and
rotational forces transmitted by the raise
boring machine.
The dimensions and position of the
mounting system, and the exact loca-
tion of the pilot hole collaring point and
base plates, must be indicated on the
site layout drawing.
Concrete pad mounting
This mounting system is constructed by
casting a concrete pad at the raise bo-
ring site on which the derrick base pla-
tes or sub bases are mounted. The latter
are used when boring at dip angles of
less than 45 degrees from horizontal.
Concrete pad systems are typically
designed with a sunken channel run-
ning between the base plates to permit
collaring of the pilot hole, drainage of
the bailing discharge, and installation
of the blooie system when needed.
Advantages of using the concrete pad
system are: it is the least expensive of
the derrick mounting systems; it is rela-
tively simple to design and construct;
it ensures a smooth horizontal surface
for the mounting of the base plates; and
steel reinforcement of the concrete is
usually unnecessary.
Design considerations for concrete
pad mounting systems include:
1. The surface area of the concrete pad
must be significantly larger than the
raise final diameter to protect both

40 raiseboring
 Talking Technically

Derrick

Base plates

Concrete pad
Sloped sunken channel
Rock bolts

Concrete pad mounting system.

derrick and concrete pad from slum- Steel beam mounting concrete pad or directly to the invert
ping into the hole upon completion. rock, or to reinforced concrete pads at
2. It is extremely important that the con- With the steel beam mounting system, opposite ends of a sunken pit.
crete pad be poured to solid bedrock the base plates are secured to a steel Advantages of steel beam mounting
to ensure the best foundation possible. structure, which can be bolted to a systems include:
3. The concrete pad must be of sufficient
quality and thickness to positively re- Steel structure concrete pad mounting.
act the maximum load transmitted
into the pad from the derrick during
the raiseboring operation.
4. The recessed channel should be slo-
ped toward the rear of the machine
to drain bailing fluid and cuttings Bolts fastening the
away from the working areas at the base plates to the
front of the machine. steel structure
5. The upper concrete pad surfaces on
each side of the recessed channel must
be smooth, absolutely horizontal, and
level with one another.
Concrete pad Steel structure
6. The horizontal base plate mounting
surfaces of the concrete pad must be
designed to accommodate the dim-
ensions, spacing, and hole pattern of
the base plates. These are given in
the section "Site Preparation and
Equipment Setup" in the service ma-
nual supplied with the purchase of Rock bolts Rock bolts
each raiseboring machine.

raiseboring 41
 Talking Technically
Steel beams bolted to the concrete pad.
1. They can be reused with the same
raiseboring machine on future raises.
2. They provide support for the reamer
during removal of the derrick and
for excavation of the top of the raise.
Reamer breakthrough using steel beams.
42 raiseboring
3. They elevate the derrick off the site
floor making collaring of the pilot
hole easier, and facilitating bailing
discharge drainage and installation of
a blooie system.
4. Complete reamer bore-through is pos-
sible with a sunken pit, eliminating
drill and blast to excavate the last
portion of the raise, reducing the cha-
nce of damage to reamer and cutters.
5. Rock bolts can be placed outside the
reamer envelope.
Design considerations for steel beam
mounting systems depend on the exact
mounting configuration to be used with
the steel structure. Three configurations
are commonly used: steel structure - con-
crete pad; steel structure - direct rock;
and steel structure traversing a sunken
pit.
Steel structure - concrete pad
Design considerations for the steel struc-
ture include: the upper surfaces must be
made horizontal and level with one an-
other, possibly using shims; any space
left beneath the steel beams should be
fully shimmed or grouted to provide
maximum support; the steel structure
must accommodate the dimensions, spa-
cing, and hole pattern of the base plates

Robbins 97RL at work in a typical cavern with good overhead clearance.
or sub bases. The concrete pad must be
designed to accommodate the dimen-
sions of the steel structure.
Steel structure - direct rock
Design of the steel structure is similar
to that described above for concrete
pad mounting.
Care should be taken to ensure the
rock formation is smooth, level, compe-
tent, and of sufficient strength to po-
sitively react the maximum load trans-
mitted from the steel structure during
the raiseboring operation.
Steel structure traversing a
sunken pit
With this type of system, the steel struc-
ture traverses the sunken pit and is se-
cured to reinforced concrete pads at op-
posite ends of the pit.
Design considerations for the sun-
ken pit include: the inner walls of the
sunken pit must be designed to allow
complete clearance of the reamer upon
breakthrough; the walls and floor of the
raiseboring 43
circular pit must be competent, or be lined
with concrete in softer, structurally un-
reliable rock formations. The centre of
the pit should be at the section axis of
the raise, and its wall clearance should
allow for construction misalignments or
slight deviation upon collaring of the
pilot hole. The pit must have sufficient
depth beneath the steel structure to per-
mit stinger clearance for complete reamer
borethrough. Design of the steel struc-
ture is similar to that for concrete pad
mounting.
When using a steel structure with
a sunken pit, steel mounting pads must
be placed between the steel beams and
the concrete pads in order to move the
load path from the steel structure into
the concrete pads as far from the edge
of the sunken pit as possible.
Steel reinforcing may need to be in-
corporated into the concrete pads for
added tensile strength. This additional
strength is sometimes required in the
surfaces of the concrete pads to prevent
sloughing of the pads into the sunken
Talking Technically
pit. Note that the rockbolt holes on the
concrete pads for the mounting of the
steel structure must correctly located.
The choice of bailing fluid will in-
fluence the choice of mounting system
for the raiseborer. This is dealt with
in detail in the earlier article entitled
Selection of Bailing Fluid.
Floorspace and overhead
clearance
The raiseboring site layout must take
account of the number and type of drill
string components to be accommodated.
Easy loading into and removal from the
derrick of these components is the main
consideration.
Their storage is usually decided by
many factors at site, such as natural
layout, resources available, and method
of transport.
A timber-constructed rod rack is very
popular, arranged so that the compo-
nents can be rolled to the raiseboring
machine pipeloader. Sometimes a rail
 Talking Technically
Erection of a Robbins 34RH.
system is laid to the pipeloader and the
delivery rail cars used for storage. The
raiseboring site must have adequate
overhead clearances for the setup and
complete extension of the derrick. If
the raise is to be bored at an angle, the
angled extension of the derrick must be
provided for. The required dimensions
can be found in the section entitled Der-
rick Assembly in the particular machine
service manual. If a transporter sy-
stem is to be used for derrick erection,
adequate overhead clearance is required
above the positioned transporter to swing
the derrick from its horizontal trans-
port position to its boring position on
the mounted base plates.
The raiseboring site must have suf-
ficient floor space for locating and cor-
rectly positioning all necessary equip-
ment. This equipment typically includes
the following: derrick and mounting sy-
stem; hydraulic system; electrical sy-
stem; control console; pipeloader; drill
string components; tool boxes; auxiliary
44 raiseboring
mine transformer; bailing fluid and
cuttings handling system; barrels to fill
hydraulic reservoir and lube tanks; and
any other required accessories.
The site layout must allow every-
thing to be positioned for all electrical
cables and hydraulic hoses to be inter-
connected. The service manual provi-
ded with each machine lists its cable
and hose lengths. Extra floor space is
required to allow the derrick tran-
sporter, where used, to be properly posi-
tioned for derrick erection.
Site services
Compressed air is required at site to
power pneumatic tools and to provide
a bailing medium during pilot hole dril-
ling. Also, some crawlers are driven by
compressed air.
Clean water is required at the raise-
boring site for cooling the hydraulic oil,
the lubrication oil, and the electrical
cabinet SCRs used on machines with
DC main drive motor systems. Some
motors may also require water for
cooling, and water may be used as
the bailing medium during pilot hole
drilling.
In extremely cold temperatures, anti-
freezing precautions should be taken.
The electrical power supply requ-
ired by the raiseboring machine at the
site is dependent upon the individual
machine being used. Additional elec-
trical power may be required at the site
for lighting and accessory equipment.
Minimum compressed air, water and
electricity requirements are listed under
General Specifications in the section
entitled General Information of each
machine's service manual.
Adequate lighting is required at the
raiseboring site, and whitewashing helps
to eliminate shadowed areas.
A telephone communication link
must be provided between the raisebo-
ring site and the breakthrough site to
enable installation and collaring-in

Robbins 73RH C set up in Tayahua Mine, Mexico.
of the reamer at the breakthrough site;
for lowering and raising the reamer
during cutter changes or reamer repair/
replacement; for cleaning the rock cut-
tings from the breakthrough site; and
to stop the reaming operation in the
event that broken reamer or cutter parts
are found in the cuttings. The mine te-
lephone system can be used, or a com-
patible sound-powered system can be
supplied by Atlas Copco Robbins.
Ventilation
The ventilation air supplied to the raise
boring site should be fume-free, with
a dust count kept at acceptable levels.
The air temperature should be comfor-
table for the operating crew and accep-
table for machine operation. Excessively
high air temperatures can lead to the
overheating of hydraulic and lubrication
oils, and damage of electrical and hy-
draulic equipment. Furthermore, high
dust and fume levels promote frequent
raiseboring 45
electrical cabinet air filter replacments.
Upon completion of planning and the
layout drawing, the site must be sur-
veyed and excavated to the required
dimensions.
Site survey
Upon complete construction of the der-
rick mounting system, a site survey must
be carried out to ensure the base plate
mounting surfaces are absolutely hori-
zontal. The exact locations of the pilot
hole collaring point and the base plates
should be recorded. The concrete or
rock formation surface at the collaring
point should be smooth and perpen-
dicular to the axis of the raise to avoid
pilot hole deviation.
The surveyor should check that the
excavation is to planned dimensions
with full overhead clearance, and that
the derrick mounting system has been
correctly positioned in relation to the
sidewalls of the site.
Talking Technically
Locating and installing
base plates
A template can be employed to locate
the drill holes that will secure the base
plates to the rock formation or steel
structure. The exact mounting hole di-
mensions for the base plates are given
in the section Site Preparation and
Equipment Setup of each machine's ser-
vice manual.
The base plate hole pattern can be
located on the mounting surfaces by
aligning the scribe marks on the base
plates with the survey line on the moun-
ting surfaces. If the raise is to be angled
from vertical, the template must be off-
set from the survey line at a distance
directly corresponding to the dip of the
pilot hole. If a steel beam mounting
system is being used, the base plate
mounting holes should be oversize to
cater for any misalignment. Washers
made of thick steel plating are generally
installed between the bolts and nuts to
 Talking Technically
Concrete pad with bailing trench and pump pit.
enable the base plates to be secured to
the structure. If required, stops can be
welded to the steel structure at the rear
of the base plates to prevent sliding,
which can occur when pilot hole drill-
ing a dipped hole.
When using a concrete pad system
for derrick mounting, rock bolts must be
secured into the rock formation be-low
the pad. Any annulus between the bolt
and hole must be backgrouted. The
base plates can then be fastened to the
concrete pad using threaded rock bolts
and a locking nut system.
After the base plates are installed to
the mounting surfaces, they must be
checked by survey to ensure that they
are absolutely horizontal and level with
one another. If the base plates are not
correctly orientated, it may be neces-
sary to correct any inaccuracies using
steel shims.
If sub bases are used, the base plates
must be fastened to the sub bases using a
locking nut setup with threaded bolts of
46 raiseboring
The excavation must be large enough
to allow both the reamer to be posi-
tioned and to accommodate the rock cut-
tings produced by the boring operation.
The site must also be accessible to load-
ing and transport equipment.
Direct communication between the
breakthrough site and the machine ope-
rator at the raiseboring site is essential
during operations involving the pilot
bit/bit reamer-stabilizer removal and
reamer installation. A telephone system
is typically installed to serve this pur-
pose.
A supply of water and compressed
air is necessary at the breakthrough site.
Water is required for cutter changes,
hosing down the reamer during prepa-
ration, and when any necessary exami-
nation of the reamer is to take place.
Compressed air is required for the ope-
ration of pneumatic hand tools.
Additional preparations include set-
ting up proper lighting and ventilation,
and installing at least one lifting eye
for reamer assembly and positioning.
The breakthrough site should also have
adequate drainage, especially important
if water is to be used at the rock face
during the reaming process.
Rikard Erlandsson
equal diameter to the rock bolts used
for securing the sub bases.
Additional installations
The bailing fluid and cuttings handling
system may now be installed, together
with any lifting eye bolts needed for
setup and operation of the raiseboring
system. It is good practice to install at
least one lifting eye above the derrick
in case main drive motor system re-
pairs become necessary. If the derrick
has to be dismantled for transport, lift-
ing eyes must be located directly over
the final assembly positions of each
major component.
Breakthrough site
preparation
The breakthrough site must be exca-
vated to size to permit removal of the
pilot bit and reamer-stabilizer, and to
Oil trap under hydraulic power pack.
install the reamer.
 Talking Technically

Operating the raiseborer

Machine manual
Proper operation of the raiseborer
can be summarized in the meth-
ods and sequence required to
complete the raise safely, keep-
ing in mind reliability, cost ef-
fectiveness, and maximum per-
formance usage of the machine
Drilling a raise is only effective if
it meets the requirements of the
project.
Each raise drill is selected to
perform a defined requirement,
so it is imperative to understand
the capabilities, limitations, and
safety requirements involved in
the methods and usage of the
equipment. The manual supplied
with each machine gives instruc-
tions on how to maximize its uti-
lization.
While the operational details
are specifically defined by the
model and function, the funda-
mental objective remains the
same: to excavate the raise from
start point A to finish point B on
time and in a safe, cost effective
way. The manual describes the
method and procedures for set-
up of the specific machine, pilot
drilling, reaming, and removal of
the in-hole equipment. Robbins 34RH C.

Worksite preparation
The first stage of the raiseboring opera-
tion is the preparation of the worksite, ke-
eping in mind the layout required for the
machine, power units, drill pipe, and ac-
cessories. This is planned and defined in
advance of the arrival of the machine,
because items such as power supply and
disposal of the cuttings are crucial to the
efficiency of the operation. A suitable
concrete pad or structure must be provi-
ded upon which the base plates and rig are
secured.
Transportation of the equipment to
the worksite is the next step. Crawler,
sled or rail bound haulage may be used
to carry the machine as a complete unit
or in component parts, depending on its
size and the roadway clearances along
the route. If assembly at the worksite is
required, the area must be prepared in
advance to ensure sufficient floor space
and headroom.
Once assembled the equipment must
be positioned in the base plates. The
base must provide sufficient anchoring
to lock the machine in place, and must
be able to react to the torque and thrust
forces that will be generated during ope-
ration. Poor anchoring of the base may
cause displacement of the equipment.
This will move its centreline and cause
loss of direction, inducing bending mo-
ments in the drill string and increasing
the risk of failure.
The pad must be designed to take
into account the bailing method used for
pilot drilling, which may imploy water,
air, a mix of the two, or a special fluid.
Cuttings disposal must be planned in
advance as this varies according to eq-
uipment, ground conditions and local
services.
Anchoring and aligning the equip-
ment correctly during the set-up process
determines its orientation and ensures
accurate targeting of the lower point.
After collaring the pilot hole, alignment
should be re-checked.
During the collaring process a series
of precision machined starting pipes
and subs are added. These are guided
through a bushing to assure centre line
direction. Collaring is carried out through
the concrete base and into the rock for-
mation. The drilling characteristics of
these materials are different, so excess
force and speed must be avoided, other-
wise deviation of the hole may result.
Correct pilot drill bit configuration for
the expected rock conditions and flush-
ing medium are crucial.
Used pipes should be checked for
condition, and handled and stored care-
fully. A file can be used to smooth down

raISEBORING 47
 Talking Technically
Crawlers increase mobility of the raiseboring
machines .
any protrusions in the drill string in
order to avoid chances of damage to
the bronze guided sleeve of the starter
bushing.
A milled-tooth bit is generally used
to drill into the recess area of the con-
crete base for the blooie installation.
When using compressed air to flush the
pilot hole, the blooie seal is installed at
the top of the annulus to divert the high
velocity cuttings away from the drilling
personnel.
Pilot hole
Before drilling of the pilot hole can
commence, the tricone bit has to be col-
lared deep enough to accommodate the
bit sub and stabilizers just behind the
bit and establish their direction. Col-
laring is carried out using the starter
sub and pipes for drilling, and adding
two or three six-rib stabilizers behind
the bit reamer-stabilizer to provide dril-
ling accuracy. In soft, blocky ground,
or when drilling low angles, additional
stabilizers may be used at intervals be-
tween drill pipes if required.
The starting bushing comprises a
strong holder with a bronze element to
guide the drill string components. This
bushing must be monitored for hot spots,
which are an indication of forces tending
to deviate the bit. These can be caused
by the rock formation, improper drilling
operation, or changes in the machine
centreline set-up. A deviated start will
48 raISEBORING
result in an off-target holing and, if it
cannot be corrected, the hole may have
to be cemented and re-drilled.
The diameter of the pilot bit must
be checked using a bit gauge to ensure
it is within recommended tolerances.
Nozzles may be installed in the bit when
drilling with air. For water, any nozzles
should be removed.
Collaring procedure
A liberal coating of general purpose
grease is applied to the collaring com-
ponents, after assuring there are no pro-
truding spots in their surfaces. Likewise,
the machined outer surface of the starter
pipe must be greased. It is important
not to use thread lubricant for this pur-
pose.
The bailing medium is then turned
on, and the passages through the pilot
bit checked to ensure they are clear and
properly configured. Only minimum
volume is required at this stage. If air
is the medium, add water as necessary
to control dust. Until the pilot bit is col-
lared in, the rotational speed should not
exceed 10 rev/min.
At the BIT FORCE indicator section
of the control console, set the switch to
the PILOT position. Refer to the instruc-
tions in the Service Manual on how to
setup and use the bit force indicator
system to be sure to zero the readout
before touching the face. When the
pilot bit contacts the concrete surface,
adjust the machine for minimum force
needed to start penetration.
At this stage, the starter pipe and
bushing are providing guidance, so the
initial collaring should be carried out
very slowly at, say, maximum 10 mm/
min (0.5 in/min).
Down drilling at minimum bit force
should be continued until the lower
wrench flats of the starter sub are below
the worktable of the machine. Grease
or oil should be applied to the starter
pipe as required.
Once the start section is completed,
the starter bit sub is replaced by the
roller bit sub, and the process is repeated
using the starter pipes and bushing. The
float valve should be installed at this
stage. The float valve prevents back-
flow and entry of cuttings into the bit
that may plug the passages. The gauge
and condition of the roller bit sub cutters
should be checked, and any worn or
damaged rollers replaced. All passages
should be clear, and each roller free to
turn.
Continue guiding the pilot hole by
replacing the starter pipes with the sta-
bilizers, until at least two stabilizers are
in the hole. Three stabilizers may be
needed to guide long holes.
Exercise care to prevent foreign ma-
terial, particularly metal objects, from
entering the open drill hole, because
these will damage the pilot bit when
drilling resumes.
The starter pipes and bushing can
now be coated with a light lubricant
such as diesel oil and stored until the
next raise.
Drilling the pilot hole
Pilot hole drilling can be started once
the collaring process is completed. Be-
cause rock is not usually homogenous,
continuous monitoring and adjustment
will be required to maintain the opti-
mum cutting rate, feed rate, rotation
speed, and bit force. Refer to the instruc-
tions in the Service Manual on how to
setup and use the bit force indicator sy-
stem to be sure to zero the readout before
touching the face.
Different ground conditions require
different approaches, needing skilled
and experienced operators. Every raise
represents a series of challenges from
which the operators learn their skills.
Drill pipes must be inspected before
use, and the connections greased. A
damaged thread will transmit the fail-
ure to the mating part, so pipes should
always be handled and treated as preci-
sion items.
Because of the high torque and ten-
sion on the connections, only approved
greases should be used. This will help
ensure that each connection is loaded
with the correct torque. Loose threads
may over-torque, causing over-tight
connections when pilot hole drilling-
Likewise, these may loosen during the
reaming process.
Raiseboring operations require high
tension and torque in all of the pipe con-
nections, and these must be tightened
properly to ensure a uniform coeffi-
cient of friction and prevent galling
 Talking Technically

during unthreading. Only thread lubri-

cant approved by Atlas Copco should
be used. The drillpipes must be de-rated
as their outside diameter wears. Torque/
tension graphs, published by the pipe
manufacturer are available, and should
be consulted for minimum and maxi-
mum values and de-rating factors. When
worn in excess of 4 to 6 mm the pipes
should be removed from service. If in
doubt it is better to discard a pipe rather
than risk losing an entire string.
A drill string inspection programme
must be maintained and, in particular,
any pipe that is dropped or mistreated
must be inspected before use. Thread
protectors should be installed when the
pipes are not in use. If threads are ac-
cidentally bumped, they should be re-
paired before use. A drill string is as
strong as its weakest pipe or connec-
tion.

Efficient drilling
Drilling can be controlled by speed or
bit force. The choice of method is ba-
sed on experience, skills in the specific
ground, and site conditions. Atlas Copco
Robbins raise drills have independent
controls and monitoring instruments for
feed penetration rate and bit force. The
conventional penetration speed control
is recommended, which is more focused
on the accuracy of the hole. The pene-
tration rate should be limited to a maxi-
mum of 2 in/min (50 mm/min) to mini-
mize deviation. The operator should
monitor and record the parameters of
the pilot drilling operation in order to
provide ground information for reaming.
The maximum penetration rate may
also be controlled by predetermined bit
force using the rotation speed and feed Surface commissioning of a Robbins 73RH C.
rate controls. This method will achieve
a faster pilot hole. Whatever method is cuttings have been removed from the while sandy discharge indicates insuf-
used, the maximum weight on the bit face before turning off the bailing, at ficient load on the bit or inappropriate
is the ruling consideration, limited by least theoretically. Operators have to be bailing volume. Both promote regrinding
the rotational speed of the machine and prepared to make control adjustments of the cuttings, and are detrimental to
the capacity of the bailing system to during the drilling process, since different the drilling process. If voids are en-
remove the cuttings from the hole. rock types, formations and character- countered, the returning medium will
Before changing rods, it is essential istics may be encountered. Penetration be lost, and the drill string should be
to clear the cuttings from the hole, oth- speed should be regularly monitored to withdrawn. Attempting to drill without
erwise they may settle, cementing the ensure it stays within the required range. returning medium can cause a stuck
string. Given the depth of the hole and The bit force indicator will show changes drill string, with loss of both equipment
the annulus area, the bottom-up-time in rock hardness. The cuttings being dis- and hole. Cementing the hole may be
can be calculated. This is the minimum charged can be inspected to for chip size. necessary to seal the voids and stabilize
flushing time required to ensure all the Small chips indicate efficient cutting, the hole.

raISEBORING 49
 Talking Technically
Additives such as bentonite may be
used to seal fissures and prevent exces-
sive losses of return fluid. When drill-
ing angled hard formations it is possible
that only one of the bit cones will be
making full contact. This is usually
caused by reduced weight on the drill-
string as it transitions from down thrust
to hold back. This can cause harmonic
oscillation on the drill string that can
be transmitted up to the machine, charac-
terized by the drill pipe jumping. This
is normal, but requires the operator to
adjust the rotation speed and force away
from the harmonic point.
Shock absorber tools are available
for use where harmonic oscillation is a
recurrent problem.
Because of the variables that affect
pilot drilling, the breakout point at the
lower level cannot be fully predicted,
so precautions must be taken. Breakout
may be accompanied by an explosive
burst of rock and discharge of water, so
the area must be properly secured.
The reaming process
Accurate ground information acquired
during the pilot hole drilling will assist
the operator to prepare for the reaming
process. In very hard formations, this
can help the decision to continue rea-
ming or to lower the reamer for inspec-
tion. It may also indicate cutter failure.
Once the pilot hole is completed, the
drill string must be lowered to allow
the removal of the drill bit stabilizer, to-
gether with any other stabilizers.
At least one stabilizer must remain
on the string. Caution is necessary to
avoid sharp shocks to the drill bit or
the roller cutters. The roller bit stabi-
lizers can be removed as one unit.
The bit must be removed with the
raiseboring machine.
The make-up/breakout tool should
be used to loosen the connections. To
prevent seizing or rusting of the compo-
nents they should be cleaned and stored
in a bath of oil or coated with grease or
light lubricant such as dieseline.
The number of stabilizers required
on the reamer stem can vary, but at
least one stabilizer must be left in place.
To minimize the chances of break-
ing the stem, which is expensive and
tedious to remove, a saver sub can be
50 raISEBORING
installed as a sacrificial piece to protect
the stem against excessive loads.
To avoid premature wear of the hex
stabilizer, a saversub is often used just
above the reamer stem, which experi-
ences the highest wear.
Flexers can be introduced into the
drill string to absorb bending moments
induced by uneven rock formations.
If the reamer detaches and drops to
the bottom of the hole, it can be fixed
and reconnected. If it gets stuck in the
raise, then the situation is more serious
and potentially dangerous, so assist-
ance should be sought about methods
and techniques for retrieval.
The golden rule is to never work un-
der an open raise, because of the danger
of falling rock and equipment.
While reaming, the cuttings must be
removed continuously. Nevertheless, it
is a good idea to leave a few cuttings
to act as a cushion in case the reamer
is dropped. It should be remembered,
however, that cuttings can compact in
the hole, forming a plug that may break
loose unexpectedly with explosive force.
If problems occur with cutting clean-
ing at the lower level, reaming must be
stopped for rectification.
Once the reamer head is connected,
communication with the machine ope-
rator must be established. Proper lubri-
cation and alignment of the reaming
attachments is required to prevent cross-
threading or damage to threads, and
correct torque should be applied to the
connections using the make-up/breakout
tool. A loose connection is the most
common factor in drill string break-
ages. This can accompany stalling of
the reamer and, once loose, will act as
the fulcrum point of the connection. It
will either unscrew during a stall, or
will break the connection items.
It takes longer to rescue, fix and re-
install a reamer than to tighten the con-
nections correctly.
Collaring the reamer
Starting the reamer is a slow process un-
til all of the cutters are in contact with
the face. The force used varies with the
number of cutters in contact at a specif-
ic time, and it is necessary to go slowly
to avoid stalls in high spots that can
create spin backs.
Refer to the instructions in the Ser-
vice Manual on how to setup and use
the bit force indicator system to be sure
to zero the readout before touching the
face.
Once collaring of the reamer is com-
pleted, the raise can continue at normal
drilling rates.
The cutters are loaded to the opti-
mum spalling point to break the rock,
and then maximum possible rotation is
applied to increase the penetration per
revolution. By observing the cutters it
is fairly easy to determine the cutting
efficiency, and the bigger the chips the
better the raise. Be aware some lime-
stone formations may produce huge
boulders which make reaming very
difficult.
The objective is safe, effective cut-
ting within the scale of maximum per-
missible load/cutter.
Continuous monitoring and adjust-
ments may be required to maintain the
optimum cutting rate, feed rate, rotation
speed, and cutter force. The drilling re-
cord from the pilot raise indicates the
rock conditions that can be expected.
The set-up of the site will determine
the options for clearing the site after
drilling the hole. In very short vertical
raises, it is reasonable to lower the rea-
mer, disconnect it at the bottom, and then
remove the pipes at the top. In long, or
angled raises, the ideal is to remove the
reamer from the top.
The concrete base at the top of the
hole must be wide enough to provide
support around the perimeter of the rea-
med raise, and strong enough to absorb
the required thrust. Placing an extended
concrete base may be necessary.
Once the reamer is properly secured
in place at the top, the machine can be
moved from site and a crane or hoisting
device used for the removal of the head.
Extreme caution must be taken when
working near open raises. An inrush of
air can be expected when the reamer is
removed.
Various accessories and methods are
available, depending on the machine
model and size, and intended raise.
Roberto Lopez
 Talking Technically

Bailing considerations
Importance of
bailing
It is important during pilot hole
drilling to provide a bailing med-
ium such as water, compressed air,
or compressed air with water. This
should be of sufficient quantity
and pressure to ensure that all ma-
terial being cut is removed im-
mediately from the bottom of the
hole and exhausted up the annu-
lus between the drill string and the
pilot hole walls. Adverse effects
of inadequate bailing are: short-
ened bit life due to the abrasive
effect of reground cuttings; bai-
ling pressure goes up and bailing
return is lost; sticking of pilot bit
or drill string, which could result
in twist-off of the bit; lower pe-
netration rate; rougher drilling op-
eration; and greater hole deviation.
Obviously, for a trouble-free hole,
bailing is a major consideration.

Air and water

The bailing medium is injected at the
raiseboring machine through a rotary
seal housing into the hollow core of
the drill string. It exits at three ports
in the pilot bit, removing the cuttings
from the bit face and forcing them up
the annulus, where they are directed
away from the finished pilot hole.
If compressed air alone is used as
the bailing medium, a blooie system
must be installed at the collaring sur-
face to seal off the annulus. The cut-
tings and dust are directed away from
Part of the site set up cavern blocked off to create a water and settling tank.
the machine through an abrasive re-
sistant line to a convenient discharge
point. and increased friction on the pilot hole When drilling with air, the pilot bit
If compressed air with water is used surface. should be air-cooled. This type of bit
as the bailing medium, a blooie system Too much water will also reduce bai- utilizes a portion of the air to cool its
may or may not be used. It is impor- ling action. An important fact to re- bearings. When drilling with water, bits
tant that the water being injected into member is that it takes approximately having sealed bearings should be used
the air stream be controlled carefully. 1 psi of air pressure to lift water 1 ft in for longer bearing life.
The approximate amount of water for the annulus. If water alone is used, a After adding drill pipe, the bit should
this mode is 20 lit/min (4.5 gal/min). blooie system is not required. There is be raised off the bottom of the pilot
Too little water may create sticky mud, no dust to contend with, and the velo- hole and rotated with bailing applied
which can severely limit bailing action, city of the return water is much less than to flush the bit bearings and bottom of
due to caking around the drill string with compressed air. the hole.

raiseboring 51
 Talking Technically
Raiseborer set up with trench for bailing pump.
Drilling with compressed air
The general consensus of bit manufac-
turers is that at least 23 cu m/min (800
cu ft/min) of air supply through the an-
nulus at 414-552 kPa gauge (60-80 psi),
with a minimum velocity of 1,500 m/min
(5,000 ft/min), is necessary when drill-
ing with compressed air. This velocity
52 raiseboring
ensures that cuttings are being removed
from the bottom of the hole. The ap-
proximate bailing velocity can be cal-
culated using the equations overleaf.
Velocity of bailing air will be de-
creased under the following conditions:
if water is encountered during drilling,
or added into the air supply; if heavier
material is encountered; as hole depth
increases; or as the amount of cuttings
in suspension in the annulus increases
due to heavier cuttings or deepening
holes.
When drilling with compressed air
it is important to ensure that all cut-
tings are removed from the pilot hole
prior to shutting off the bailing air after
drilling each pipe-length. This is par-
ticularly important at increased depths.
Manufacturers assume that the air sup-
ply will cool the bit bearings. There-
fore, it is necessary to provide suffi-
cient backpressure through the bit to en-
sure adequate cooling flow through the
bearings. For normal applications in
raiseboring, nozzles with orifices of
diameters 12.7 mm (0.5 in) to 15.9 mm
(0.625 in) are adequate. The nozzles
also act to increase velocity at the cut-
ting face.
Drilling with water
Drilling with water as the bailing me-
dium generally requires 570 lit/min
(150 gal/min) at a pressure of 552-690
kPa gauge (60-100 psi). This will pro-
vide a bailing velocity of approxi-
mately 50 m/min (160 ft/min). This, of
course, is dependent on the same fac-
tors as mentioned for drilling with air.
Pilot bit manufacturers recommend the
use of sealed-bearing bits for longer
bit life.
Selection of the bailing
fluid
A supply of pressurized bailing fluid
to the bit is required during pilot hole
drilling. Water, compressed air, or a
combination of the two, are typically
used.
Under normal circumstances, water
alone is the preferred bailing fluid be-
cause of its ease of handling and dust
suppression qualities. For this reason,
bailing fluid selection is usually depen-
dent upon the availability of water at
the site.
Bailing fluid selection guidelines are
as follows:
1. Where water is plentiful at the site and
site drainage adequate, water should
be used as the bailing fluid. If con-
servation is desired or site drainage
poor, water can be collected at the

site, settled, and recirculated using a
reservoir system.
2. Where the geological description of
the proposed raise indicates the pre-
sence of water through the section
axis of the raise, it is recommended
that water be used as the bailing fluid.
This will stop the formation of sticky
mud in the pilot hole caused by the
mix of cuttings and ground water.
Compressed air bailing fluid, or a
compressed air and water mixture,
used under these conditions forms a
mud, which cannot be efficiently lif-
ted up the hole.
3. Where water is in very limited sup-
ply, compressed air with the addi-
tion of a small amount of water for
dust suppression, say 20 lit/min (4.5
gal/min), can be used for bailing the
pilot hole. The water can be added
to the compressed air line with a wa-
ter injection elbow. If the water is
added to the exhaust line, a nozzle
should be used in the elbow to intro-
duce the water as a mist to the com-
pressed air.
4. Where water is not available, com-
pressed air alone can be used for bai-
ling the pilot hole.
5. Under special circumstances, water
can be mixed with a water-soluble
material, such as bentonite, to create
a high viscosity bailing fluid. This
type of bailing mixture is utilized in
porous ground conditions to help seal
the pilot hole walls and improve the
return of bailing fluid and cuttings to
the raiseboring site.
Recommended bailing fluid flow and
pressure values for both water and com-
pressed air are given under the heading
Bailing System in the Description sec-
tion of each machine's service manual.
Minimum bailing return velocities are
as follows:
for water Vw = 50 m/min (160 ft/min)
for air Va = 1,500 m/min (5,000 ft/min)
Bailing return velocity or pump/com-
pressor output, depending on which
value is known, can be calculated using
the following equations:
For water
Q1 = (D1sq - D2sq) x V1/24.5
Q2 = (D3sq - D4sq) x V2/1273
V1 = Q1 x 24.5/(D1sq - D2sq)
V2 = Q2 x 1273/(D3sq - D4sq)
raiseboring 53
Where
Q1 = pump output (gal/min)
Q2 = pump output (lit/min)
V1 = bailing return velocity (ft/min)
V2 = bailing return velocity (m/min)
D1 = pilot hole diameter (inches)
D2 = drill pipe diameter (inches)
D3 = pilot hole diameter (mm)
D4 = drill pipe diameter (mm)
For air
Q1 = (D1sq D2sq) x V1/183.3
Q2 = (D3sq - D4sq) x V2/1,273,240
V1 = Q1 x 183.3/(D1sq D2sq)
V2 = Q2 x 1,273,240/(D3sq D4sq)
Where
Q1 = compressor output (cu ft/min)
Q2 = compressor output (cu m/min)
V1 = bailing return velocity (ft/min)
V2 = bailing return velocity (m/min)
D1 = pilot hole diameter (inches)
D2 = drill pipe diameter (inches)
D3 = pilot hole diameter (mm)
D4 = drill pipe diameter (mm)
Site availability values should be che-
cked against recommended values when
deciding on the type of bailing fluid to
be used. If water is to be used as the
bailing fluid, the water pump supplied
should have a rating higher than recom-
mended to deal with plugged pilot hole
conditions.
Furthermore, a second water pump
with a rapid connection should be kept
on site. If air is to be used as the bailing
fluid, elevation derating values must be
applied to compressor specifications
for high altitudes.
As a precaution, the bearing and seal
design of the pilot bit to be used must
comply with the bailing fluid type. Fai-
lure to check the bit design against the
bailing fluid type can result in prema-
ture bit failure.
Provisions must be made for the dis-
charge of bailing fluid and cuttings.
After the bailing system has been de-
cided and designed, its dimensions and
location should be recorded on the site
layout drawing.
Water
Two water systems are commonly used
for bailing: non-recirculated and recir-
culated.
Talking Technically
Blooie assembly used mainly for drilling with air
or a mix of air and water.
Non-Recirculated
When water is chosen and is not to be
recirculated, the discharge handling sy-
stem should be designed to conform to
the natural layout of the raiseboring
site. This, and the design of the derrick
mounting system, will usually deter-
mine the method of transporting the
bailing discharge from the pilot hole
collaring point to the cuttings handling
area.
Site layout permitting, the derrick
mounting system and bailing discharge
handling system can be jointly designed
to direct the bailing discharge to the
cuttings handling area using the force
of gravity, as with a ditch or channel
system.
When using a steel structure with
a sunken pit, a standpipe may need to
be installed to prevent cuttings from
re-entering the pilot hole upon loss of
bailing fluid pressure. The standpipe
should be sealed at the pilot hole col-
laring point. The bailing discharge can
then be pumped from the sunken pit to
the cuttings handling area.
In other cases, it may be necessary
to construct a reservoir near the der-
rick, direct the discharge to the reser-
voir from the derrick, and pump the
bailing discharge from the reservoir to
the cuttings handling area.
 Talking Technically
Recirculation reservoir arrangement.
Bailing discharge must be directed
to an area at or near the raiseboring
site with ample storage space for cut-
tings and with adequate water drainage
or a method of water removal. If the
cuttings are to be removed from this
area, the area must be accessible by
personnel and transport equipment.
To plan for the volume of cuttings stor-
age required, use the following equa-
tions:
V1 = D1sq x L1 x FF/4,950
V2 = D2sq x L2 x FF/1,273,240
where
V1 = volume of cuttings (cu yd)
V2 = volume of cuttings (cu m)
D1 = pilot hole diameter (inches)
D2 = pilot hole diameter (mm)
L1 = depth of pilot hole at completion (ft)
L2 = depth of pilot hole at completion (m)
FF = fill factor (generally 1.3 to 1.4)
The simplest method of handling cut-
tings at the raiseboring site is to direct
the bailing discharge onto the site floor
54 raiseboring
and utilize the cuttings as site floor fill.
If this method is to be used, proper
floor drainage is required. If floor drai-
nage is inadequate, bailing water can
be pumped to a drain or into a trans-
port car with a screen liner and drain-
age holes.
Recirculation
Guidelines for transporting bailing dis-
charge when using recirculated bailing
water are similar to those shown above.
For water recirculation, the cuttings hand-
dling area must be set up as a reservoir
or series of reservoirs at or near the
raiseboring site. Design considerations
for the reservoir system include:
1. The reservoir system must separate
the cuttings from the return water be-
fore the water is recirculated, possi-
bly with a series of settling reser-
voirs. Alternatively, a series of gates
may be added to a single reservoir
to separate the discharge area from
the suction area.
2. The reservoir system must be made
watertight, usually by lining with pla-
stic membrane.
3. The cuttings collection area should
have ample storage space for cut-
tings. Refer to the equations given
earlier for volumetric calculations.
If the cuttings are to be removed,
the collection area must be accessi-
ble by personnel and transport equip-
ment.
4. The reservoir system must have suf-
ficient volume to compensate for loss
of bailing fluid return due to porous
or faulty ground conditions.
5. Water must be available at the site
to refill the reservoir system to its
proper level in the event of bailing
loss.
Compressed air and water
The installation of a blooie system and
abrasive resistant pipes is required for
bailing discharge transport when a com-
pressed air and water mixture is used
 Talking Technically

Bailing discharge
Compressed air

Abrasive
resistant pipe
Blooie Drill pipe
system
Nozzle

Compressed air and cuttings

Water injection elbow

Blooie system and exhaust pipe.

for pilot hole bailing. The pipe system given previously in the section Comp- the bailing water should be recirculated
connects to the outlet housing of the ressed Air and Water. for reasons of economy.
blooie system, and can be designed to Site planning considerations for
direct the bailing discharge to the cut- High viscosity water (mud) the transport of bailing discharge and
tings handling area. the handling of cuttings are the same
The bailing fluid and cuttings must When additives such as bentonite are as those given earlier.
be discharged into an area with ample used with water to form a high viscosity
storage space and accessibility to per- bailing fluid for reducing bailing losses, Roberto Lopez
sonnel and transport equipment if the
cuttings are to be removed from the
Water circulation.
area.
If possible, the discharge area should
be isolated from the operating area of
the raiseboring machine and any other
areas frequently occupied by personnel.
An isolated discharge/handling area re-
duces noise and dust levels for the crew,
and eliminates any danger posed by high
velocity cuttings discharge.

Compressed air
Site planning considerations for the
transport of bailing discharge and the
handling of cuttings when using com-
pressed air alone are the same as those

raiseboring 55
 Talking Technically

Cutter and reamer design

Raiseboring
components
Cutters, reamers or heads, stems
or stingers, and pilot bits are all
components of the raiseboring
system, on the opposite end of
the drill string relative to the drill,
that have direct contact with the
rock formation being drilled. This
section will discuss these compo-
nents with regards to the design,
features and benefits and how
they interface with the rock.

Rock interface
The raiseboring system includes the
raiseboring machine, drill string com-
prising pipe, stabilizers, various subs
Figure 1: The cratering and kerf breaking mechanism.
and roller reamer stabilizers for the
pilot hole, the stinger, the reamer, and
the cutters. Only the cutters come into remainder of this chapter addresses carbide insert cutters, rowed cutters and
contact with the formation for the pur- multi-row carbide cutters. randomly placed carbide insert cutters.
pose of fracturing the rock. The cutters A carbide cutter has multiple cutting Each of these cutters employs a crush-
are mounted on the reamer using sad- rows machined into an integral steel ing mechanism in which adjacent rows
dles. The stinger connects the drill string cutter hub. Tungsten carbide inserts are of steel, carbide or adjacent inserts in-
to the head. Thrust and torque are tran- placed in each of the cutting rows to duce cracks that propagate between
smitted from the machine, through the increase cutter life. each other and spall out a kerf, or frag-
drill string and stinger, to the reamer Multi-row carbide cutters are de- ment of rock (figure 1).
cutters and the rock formation. signed in the shape of a truncated cone. Disc cutters have gradually fallen out
Since the cutter interface with the The larger diameter end of the cutter of favour due to the increased diame-
rock is very important to the perfor- is designed to be mounted outboard of ters being drilled, the increased demands
mance of the raiseboring application, the the smaller diameter. on the cutters, and the introduction of
design of the cutters is important. new types of cutters more suited to the
Main cutter types current challenges. A disc cutter origi-
Cutters nally employed steel rings with dif-
There are at least four types of cutter ferent shapes on the outer diameter of
Cutters are used to excavate rock when geometry used for raiseboring appli- the ring depending on the hardness of
reaming or boxhole boring upward, or cations. These are disc cutters, kerfed the rock (figure 2). Generally, the harder
shaft sinking downward. These are mo-
unted on cutter housings positioned and Figure 2: Disc cutter, cutting ring profiles.
welded to the reamer, and are designed
to be the expendable wear item of the
raiseboring operation. Hence, they are
removable and can be replaced in the
field.
Single row steel disc cutters can be
used for raiseboring, particularly in soft
rock formations or for short raises. How-
ever, since most raiseboring occurs in
medium to hard rock formations, the

56 raiseboring

Figure 3: Steel ring disc cutter.
the rock, the blunter is the outer dia-
meter of the disc cutter (figure 3). Tung-
sten carbide insert rings have been used
widely on disc cutters over most of the
last decade.
Disc cutters are usually employed on
a domed type of reamer (figure 4), with
disc spacing between 25 mm (1 in)
and 100 mm (4 in). This spacing chan-
ges, along with the shape of the out-
side diameter of the disc cutter, relative
to the hardness of the rock and the lo-
cation on the head. Disc cutters and
domed reamers in combination served
the industry adequately in the early
years of raiseboring in soft and me-
dium applications.
The domed type reamer has declined
in popularity for a number of reasons.
Disc cutters tend to require more torque
to spall out kerfs, and this is compounded
on domed profiles. The domed reamer
Figure 5: Cuttings produced by kerf cutters.
raiseboring 57
Figure 4: Domed reamer.
design is generally difficult to work with,
difficult to measure, and difficult to ex-
pand. Although the disc cutters still have
useful applications, the industry has
moved to kerf cutters, rowed cutters,
or random carbide cutters.
Kerf cutters
Kerf cutters use an extension of the rock
failure mechanism described for disc cut-
ters. When properly spaced kerfs are
combined with sufficient cutter force,
very efficient drilling results, since the
kerf maintains almost continuous con-
tact with the formation. Interaction be-
tween adjacent paths produces shear
failure of the rock between them. Kerf
cutters tend to spall out 4 to 8 in-long
banana shaped chips and smaller, al-
most circular chips, depending on the
formation and the loading (figure 5).
Figure 6: Rock face, worked by a kerf cutter reamer.
Talking Technically
They produce a pattern of grooves on
the drilled rock face relative to the spa-
cing between the cutter rows.
Compared to randomly placed car-
bide insert cutters, kerf cutters tend to
require higher thrust and torque to spall
out chips, but are more efficient if suffi-
cient load and torque are available. Gro-
oves between the inserts aid in cuttings
removal (figure 6).
Kerf cutters have historically been
designed to reproduce the geometry of
disc cutters with row spacing between
25 mm (1 in) and 100 mm (4 in).
However, most of the kerf cutters used
in the raiseboringmarket today have
the ability to provide 25 mm (1 in) and
50 mm (2 in) spacing. Usually one cut-
ter geometry is utilized to produce 50
mm spacing, and both geometries are
used to produce 25 mm kerf spacing.
Kerf cutters are not as flexible as disc
 Talking Technically
Figure 7: A pair of Magnum kerf cutters.
cutters because the latter can be rearr-
anged individually for each cutting row.
The kerf cutter is generally emplo-
yed in flat or barrel-shaped profiles,
rather than in domed profiles. It is ge-
nerally less expensive to operate, since
fewer saddles are required to cover dia-
meters in medium to hard rock condi-
tions, and the bearing component is not
required for each row of carbide as for
a disc cutter.
Each kerf cutter design provides cer-
tain benefits to the application. The RCC
cutter design, for instance, provides a
Figure 8: A RCC11 cutter.
58 raiseboring
cutting structure with more relief within
the rows for better cuttings removal,
and can provide true 50 mm row spac-
ing. With both cutters run in pairs, the
row spacing becomes a true 25 mm.
When coverage from both cutters is not
required on the gauge row, these can
be staggered to provide an extra inch
in the length of coverage in the cutting
path. This can reduce the number of cut-
ters required on larger heads, and in-
crease unit loading.
This cutter also utilizes a 14 degree
cone angle, which provides true rolling
at smaller diameters than possible with
flatter cutter designs, and non-true rolling
at larger diameters. In soft and medium
ground this non-true rolling can enhance
penetration rates, as the cutter tends to
include an element of rock shear to en-
hance the crushing action.
The Magnum cutter design is longer
and flatter than the RCC cutting struc-
ture, so it employs true rolling in a
slightly larger diameter. This provides a
true 25 mm row spacing, but not quite
true 50 mm row spacing, since both cut-
ters employ insert rows spaced 25 mm
apart, either on the gauge (MKC55G) or
the nose (MKC55N) (figure 7). This
cutting structure allows for extra cove-
rage on the nose of the cutter and the
gauge of the cutter, when run in pairs.
This feature provides longer life in
transition areas where carbide is stres-
sed more than in the flat areas of the
head. The paired cutters can also be
staggered to provide an extra 50 mm
in the cutting path coverage, which
can reduce the number of cutters used
on larger heads, and will increase unit
loading.
In addition, the Magnum insert pat-
tern within each row is designed to re-
duce the incidence of tracking by em-
ploying an increasing or decreasing pitch
between inserts. This patented insert lo-
cation has proven to physically reduce
tracking.
The kerf cutter has become the in-
dustry standard, while rowed cutters and
random cutters have been relegated to a
smaller role in the raiseboring market.
Carbide rowed cutters
Carbide rowed cutters perform some-
where between the kerf cutter and the
random insert cutter (figure 8). Eleven
distinct rows can be seen on this cut-
ting structure, hence the nomenclature
RCC11. The nose and gauge of this cut-
ting structure are reinforced to improve
life, but the inner rows have reduced
numbers of carbide to improve cuttings
removal and enhance penetration rates.
The rowed cutter design has multi-
ple rows of inserts, but no steel kerfs.
The lack of kerfs allows more room for
cuttings removal, affords less oppor-
tunity for abrasive formations to wear
away the cutter shell, and facilitates
 Talking Technically

greater penetration of the inserts into

the formation, with less power con-
sumption.
The staggered insert location, lighter
insert coverage on the inner rows, and
multiple rows, tends to decrease the tor-
que requirements, in somewhat similar
fashion to the random cutting structure.
The rows of inserts allow for rock kerfs
to spall out of the formation. These are
generally smaller than for a pure kerf
cutter design, since the spacing between
rows is smaller. The rowed carbide cut-
ting structure design also employs the
method of skip pitch on inserts within
the row. The pattern on the rock forma-
Figure 9: Cuttings produced with random cutters.
tion is somewhere between the pattern
left by the kerf type cutting structure
and that of the random insert location pressure bulbs. No discernable pattern Bearing and seal design
cutting structure. or row is evident on the cutting face,
except at the nose and gauge of the Bearing designs have evolved into two
Random insert cutters cutter. An additional benefit of the ran- distinct types, known as preloaded ta-
dom insert location is a reduction in pered roller and roller-ball-roller.
Random insert cutters offer a fairly tracking. Tracking occurs when the in- Examples of both of these designs are
dense axial coverage in a complete re- sert slips into a pressure bulb crater shown in figure 11.
volution by placing inserts in a random created by the previous pass of the cut- The tapered roller bearing uses off
pattern on the cutter shell. ter. It can wear the edge of the insert the shelf bearings with integral bearing
This design has shown significant in- prematurely and result in shear failure races. This type is preloaded using spa-
creases in drilling rates, while reducing of the carbide, reducing the penetration cers between the bearings and is very
drilling torque, which is beneficial where rate. Tracking can be reduced in non- impact resistant.
the length of the raise or the rock for- random cutters by varying the angles The roller-ball-roller utilizes carbu-
mation are outside the scope of a ma- between the inserts in a given row. rized races, which are machined into the
chines capabilities. The random cut- The random location of the inserts journal and shell along with roller and
ter spalls out small circular chips of helps produce a new pattern with every ball bearings made from high quality
approximately 1.5 in diameter (figure 9). pass of the cutter. As a result of this bearing steel. Unlike the tapered bear-
Multiple passes of the cutter can provide design, efficient drilling can be achieved ing, this approach does not require a
a wide range of insert spacing on the over a wide range of rock conditions, preload.
formation. Rock failure occurs when independent of kerf spacing. Figure 10 Special greases are used that enhance
sufficient passes have been made to shows a random cutter cutting structure. the seals, while additives provide high
achieve the shear failure between insert load carrying capacity to the bearings.

Figure 10: Random cutter cutting structure. Figure 11: Preloaded tapered bearing and roller-ball-roller bearing systems.

raiseboring 59
 Talking Technically
Figure 12: 1.8 metre integral head.
Both cutters employ metal face seals fea-
turing two metal rings and two elasto-
mer o-rings on either end, to maintain
the resiliency of the seal under ope-
rating conditions.
Reamers
Reamers are available for excavating
a wide range of raise diameters in varying
rock conditions. The reamer is attached
to the drill string by means of a Dl-22
threaded connection on the reamer
stinger. The stinger is normally remov-
able from the reamer, but, in a few in-
stances, it is an integral part.
Cutters are held securely to the rea-
mer by steel cutter housings, or saddles.
These are generally fastened to the main
reamer body by welding, but bolting
may be used near the centre of the as-
sembly. The bolted design enables these
housings to be detached and reposi-
tioned on the reamer. This allows for
removal of the stinger, and the use of
different drill string sizes with the same
reamer.
Positioning of cutter housings and
cutters on the reamer has to be exact
for efficient boring performance. Cutter
60 raiseboring
housings are located precisely on the
main reamer body using dowel pins, so
that the cutter housing may be removed
for rebuild or replacement in the field.
Cutter housing locations can be re-
checked in the field using a profile check
assembly, which is a precisely notched
steel template of the exact radial position
of each cutting row of the reamer. The
profile check assembly permits this tem-
plate to be installed at the centre of the
reamer and swung 360 degrees about the
reamer's cutting profile. In this way, the
positions of the cutting rows of each
cutter can be checked against the po-
sitions located on the template.
Reamers equipped with water spray
systems for cutter cooling and dust sup-
pression are available on request.
The general cutting profile of the
reamer is flat, with a slightly depressed
angle at the stinger, and a standard be-
vel at the gauge area. This flat profile
reduces the number of cutters needed
to excavate the desired raise diameter.
With fewer cutters on the reamer, less
torque is required to rotate the reamer,
which leads to more efficient drilling.
The bevel at the gauge area adds ream-
ing stability.
The reamers are designed with several
paired cutter housings. Both housings
of each paired set are an equal distance
from the centre of the reamer.
Cutters multi-track at the inner and
outer transition areas between the flat
and bevelled parts of the reamer profile
to offset the high stress and wear nor-
mally expected at the corners of these
transition areas.
Head design
Reamers or heads are designed in dif-
ferent ways for several different require-
ments. Some of the standard head designs
are integral heads, expandable or mo-
dular heads, downreaming heads and
boxhole heads. Other heads are gene-
rally modifications of one of these four
designs.
Integral heads
Integral heads are designed to drill a
single diameter. They are generally
cheaper, stronger and shorter than ex-
pandable or modular designs, because
there is no attachment mechanism re-
quired to expand the reamer or head to
a larger size. Integral heads may have
integral or replaceable stems or stingers.
Integral heads may be as small as
65 cm (26 in) diameter, but generally
range in size from 1 m (39 in) to 3 m
(10 ft). Some of the general features
for integral heads are low profile design,
open spaces for cuttings removal, and
ability to cover the prescribed dia-
meter.
Examples of integral heads are
shown in figure 12. They are used in a
number of applications, including slot
raising, where diameters rarely change.
Expandable or modular
head design
Expandable or modular heads are de-
signed for easy change of diameter, ac-
cording to the requirements of the mine.
They all employ replaceable stems or
stingers.
Two examples of expandable or
modular heads are shown in figure 13.
Critical features for an expandable or
modular head design are: the head
should provide the diameters required;

Figure 13a: Mini superbase with 4.0 metre extensions.
the head and wings are small enough
to be transported and assembled on site;
the head is rigid enough to function at
the diameters required; the head cleans
rock cuttings; and the attachment mech-
anism is simple, effective, easy to ope-
rate and quick to assemble.
The attachment mechanism is very
important to the design of the head, and
may range from a simple bolted flanged
connection, to the dowels and keys and
wedges.
There are a number of attachment
mechanisms available to keep wings
attached to the base head. The simple
bolted connection is used frequently in
the industry, and may require torque
tools ranging from hand tools with mul-
tipliers to hydraulic torque tools depend-
ing on the diameter of the bolts and the
torque required. An example of a simple
Figure 14: Attachment using a simple bolted
connection.
raiseboring 61
Figure 13b: RRS reamer in 2.4 metre mode.
bolted connection is shown in figure
14. Wing attachment mechanisms also
include this design, which incorporates
dowels to locate the wing easily, and
keys and bolts to handle the loading.
Figure 15 shows a design that incor-
porates all of these features. Using hy-
draulic torque tools, the wings are as-
sembled easily and quickly to the base
head.
Wedge, bolt and dowel mechanisms
are also utilized to attach wings to base
heads very effectively.
Figure 16 shows one such method,
allowing small diameter 25 mm bolts
to be used to attach the wing.
This design employs only two wings,
rather than the standard four wing
design. Two dowels, two wedges, and
24 off 25 mm bolts are required to hold
the wing in place.
Figure 15: Attachment using dowels for guiding and
a combination of bolts and keys to handle the load.
Talking Technically
Expandable or modular bases are well
adapted to the right drilling application,
but there are other jobs that require a
different set of design requirements.
These include boxhole and down
reaming applications, where different
machines are used, requiring different
designs.
Boxhole heads
Use of boxhole heads has decreased
in recent years. These are designed to
drill upwards, being pushed and rotated
by the machine.
Commonly, a boxhole will follow
a pre-drilled pilot hole Alternatively,
the pilot hole may be drilled as part of
the boring operation.
The connection to the drill string
is either through a flanged connection
Figure 16: Attachment using a combination of
wedge, bolts and dowels to handle the load.
 Talking Technically
Figure 17: Boxhole reamer.
or a DI22 connection on the bottom of
the head, or both (figure 17).
Boxholes are generally used where
there is limited top access, or when it is
financially more feasible than a raised
hole. Boring boxholes may be the pre-
ferred method of raising because of
poor ground conditions, or because of
its better profile. The most common box-
hole diameters range from 1.5 m (60 in)
to 1.8 m (72 in), with a maximum dia-
meter of around 2.1 m (84 in).
Figure 18: 720 mm down reamer.
62 raiseboring
Down reaming heads
Down reaming heads follow down an
existing pilot hole from the raiseboring
machine, employing rotating or non-
rotating stabilizers. In general, down
reaming is used when the ground con-
ditions preclude attaching the reamer at
the bottom of the pilot hole and reaming
back toward the machine. Most down
reaming heads have been relatively small
in diameter, due mainly to the require-
ments in the market. Historically, down
reamers have utilized two cutters to ream
from the pilot hole out to the final dia-
meter, but recently three-cutter versions
have been utilized, which bore faster and
smoother. Down reamers are generally
designed with a built-in stabilizer and
a stem or stinger, with replaceable nose
guide. Some down reaming heads can
be used as an integral raiseboring head.
Figure 18 shows a version of the current
down reamers used in the industry.
Non-standard heads
There are a number of other head de-
signs based on customer requirements
which include heads adapted to drill at
low angles or completely horizontal, as
well as a number of other specialized ap-
plications where access may be limited,
dangerous or unprofitable with stand-
ard designs.
Stinger designs
Stingers, or stems, are a critical part of
the raiseboring process. These are made
from high strength steel, and connect
the drill string to the head, transfering
the thrust and rotation from the raise-
boring machine to the head under a
great deal of stress. The stinger con-
nects to the drill string with a Dl-22
threaded connection.
Stinger designs have changed over the
years, and a number of different types
are still used in the industry. These are
known as weld-in, Taperlok, Bikon and
flanged stingers.
Most stingers are removable from the
reamer, so that transportation dimen-
sions are reduced, and a single reamer
will suffice for different pilot hole sizes
and raiseboring machines. Reamer
repair down time is also reduced in
the event that a stinger is damaged.
The upper portion of the stinger re-
mains in the pilot hole during reaming,
and is designed to act as a stabilizer. It
is wear resistant against the abrasiveness
of direct rock contact. Stingers having
more than 6.4 mm (0.25 in) wear on
their outer diameter should not be used
until rebuilt.
Designs of the upper portion of the
stinger differ, with some having a re-
placeable wear sleeve. Other stingers are
hard-faced using multiple weld passes
of extremely hard metal alloy, or ribs
embedded with tungsten carbide inserts.
Hard-faced wear ribs can be an integral
part of the stinger, or welded-on wear
pads. Each of the above types has its
advantages.
The wear sleeve and welded-on wear
pads can be replaced in the field. The
tungsten carbide insert type offers ex-
tended wear resistance, but cannot be
replaced when worn.
Weld-in or integral
stingers
Some stingers, especially on smaller
heads and downreamers, are either
machined directly into the head, or
welded in place. These are generally very
similar to replaceable stingers, and may
have wrench flats, burnout rings, flex
points or other design features requested
by the client.
 Talking Technically

For example, with down reamers a

pocket is relieved in the stinger to accept
the closest cutters.

Bikon stingers
Bikon stingers are fitted using large ta-
pered dowels and clamp rings, are very
reliable, and are relatively cheap to
manufacture. In the standard capacity
design, approximately 100 bolts have to
be torqued to specifications to keep the
stinger in place (figure 19). The Bikon
design comes in sizes commonly used in
raiseboring, and is the only standard
stinger type that can be lowered into
the head from above.

Taperlok stingers Figure 19: The Bikon stem connection.

Taperlok stingers are installed using a
hydraulic injection system, in which a the pilot hole. Pilot bits used in raise- up, or the bit reamer-stabilizer during
mating taper in the head is expanded boring are equipped with an API regu- pilot hole drilling.
and the stem is pressed into place. The lar threaded pin for connection to either
mating taper is then allowed to shrink the starter sub during pilot hole start Steve Brooke
to its original geometry. The Taperlok
is one of the most reliable stingers, but Figure 20: Taperlok stem. Figure 21: Flanged stem.
its design is very dependent upon exact
geometry and cleanliness, which is not
easy to attain underground. The manu-
facturing cost is lower than for other
designs, but special hydraulic pumps
and injection tools are required.
Figure 20 shows an example of the
Taperlok design.

Flanged stinger
Flanged stingers are attached to the head
using bolts and dowels. They have be-
come the industry standard over the
years, see figure 21. The flanged stinger
is designed to fit all standard pilot
holes used in raiseboring. The assembly
requires an adequate lifting device and
torque tool. This design is very strong
under tension, but has some limitations
when loaded in compression, such as
when removing a stuck head from a hole,
or putting the weight of the drill string
on the head. The flanged stinger design
is more expensive to manufacture than
most other designs, due to material costs.

Pilot bits
The pilot bit is installed at the bottom of
the drill string and utilized for excavating

raiseboring 63
 Talking Technically

Raiseboring drillstring
components
Safe mechanical
connection
The drill string is the mechanical
connection between the cutting
components and the raiseboring
machine. It is hollow, to allow the
passage of fluid for cooling and
removal of cuttings. It is sufficient-
ly robust to consistently transmit
rotational and thrust forces from
the machine to the pilot bit or rea-
mer, and to provide support for
the reamer in the raise when ad-
ding or removing drill string com- Drill pipe
ponents. The design of the drill
string must always be compat-
ible with the machine on which
it is used. Atlas Copco drill string
components are designed for pur-
pose and manufactured in lengths
that are easy to handle, store, and
transport. Crucially, they are sized
to be readily installed and removed Six-rib stabilizer
from the derrick of the raiseboring
machine, making them safe and
efficient in use.

Drill string
Bit reamer-
The drill string is commonly known as all stabilizer
the components used for the drilling ope-
ration, including the drill pipe, subs, and
stabilizers. Pilot bit

Bottom pack
Bottom pack is known as the bottom sec-
tion of the drill string that determines the
pilot hole diameter. These are made of the Reamer
tricone bit, roller bit sub, and stabilizers.
These can vary from standard configura-
tions to fit the requirements.
Pilot drilling and reaming.

Starter pipe
Starter pipe is required for pilot hole
start up, this pipe is different from re-
gular drill pipe only in that outer diam-
eter are machined. They are available in
various lengths and diameters depend-
ing on the application. The starter pipes
are used in conjunction with the starter
bushing.
Starter sub
The starter sub is connected directly to
the pilot bit during initial stages of pilot
hole startup. It is equipped with a DI-22
threaded pin and an A.P.I. thread on the
box end to accommodate the tricone
bit. This component is used in conjunc-
tion with the starter pipes.
In addition to the wrenching areas
located near the upper DI-22 threaded

64 raISEBORING
 Talking Technically

pin, the sub is equipped with wrench-

ing areas near its lower A.P.I. threaded
box end.
These lower wrenching areas enable
make up of the floating box starter sub
connection without reacting machine
torque through the weaker A.P.I. starter
sub pilot bit connection. The use of the
lower wrenching areas is necessary for
this makeup when there is insufficient
distance between the machine work ta-
ble and the collaring surface to utilize
the upper wrenching areas of the starter
sub.

Stabilizers
Stabilizers are connected in the drill
string adjacent to the cutting compo-
nents. They reduce pilot hole deviation,
maintain the full gauge diameter of the
pilot hole, and reduce bending stresses
in the drill string during raise reaming.
Two stabilizer types are used in raise-
boring.
Bit reamer stabilizer
Rib stabilizer
Bit reamer stabilizer
The bit reamer stabilizer is installed ad-
jacent to the pilot bit during pilot hole
drilling. It is equipped with a DI-22
threaded pin at its upper end and an
Bit reamer stabilizer.
A.P.I. regular threaded box at its lower
end. The bit reamer stabilizer uses three
or six cylindrical rolling cutters to
ensure the pilot bit is centred and uni-
formly loaded in the pilot hole. It is the
function of the cutting roller on the bit
reamer stabilizer to maintain the cor-
rect pilot hole diameter, compensating
for any wear on the tricone bit. This
will ensure that the pilot hole is to the
proper dimensions for the stabilizers.
Rib stabilizer
A number of four-rib or six-rib stabi-
lizer are added to the drill string after
installation of the pilot bit reamer sta-
bilizer.
These types of stabilizer are manu-
factured with a DI-22 threaded pin
and box at opposite ends. The number
of six rib stabilizers used in the drill
string can vary from one raise to the

Straight and spiral stabilizers are available.

raISEBORING 65
 Talking Technically

next according to specific factors of the

particular raise. The rib design can be
straight or spiral depending on the appli-
cation. The stabilizer can be considered
as the primary guide maintaining direc-
tion of the pilot hole.

Shock absorbers
A shock absorber is a specially desig-
ned component that is available for the
pilot drilling. The shock absorber adds
suspension to the drill string, helping
the bit to ride the rough bottom of the
hole, reducing movement throughout
the whole drill string. This movement
is taken up by springs in the shock sub.
The load on the bit is then more constant,
and vibration is taken up by the shock
sub. These components are specially
designed to control the very high cyclic
A typical section of raiseborer drill pipe.
loads generated as the bit cones go over
the higher and lower areas at the base
of the hole. Stress or flex modifiers Reamer
Drill pipe float valve Stress modifiers or flex modifiers are The reamer head is used to back ream
specially designed drill string compo- the pilot hole. Various design types
The float valve is used during pilot hole nents designed to flex the connection of cutters and reamers in a choise of
drilling to act as a check valve, preven- between the reamer head and the drill diameters are available depending on
ting reverse bailing fluid flow from en- string. the specified ground conditions and
tering the drill string through the pilot Unlike the saver sub the stress or customers needs.
bit upon a depressurization of the bailing flex modifiers are designed, to absorb
fluid in the drill string. bending forces without breaking. Roberto Lopez
Depressurization is necessary when
adding or removing drill string compo-
Secoroc pilot bits for raiseboring.
nents at the derrick assembly. Before
pilot hole start up, the float valve is in-
stalled into the lower end of the bit-
reamer stabilizer adjacent to the pilot
hole drill bit

Pilot bit
The pilot bit is a tricone type bit used
for drilling the pilot hole. Various types
of bits are available depending on the
specified ground conditions.

Saver sub
The saver sub is a small section of pipe
with threaded connection to match the
drill string and the stem or stinger.
Its function is to serve as a fuse and
absorb all the bending forces between
the reamer and the stabilizer. This com-
ponent is designed to break and protect
the stabilizer connection.

66 raISEBORING
 Boxhole Boring at El Teniente

Boxhole boring at El Teniente

The lieutenant Basic facts in new operation
Main caving level

marches on
Level: 2,210 m above sea level.
Drifts: 15 m. Section: 3.6 x 3.4 m.
Caving with horizontal cut: 4 m in height.
State owned Codelco is Chiles lar- Production level
Level: 2,162 m above sea level.
gest company and the worlds lar- Drifts: 30 m. Sections: 4.0 x 3.6 m.
gest producer of refined copper. Draw Bell: 17.3 m
The Codelco-owned El Teniente
(The Lieutenant) mine is presently Orebody (narrow cut)
the worlds largest underground
mining operation. The mine ave-
rage production rate is currently
126,000 t/day. Boxhole boring be- Slot hole
tween the production and haulage 0.7 m diam/15 m long
levels using Atlas Copco Robbins
machines is a major component in
achieving such high outputs. Production level
Recently, two raiseborers mo- Loading, LHD
Robbins
dified to suit the El Teniente mine Dumping 34RH
conditions were commissioned by Ventilation
Atlas Copco. They were evaluated Orepasses shaft, 1.5 m
for three months, during which diameter
time the crews were trained in 45 m long
their operation. Both exceeded the Ventilation shaft, Tapping (max: 75 m)
set target performance criteria. 1.5 m diameter
35 m long

Introduction Robbins
53RH Transportation level
Codelco, renowned for its refined copper
output, is also the second ranked world
supplier of molybdenum, as well as being Ventilation level
a major producer of silver and sulphuric
acid, both of which are by-products of its
core copper production. Mining method at El Teniente.
The El Teniente mine, located high
in the Andes at an elevation of 2,100 m,
has been producing copper since 1904.
The orebody is 2.8 k m-long by
The 3.6 x 3.6 m operating limits at
1.9 km-wide, and is 1.8 km-deep, with
the mine work sites demanded an
proven reserves of some 4,000 million t, extremely low reamer design with
sufficient for a mine life of 100 years. a quickly detachable stinger.
Approximately 2,800 miners work This reamer is bolted onto the
seven levels on a 24 h/day, 7 day/ week machine when not in use.
operation. When piloting, the stinger is
El Teniente production increased si- removed from the reamer, to allow
gnificantly in 2005, when its new Es- the drill string to be fed through.
meralda section came on line, using the In reaming mode, the stinger is
pre-undercut panel caving method. Over- refitted using the pipe loader,
all mine output has increased by 31,000 and the locking bolts are
t/day, with 45,000 t/day coming from tightened manually.
the Esmeralda Project, making it the
most important sector in the mine. The
two new boxhole boring systems sup-
plied by Atlas Copco Robbins are a
vital part of this production system.

raiseboring 67
 Boxhole Boring at El Teniente
Schematic of equipment layout for boxhole boring.
Mine requirements
El Teniente tendered for the purchase of
two boxhole boring units to excavate
the draw bell slot holes for the panel ca-
ving operation. These units would also
be used to bore ventilation raises and
ore passes between the production and
the haulage level. The vertical draw bell
slots are generally 15 m-long and 692
mm-diameter. A total of 800 m, com-
prising 45-50 shafts, are bored annu-
ally.
Because drifts have not been deve-
loped on the production level, all venti-
lation raises and ore passes are bored
from the haulage level and upwards
using the boxhole boring technique. The
average length of the vertical and in-
clined ventilation raises is 25-50 m. The
inclined ore passes average 25 m-long,
but this varies up to 75 m-long. The total
annual requirement for 1.5 m-diameter
bored raises is 1,000 m.
Restrictions are placed on the ma-
chine design by the size of the under-
ground sections. Work sites measure
3.6 x 3.6 m, and maximum transporta-
tion dimensions are 2.5 m-wide x 2.5 m-
high x 4.8 m-long. The machines must
either be self-propelled or transported
on rail, and have to have tramming and
directional lights, as well as a fire extin-
guisher system. The mine electrical in-
stallations provide power at 575-4,000
68 raiseboring
V, 3-phases at 50 Hz, and 24-220 V, sin-
gle phase at 50 Hz. Each machine is de-
signed for three, or less, operators per
shift.
The operating environment is 2,300 m
above sea level, with teperatures from
+25 degrees C to 0 degrees C. Relative
humidity varies from 15% to 90% in
the mine, where acid water and occa-
sional blast vibrations may be experi-
enced. Both machines are operated 24
h/day, 7 days/week, with a maximum
machine utilization of 15-16 h/day.
Evaluation period
An evaluation period of three months
was established to study the performance
capabilities of each machine. Target per-
formance criteria for the smaller slot
hole machine was set at 264 m bored
during the three month period, and 330
m for the larger boxhole machine.
This performance target was based
on a 24 h/day operation, with net av-
ailable operating time of 15-16 h. The
number of operating personnel required,
set-up and moving time, the rate of pe-
netration and machine availability were
all recorded during evaluation period.
Atlas Copco boxhole boring units
Robbins 34RH and 53RH were found
to meet the requirements of the up-hole
boring tender, and were selected by the
mine. Built on the experience of the
52R, the 53RH multi-purpose machine
has been developed since the early
1980s. The 34RH has been used as a
raiseboring and downreaming machine
for a similar period, and was first intro-
duced in the boxhole configuration in
1998. To accommodate the restricted
working space in the mine, the already
low-profile 34RH and 53RH had to be
redesigned to further decrease the wor-
king height. Both machines are self-
propelled, and equipped with efficient
muck collectors, remote-controlled pipe
handling and automatic data logging.
Atlas Copco Robbins 34RH
The Robbins 34RH is a low profile,
small diameter raise drill, designed for
applications such as slot raises, backfills
and narrow-vein mining. This multi-
purpose, lightweight raise drill can be
used for downreaming and upward
boxhole boring, as well as for conven-
tional raiseboring.
The machine features a variable
speed hydraulic drive with a two stage
planetary gearbox, and hollow-centre
shaft to enable pilot-hole flushing. To
change boring methods, the Robbins
34RH is easily turned upside down, to
orient the drive head into either upward
or downward boring position.
The Robbins 34RH was already a
true low-profile raise drill. However, to
accommodate the restricted site dimen-
sions, and to allow room for a muck-
handling system on top of the machine,
the maximum working height had to
be lowered further. This was achieved
through the use of shorter high-thrust
telescopic cylinders, and by utilizing
750 mm-long by 254 mm-diameter drill
rods.
This reduced the working height of
the assembly to 3.6 m, including the
muck handling system.
The new muck handling arrange-
ment, which had been fitted on two ear-
lier Robbins 34RH machines commis-
sioned in 1998 and 1999, has been
further developed for efficient muck
collection in the boxhole boring mode.
The remote controlled and hydrauli-
cally operated muck collector is fully
integrated into the derrick assembly, and
remains on the machine, even during
transportation.

During pilot hole drilling and rea-
ming, the rubber sealed muck collector
is applied adjacent to the rock face. The
muck slides on a chute assembly to the
rear of the machine.
The two earlier Robbins 34RH ma-
chines featured a 270 degree working
range, with muck spilling to either side
or to the rear end of the machine, whereas
the muck chute on the new El Teniente
34RH machine has a working range of
90 degrees, due to simpler and more
compact design.
The Robbins 34RH features a remote
controlled hydraulically operated slide-
opening worktable for use in both down-
reaming and boxhole boring applica-
tions. The entire drill string, including
boxhole stabilizers and reamer, can pass
through the worktable of the machine.
The standard frame Robbins 34RH
currently in use at El Teniente accom-
modates a 692 mm-diameter reamer
through the worktable, while a wide
frame model of the 34RH accommo-
dates a 1,060 mm-diameter reamer.
The Robbins 34RH worktable is
equipped with semi-mechanized wren-
ching, which features a hydraulically
powered forkshaped wrench mani-
pulated from the operators control
console.
The rod handler is designed to pick
up all drill string components, includ-
ing boxhole stabilizers and reamer.
Robbins 53RH
The Robbins 53RH is a low profile,
medium-diameter raise drill, suitable
for boring orepasses and ventilation
shafts. It is a versatile multi-purpose
machine, capable of boring upwards
boxhole, downreaming, or conventio-
nal raiseboring, without modification
to the drive assembly.
It has a hydraulic drive to enable
variable rotation speeds and has dual
drive motors placed offline on a gather-
ing gearbox that transmits torque to the
drive heads.
The Robbins 53RH features a raise-
boring and a boxhole float box, which
allows the boring methods to be chan-
ged by simply installing drill rods in
either the upper or lower float box. In
addition, this multi-purpose unit is pro-
vided with a removable water swivel, to
raiseboring 69
Boxhole Boring at El Teniente
Robbins 53RH set up underground.
facilitate pilot bit flushing in both raise-
boring and boxhole boring modes.
The El Teniente machine has been
substantially upgraded from previous
versions of the Robbins 53RH, to in-
crease its productivity and working
range. The input power has been increa-
sed by 31% to 225 kW, the torque has
been increased by 44% to 156 kNm,
and the thrust by 21% to 3,350 kN.
To achieve the same low profile as
standard Robbins 53RH machines, high
thrust telescopic cylinders have been
used. This has resulted in a machine
with an overall height of just 2.9 m that
utilizes 750 mm-long drill rods with an
outer diameter of 286 mm.
For ease of operation, the unit is
equipped with semi-mechanized wren-
ching in the worktable, as well as the
headframe. This features a hydrauli-
cally powered forkshaped wrench ma-
nipulated from the operators control
console.
The larger Robbins 53RH does not
feature an opening worktable, as the
wings of the stabilizers and the reamer
are attached on top of the machine.
Muck is handled by a separate col-
lector system designed to suit the ma-
chine. Unlike the Robbins 34RH, this
muck collector is not integrated into
the machine design, but is attached to
the rock face by means of rock bolts.
As it is separated from the derrick
assembly, this remote controlled, hy-
draulically operated system provides a
360 degree working range for channel-
ling the muck away from the machine.
The remote controlled rod handling
system on the Robbins 53RH is used for
side and ground loading of drill pipes.
This configuration of pipeloader has
previously been used on all other
Robbins models, and is now available
on the 53RH. Due to the restricted ma-
chine dimensions, it is not possible to
add the stabilizers within the machine
frame. Instead, the pipeloader inserts
a stabilizer pipe with stabilizer wing
attachment sleeves.
Once this is pushed through the
headframe, the lightweight stabilizer
wings are attached to the sleeves be-
fore continuing on through the muck
collector, and into the hole.
A new reamer handling system has
been integrated into this machine de-
sign to eliminate the handling of the
reamer at each set up. The reamer has
been designed to bolt on top of the head-
frame during transport and erection.
The hollow centre design of the reamer
still allows prepiloting of the hole if de-
sired, in which case a special stinger
is inserted through the headframe and
into the reamer, whereas the reamer is
unbolted from the machine frame and
attached to the stinger. The diesel trans-
porter used for this machine is sized to
 Boxhole Boring at El Teniente
Diesel powered crawlers are used for transporting Robbins 34RH and Robbins 53RH.
accommodate the derrick, including the
attached reamer.
Additional equipment
The boxhole boring machines working
in El Teniente were each delivered with
a diesel powered crawler, for rapid
movement of the derrick from site to
site. The newly designed crawler fea-
tures a cordless remote controlled ope-
rating system and a high-power Deutz
diesel engine for high-altitude operation
and minimal environmental impact.
To give the mine better control over
machine productivity, a Data Acqui-
sition System was delivered with each
machine. This records operating vari-
ables in real time, and stores them on
a memory card. It also features a dis-
play panel that shows the parameters
being recorded. The machine operator
can view any variable, as well as current
time and date, and battery life during
operation.
The recording brick is configured to
log data to the memory card every 30
seconds. During the interval, variables
are continuously monitored and key
points are logged. The Data Acquisition
System is provided with a data analysis
software package which processes the
output from the recording brick stored
on the memory card, and creates gra-
phical plots of the data. The software
also generates data files that can be
inserted into spreadsheets.
70 raiseboring
Raise drill performance
As the use of boxhole boring units was
new to El Teniente mine, the evaluation
period was preceded by startup and
commissioning of the machines. After
approximately four weeks of training
and commissioning, the machines went
into full 3-shift production, and the three
months evaluation began.
Robbins 34RH evaluation
The startup period for this machine type
included classroom and maintenance
training, and the drilling of three rai-
ses. The average net penetration rate
achieved was 0.8 m/h, or 3.9 m/day. The
startup period was strongly affected by
lack of water to flush the pilot bit, poor
ventilation, and availability of concrete
pads in the working area. However, lear-
ning progressed steadily, and the ope-
rating crew was ready to begin the eva-
luation period at the completion of one
months training.
During the three-month evaluation
period, seven raises of approximately
14 m in length were drilled each month.
The average production rate was 93.3 m/
month, with a total production of 280.1
m for the entire period. This exceeded
the monthly target rate of 88 m and
264 m for the full period. The average
rate of penetration during the three
months was: 1.80 m/h; 2.15 m/h; and
2.17 m/h. Machine utilization during
the evaluation period was 29.8%, with a
mechanical availability of 95.5%.
Lack of access to the machine due
to shift changes, blasting and non-worked
weekends had the greatest negative
affect on machine utilization. The se-
cond largest contributing factor was
lack of site availability. During the com-
pletion of 20 production holes, the ave-
rage move and set-up time was between
10 and 12 h. Drilling each hole took two
days, which compensated for the low
machine utilization, and provided a high
rate of production.
Some downtime resulted from the
replacement of instruments broken by
rock falling from the face, and time
was also taken to improve the protec-
tion of these parts. The boring cycle in-
cluded pre-piloting of 1 to 2 m, depen-
ding on the ground conditions. After
that, the hole was bored to full diameter
in a single pass. The 692 mm reamer
mounts two RCC raiseboring cutters,
and an attachment for the bit sub and
pilot bit. During single pass boring, the
279 mm pilot bit is also engaged in cut-
ting the rock. To ensure adequate flush-
ing of the cuttings past the bit-sub, water
was pumped through the centre of the
drill string to the tricone bit.
As the drilling took place on the
production level of the block caving
operation, the hole actually broke
through into the broken ore. As there
is no access to the head, it was critical
to observe any changes to thrust and
torque on the machine, to know when
breakthrough occurred. The moment
breakthrough was achieved, boring was
stopped, as any further advance could
result in the reamer getting stuck.
Robbins 53RH evaluation
In addition to classes and maintenance
training on the Robbins 53RH, a couple
of holes were drilled as part of the com-
missioning. Again, the startup period
was strongly affected by lack of water,
poor ventilation, and availability of
concrete pads in the working area. How-
ever, as the personnel were, by this time,
well-trained raiseboring operators, the
evaluation period could begin within a
few weeks.
During the three month evaluation
period, three raises of approximately
 Boxhole Boring at El Teniente

40 m in length were drilled each month.

The average production rate was 111.1 m/
month, and total production was 333.2 m
for the entire period. This exceeded the
monthly target rate of 110 m and 330
m for the full period. The average rate
of penetration during the three months
was: 1.12 m/h; 2.60 m/h; and 1.63 m/h.
Machine utilization during the evalua-
tion period was 40.3%, with a mechani-
cal availability of 91.3%.
Machine utilization was again nega-
tively affected by non-worked week-
ends, blasting near the drill site, and
shift changes. The next largest factor
contributing negatively to machine uti-
lizations was site availability due to site
cleaning, waiting for concrete pads, and
the availability of electricity and water.
During the completion of nine produc-
tion holes, the average move and set up
time for the machine was between 13
and 15 h. As drilling of a hole could be
completed in a little more than 6 days,
a high production rate was achieved,
despite the low rig utilization.
The boring cycle included pre-piloting
of 2 to 3 m, to ensure the straightest
hole possible. This also facilitated easier
reamer collaring, by reducing devia-
tion caused by the dead weight of the
reamer head.
Following completion of the pilot,
the hole was bored to full diameter in
a single pass. The 1.5 m reamer mounts
eight RCC raiseboring cutters, and an
attachment for the bit sub and 311 mm
pilot bit. As with the smaller machine,
water was pumped through the centre
of the drill string to the tricone bit, to
ensure adequate flushing of the cut-
tings past the bit sub.

Conclusion
The application environment in the
El Teniente mine placed high demands
on the boxhole boring equipment sup-
plier, both in size constraints, and in
operation of the equipment. The mine
personnel also had aggressive perfor-
mance expectations, in keeping with Robbins 34RH.
the established high productivity of the
mine. features were focused on accommoda- El Teniente has provided important in-
Atlas Copco chose to offer its proven ting the restrictive work environment put to future development of boxhole
34RH and 53RH boxhole machines with and high performance expectations. boring technology.
customized features to meet the special After thoroughly monitoring the capa- With production results exceeding
needs of El Teniente. Most of these bilities of both machines, the project in expectations, it has also proved to be

raiseboring 71
 Boxhole Boring at El Teniente

a new milestone in the application of

boxhole boring machines.
Acknowledgement
Atlas Copco is grateful to the manage-
ment and staff at El Teniente for their
help and assistance with this article,
which was originally published in
2001.
Rock properties at El Teniente.
Rock Type Composition Density UCS Youngs Poissons
[%] [ton/m3] [MPa] Modulus Ratio
[MPa] [---]
Andesite Fw 36 2.75 100 55 0.12
Andesite Hw 24 2.75 125 55 0.17
Anhydrite Breccha 20 2.70 115 55 0.17
Andesite Breccha 12 2.70 100 50 0.12
Diorite 8 2.75 140 60 0.15

Robbins 53RH-EX under test.

72 raiseboring
 McArthur River, Canada

Raiseboring for production

at McArthur River
World class supplier
The McArthur River underground
uranium mine in north Saskatch
ewan, Canada, is operated by Ca-
meco Corporation, the worlds lar-
gest supplier of combined uranium
and conversion services. McArthur
River is the only operation in the
world that relies solely upon raise-
boring for production, rather than
methods requiring conventional ex-
cavation or utilizing blasting me-
thods. For this extraction technique,
the mine is using five Atlas Copco
Robbins raiseborers. This article
provides an overview of the oper-
ation, and outlines recent innova-
tions that have improved upon the
safety, efficiency and effectiveness
of this mining method to produce
over 18 million lbs/year of U3O8.
Cameco Corporations vision is to
be a dominant nuclear energy com- McArthur River minesite and headframe.
pany producing uranium fuel and
generating clean electricity, but its
core business is the supply of ura- The site is located in a valley between Radiation overview
nium concentrates and associated glacial drumlins. The Pollock Shaft is
nuclear fuel services. the main access for men and materials, Worker annual exposure limits have been
The company owns controlling as well as being a source of fresh air established in conjunction with the
interests in the worlds largest for the underground operations. It is CNSC, and take into account the cumu-
high grade uranium deposits, at
McArthur River and Cigar Lake, concrete lined, with a diameter of 5.5 m, lative exposure to alpha and gamma radi-
and the largest uranium mills, at and is approximately 680 m-deep. ation and radon gas, along with long-lived
Key Lake and Rabbit Lake, all locat- Two production levels, at the 530 m radioactive dust. Radon gas decaying to
ed in northern Saskatchewan. and 640 m elevations, provide access its progeny causes alpha radiation. It is
above and below the ore zones for raise- typically derived from radon bearing
bore mining. These two levels are also groundwater sources that enter mine
Mine access joined by a ramp, which provides access workings, and is a critical source of ra-
to a third production level at 560 m diation, particularly where inadequate
The McArthur River Operation is joint- elevation. ventilation allows gas build up.
ly owned by Cameco Corporation (70%) The No 2 Shaft, located approxima- Gamma radiation is directly propor-
and Cogema Resources Inc (30%). It tely 300 m south of the Pollock shaft, is tional to ore grade. Long-lived radioac-
entered production in December, 1999 also concrete lined, with a diameter of 6 tive dusts are essentially airborne ore
and successfully ramped up production m and a depth of approximately 530 m. particulate that has been generated by
to become the worlds largest uranium Its main purpose is mine exhaust ventila- some aspect of mining or ore handling.
mine, at over 18 million lbs/year of tion, and as a secondary means of egress Discreet radon sources need to be
U3O8. via ladders. Shaft No 3, located approx- captured in suction ventilation ducting,
The minesite is located approxima- imately 500 m south of No 2 Shaft, is and delivered to non-entry return air-
tely 620 km north of Saskatoon. Access again concrete lined, with a diameter of ways. General ventilation is normally
is by both air and all-weather road. 6 m and a depth of approximately 530 single pass to non-entry return airways
Air travel is used to transport person- m, and is used for fresh air ventilation, to limit exposure to the decay process.
nel to and from various locations in as well as a permanent means of emer- Time, distance and shielding are the key
Saskatchewan, while road transporta- gency egress, for which it is equipped design criteria used to limit gamma radi-
tion is used for materials. with a small mechanical hoist. ation exposure. Processes are designed to

raiseboring 73
 Raiseboring for production at McArthur River
Negative ventilation applied to a raiseborer.
minimize the time personnel need to be
in contact with ore sources. When inter-
action is necessary, the distance between
personnel and an ore source is maximi-
zed. Additionally, the surface area of the
ore source should be minimized where
Inspecting freeze holes on the 530 m level.
74 raiseboring
possible. Finally, shielding, typically
steel, lead, concrete, or even water, is
incorporated into processes as requi-
red. At McArthur River, much of the
process piping is Schedule 160, and ore
storage tanks typically have a suitable
covering of +300 mm concrete. Dust is
controlled by using a wet process for
ore handling, as soon as practical, and
by providing secondary process venti-
lation systems where necessary.
A full appreciation of the implica-
tions of the radiation exposure poten-
tial, provided by detailed modelling of
each step of the process at McArthur
River, led to the development of the
non-entry raiseboring mining method.
All personnel involved in ore extrac-
tion and handling carry direct reading
dosimeters (DRDs) that provide real-
time numeric readouts of gamma radia-
tion exposure. Personnel working under-
ground are also equipped with personal
alpha dosimeters (PADs) that measure
alpha radiation exposure. Extensive dust
sampling is also conducted. All person-
nel on-site are provided with thermal-
luminescence device (TLD) badges that
register gamma radiation exposure over
a specific period of time.
Ground freezing
Ground freezing is utilized around the
ore to cut off the groundwater flow path
from the sandstone. It also provides con-
solidation of the halo of poor ground
surrounding the ore, caused by major
faulting.
The ground-freezing programme is
presently required to maintain, rather
than initiate, freezing. The programme
consists of 107 holes on line around the
ore in Panels 1, 2, & 3 of Zone No 2.
Calcium chloride brine for freezing
is delivered via two 250 mm-diameter
insulated pipes installed in the Pollock
Shaft in a high-pressure closed loop.
Delivery temperature is typically 30C
to maintain the required steady-state
temperature for the underground por-
tion of the system. On the 530 m level, a
series of heat exchangers allows for heat
transfer with a low-pressure closed loop
brine distribution system that delivers
brine to the Zone No 2 area. Delivery
temperature is typically 27C. The
freeze pipes in the holes contain a smal-
ler diameter inner PVC feed pipe that
allows the brine to travel to the bottom
of the hole, prior to flowing out of the
feed pipe, while contacting the outer
casing to allow heat transfer with the
surrounding rock.
 Raiseboring for production at McArthur River

Raiseboring overview
Raiseboring was selected as the initial
mining method for Zone No 2, since it is
not possible to work in the ore zone due
to radiation exposure and ground free-
zing. There is also a need to control ven-
tilation circuits extremely well, and low
orebody rock strength eliminated the
use of mining methods requiring explo-
sives.
Initially, three raisebore chambers
were established on the 530 m level in-
side the freeze-wall. Two rows of raises
are bored from each chamber to respec-
tive extraction chambers on the 640 m
level. Each row contains from 10 to 16
raises, depending upon local geology.
All chambers are provided with a con-
crete floor, for ease of setting up the rai-
sebore drills and for cleanup, and with
halogen lighting for better visibility.
Upon completion of reaming in a given
chamber, the raisebore and extraction
chambers are backfilled with concrete,
and subsequent chambers are then deve-
loped adjacent to these backfilled drifts,
ready for reaming the next two rows of
raises per chamber.
Pilot hole deviation averages just 1%, Robbins raiseborer 53RH-EX, one of four at site.
due to careful alignment of the raise-
bore drills, and standardization of pilot 640 m level; and using proper restric- Shaft. Ore grading greater than 2% U3O8
hole drilling parameters. tive barriers to ensure that no personnel is delivered to the underground grinding
Raises completed to date have varied enter on the return air side of raisebo- circuit, with a semi autogenous grinding
from 50,000 lb to over 1,000,000 lb of ring on the 640 m level. mill, and then hoisted hydraulically to
U3O8, with raises averaging 75 m in surface. Once at surface, the slurry is
length. Due to the generally soft nature Loading ore stored in radiation-shielded storage tanks
of the ore zone, the production rate, to await transportation to Key Lake mill,
when reaming in the ore, is constrained Ore is collected at the bottom of the some 80 km away.
by ore-handling capacity. Reaming in raises by line-of-sight LHD. A simple
excess of 50 t/h is theoretically pos- chute arrangement is placed below the Direct reading dosimeter.
sible, and 20 to 30 t/h has proved to be raise to direct material to a 1.2 m-
sustainable. In a 3.05 m-diameter raise, diameter chute opening, which dumps
this equates to 0.9 m/h to 1.4 m/h. directly into the LHD bucket. Stationary
Special precautions are taken during cameras indicate when the bucket is 75%
both pilot hole drilling and reaming to full, and the driver contacts the raise-
ensure the safety of the operators. bore operator to cease reaming. The
Due to radon gas and progeny gene- driver, located 20-40 m away on the
ration, the raise air has to be contained fresh air side, then backs the LHD away
during the reaming cycle. This involves from the chute, using line-of-sight remote
maintaining a good seal at the pilot hole control.
collar, and introducing compressed air He then boards the LHD into a pres-
down the pilot hole during reaming; surized, air-filtered cab, and drives it to
utilizing a negative pressure 2.5 cu m/s a scanning station, where the ore grade
wet bath dust scrubber at the bottom of is determined by gamma radiation re-
the raise, as part of the ore collection sponse before delivery to the indicated
chute (OCC) system, that exhausts to location. Ore grading less than 2% U3O8
the return air side of raiseboring on the can be skipped to surface via the Pollock

raiseboring 75
 Raiseboring for production at McArthur River
Robbins raiseborer 73RM-H at the 530 m level.
If it is necessary for a worker to ap-
proach within 10 m of the chute area, a
Radiation Work Permit is required. A
radiation technician conducts an alpha
and gamma radiation survey, to esta-
blish both the radiation and work guide-
lines, and the personal protective equip-
ment requirements.
Upon completion of a raise, the reamer
is lowered to the collar of the raise, and a
cleanup of the area is conducted utilizing
the line-of-sight LHD, and washing the
area with high-pressure fire hoses. The
ore collection chute and dust scrubber
are then removed.
The reamer is lowered out of the raise,
and a backfill gantry is slid into place
below the raise. A remote breakout tool
is then used, which attaches to the LHD
boom after bucket removal, allowing
the reamer to be broken from the drill
string and removed remotely.
76 raiseboring
Backfilling
Once the reamer has been removed from
the raise, the backfill gantry is placed into
the correct position to act as the form-
work for backfilling the raise. This back-
fill gantry raises a platform up to the
back, and seals the raise breakthrough
with a plug fabricated of Styrofoam,
plastic, or canvas.
Concrete is used for backfilling. An
initial plug of +30 MPa strength is pum-
ped via a feed pipe through the back-
fill gantry from below, and allowed to
cure for 48 hours. This is followed by
a second pour via the pilot hole, and a
final pour of +15 MPa strength to com-
plete raise filling. During this time-
frame, the raiseborer is setting up to
drill the next pilot hole. Raises are de-
signed to overlap slightly, in order to
achieve high ore recovery.
Innovative raiseborers
Cameco is using a fleet of five Atlas
Copco raiseborers at McArthur River:
one Robbins 73RM-H machine and four
53RH-EX units, using some reaming
heads and cutters supplied by Secoroc.
As of March 2003, some 114 raises
had been reamed, for a total produc-
tion of approximately 55,150,000 lb of
U3O8. The following table highlights
the annual production.
Year Production
1999 3,410,000
2000 11,670,000
2001 17,170,000
2002 18,520,000
2003 (to March) 4,185,000
Total 55,150,000
Raiseboring standards are being
maintained using: a quality assurance
programme, with NDT testing of major
drill string components; preventative
maintenance programmes for the raise-
bore drills after every raise; and design
and fabrication of a reamer catcher
system.
For the quality assurance program-
me, every reamer is inspected before
being installed. This includes a visual
inspection for wear on pads and cutters,
as well as Magnaflux testing of the stem-
pin. Magnaflux testing is also carried
out on the pin and box ends of all stabi-
lizers, as well as wrenching rods when
used, before the rods go into the pilot
hole.
The reamer catcher system uses a cable
system, which allows safe removal of an
OCC if a reamer breaks away from the
drill string. For use with the Secoroc rea-
mers, this reamer-on-a-rope system
has a wedge anchor at one end that is in-
stalled into the pin end of the reamer
stem. The cable has an anchor that is
pushed up through the annulus of the
stabilizer/wrenching rod at the end of
the drill string, to sit at the top of the
pin of the stabilizer or wrenching rod
connected directly to the reamer. The
cable has a swivel at the other end that
is attached to the wedge anchor.
If the first joint breaks, the cable cat-
ches the reamer, which is suspended in
the raise until the OCC can be removed
 Raiseboring for production at McArthur River

using a remote LHD. Once the OCC has

been removed, a cushion of muck is pla-
ced at the bottom of the raise, and the 530 m Raiseborer machine
reamer is lowered.
A turntable is used to swing rods into
the proper orientation for the pipeloader
to grab them for loading into the drill,
while aluminium rod racks reduce the
number of injuries from lifting heavy
timbers. Rebuilding of cutters and tri- Pilot hole
cone bits is also being actively pursued. Ore zone
A two-piece reamer stem has been
introduced, which has a joint near the
platform elevation of the stem. This al-
lows the upper portion of the stem to
be changed, rather than replacing the
entire stem complete with flange.
With some of the pilot holes over-
lapping, various plastics were tried, Reaming head
before an aluminium standpipe was
implemen-ted. This lighter material
allows for the drilling out of the stand-
pipe of a previous pilot hole, without
damaging the tricone bit.
Two raises have also had to be rea-
med through to the 530 m level because
the reamers could not be lowered out of
the bottom of the raise. This required
careful planning, to ensure health and Fresh air
safety, as well as limiting worker radia- Exhaust ventilation
Remote control
tion exposures. The procedure involved scooptram
reaming to within 3 m of the sill, dril- Operator
640 m Exhaust air scrubber
ling backfill holes into the raise below
the reamer from the 530 m level, back-
filling the raise while still leaving a Schematic of production system at McArthur River.
void below the reamer for the cuttings,
reaming up through to the baseplates, proved to be quite successful, and larger development for access above and below
removing the reamer from the raise, and canvas bags are being investigated for future mining zones indicates that alter-
completing the backfilling to the sill of full plug pours, rather than just for sea- nate mining methods should be investi-
the 530 m elevation. ling purposes. gated, such as boxhole boring and jet-
boring. A test programme is also being
Innovative backfilling The future at McArthur conducted to try mining without the
River OCC under the raise, which could lead
In order to reduce radiation exposure du- to more conventional mining methods
ring the installation of the backfill gantry One of the most interesting aspects of in the future.
(BFG), a plastic plug has been introduced this mining programme is the uncon- The McArthur River Operation has
to seal the bottom of the raise. This is ventional use of raiseborers. This unique been granted ISO 14001 Certification,
utilized if ground conditions around the operation has created opportunities to underlining its commitment to protect
collar of the raise will not allow sealing reinvent drilling procedures, as well as the environment.
with Styrofoam. design one-of-a-kind equipment.
A canvas bag with attached fibreglass With the success of conventional raise- Acknowledgements
rebars, that is inflated with concrete, was boring as the primary mining method,
designed and tested. It was installed the future is bright for McArthur River. Atlas Copco is grateful to Cameco
on top of the BFG, and the BFG placed This mining method has been proven, Corporation for permission to publish
under the open raise remotely. Then, the and has matured to such a level that it this article, and in particular to chief
canvas bag was inflated with concrete, is the primary mining method planned mine engineer V Clay Wittchen, who
sealing the bottom of the raise and pla- for new mining zones. However, upco- wrote and presented the papers on which
cing the rebars vertically. This initial test ming challenges in regard to the required it is based.

raiseboring 77
 Ovre Ardal, Norway

Replacing Norways Tyin

hydropower plant
Environmentally
sensitive
construction
Norwegian contractor Selmer
Skanska has completed its part
of the construction of the replace-
ment for the 1940s hydropower
station serving the rdal alumini-
um smelter, located near Sogndal
in western Norway.
Overall cost of the project will
be approximately 180 million,
with the Selmer Skanska con-
tract accounting for 60 million.
The new power station has been
excavated in rock, together with
nearly 21 km of associated tun-
nels of various cross sections.
The client, Norsk Hydro, is
c ommi t te d to pre s e r va tion,
and this is reflected both inside
and outside the mountain, and
includes health, environment and
safety. This was emphasised when
they awarded the contract, along
with an insistence that their cur-
rent daily production of electricity
should not be disrupted.
Three generations of Atlas
Copco drill rigs were used at Tyin,
ranging from the older Boomer
H185 and 322, through Rocket
Boomer 353C, to the latest L2C
and fully computerized WL3C,
equipped with COP 1838HF rock-
drills. Secoroc supplied its Mag-
num SR35 rock tools for the drill
rigs, and Atlas Copco refurbished
a Robbins 97RLC raiseborer for Robbins 97RL C in operation.
the surge shaft excavation. There
was even an Atlas Copco ST1000
Scooptram at site! Tunnel system approximately halfway along its align-
The compact dimensions of the ment. Selmer Skanska subsidiary E-Ser-
Robbins 97RL C raise drill enabled The tunnel system runs from a laketap vice drilled the 1 m-diameter x 25-50 m-
the surge shaft to be drilled safely intake in Lake Tyin to the existing stor- long holes to connect the creeks to the
from the surge chamber, for which age lake at Torolmen, and then on to the existing headrace.
access was limited and difficult. An access tunnel 1.54 km-long with
powerstation penstocks and turbines,
Tyin is a testament to the abil-
ity of a single company to supply finally discharging through a tailrace 50sq m cross section was driven down-
and support all the equipment at rdalsvatnet. grade at 1:10 to reach the power station
necessary for a major tunnelling Five surface creek intakes have also site in June, 2002. The rock cover of
project, while complying with the been constructed. These have been cou- 1.5 km is resulting in heavy pressure
environmental strictures placed on tunnel face and crown.
pled to the existing power tunnel, which
on working in sensitive areas of
the world. will then work as a top feed to the new It involved some 75,000 cu m of
tunnel, connected by a shaft located excavation using an Atlas Copco Rocket

78 raiseboring

First worksite for the upgraded
Robbins 97 RL C raiseborer
Existing tunnel
Shaft
New tunnel
New powerhouse
Lake rdal
above sea level
Idealized section of Tyin tunnel system.
Boomer 353C equipped with 5.5 m-long
Secoroc Magnum SR35 rods to drill the
hard gneiss. Some 75-80 x 48 mm holes
were drilled per round, using Secoroc
Magnum SR35 button bits, to obtain a
4.85m pull. Dyno Nobel slurry explo-
sive and Nonel detonation provided
good fragmentation, and spoil removal
was undertaken by a subcontractor.
Power station
The power station excavation was com-
pleted in October, 2003, with dimensions
17 m-wide x 60 m-long x 38 m-high,
beneath 1.6 km of rock cover. It is de-
signed to replace output from the ex-
isting plant and to add an extra 15%,
bringing electricity production to 1,400
GWh annually, without changing the
water reservoirs.
The power station roof was profile
drilled using a Rocket Boomer 353C
and supported by 6 m-long resin an-
chored rockbolts installed on a 2 m
square pattern in holes drilled by an
Atlas Copco Boomer H185 drill rig.
Some 7-10 cm of steel fibre reinforced
shotcrete was applied, using a truck-
mounted jumbo.
An Atlas Copco ROC 642HP quarry
rig drilled 4 m-long x 64 mm-diameter
vertical blastholes with 2.5 m burden on
the benches for bulk excavation of the
powerhouse, where the generator pit will
house two Pelton turbines. These will
be driven by the hydrodynamic forces
raiseboring 79
Replacing Norways Tyin Hydropower Plant
Tyin
Torholmen 1073-1083 m.o.h.
Tya
created by over 1,000 m of head between of the fjord that has been reclaimed as a
Lake Tyin and the powerhouse. Massive nature reserve. The access and tailrace
crane rails have been installed to cope tunnel entrances are 3 km apart along a
with the turbine components and the tarmac all-weather public highway.
240 t transformers. Large 1.8 m-diameter fans and 2 m
ducts provided 35 cu m/min of fresh air
Tailrace to the faces.
The tailrace tunnel is 2.7 km-long, and Headrace
9.5m-high x 5.5 m-wide, with 46 sq m
section. This was driven by an Atlas The pressure tunnel was advanced at
Copco Rocket Boomer WL3C drill rig 27 sq m section on a 0.5% gradient from
with three booms and a basket, delive- the power station position towards
red new in February, 2002. The WL3C Lake Tyin. Meantime, development of
was equipped with the latest 1838 HF
rockdrills, which drilled at 1.5 m/min Atlas Copco ROC 642 HP used for bulk excavation
in the granite gneiss. It drilled 90 holes/ of power station cavern.
round using 5.5 m-long rods and 48 mm
button bits with Secoroc Magnum SR35
thread, with blasting by Dyno Nobel
slurry with Nonel detonators.
The rock cover of 1.5 km resulted in
heavy pressure on the mountain side of
the drive, causing blocky ground which
had to be secured using 4 m-long resin
anchored bolts. Some 12-15 bolts were
installed per round, in alternating rings
of 6 and 7 at 2.5m spacing. Where the
rock tension permitted, 2.4 m-long
bolts were used. Steel fibre reinforced
shotcrete was applied as a matter of
course.
Turning niches were excavated at
130 m intervals for the wheeled load-
ers, which discharged into road tippers.
Rock from the tailrace tunnel was car-
ried by bottom dump barges to an area
 Replacing Norways Tyin Hydropower Plant
At the controls of the Rocket Boomer WL3 C.
One of the Atlas Copco Rocket Boomer 353 C drill rigs.
80 raiseboring
the 350 m-long Biskopsvatn adit was
commenced in October, 2001, at a point
approximately halfway along the 7
km alignment between the power sta-
tion and the storage lake known as
Torolmen. Biskopsvatn adit reached the
pressure tunnel horizon by Christmas,
2001.
From here, the pressure tunnel was
advanced in both directions using two
identical Atlas Copco 353S drill rigs
and tracked loaders with 2.1 cu m
side tipping buckets at each face, oper-
ated by single crews on each of two
shifts. A maximum 35 rounds/week was
achieved, with an average of 26 rounds,
which equated to 65 m advance.
Both rigs used Secoroc Magnum SR35
equipment, 5.5 m-long rods and 48 mm
button bits, in the 29-30 sq m section,
and each round took around 2 hours to
drill.
A workshop was established under-
ground at the junction of the Biskopsvatn
adit and the pressure tunnel drives. To-
wards the right downgrade side, the
drive was in granite, and towards the
 Replacing Norways Tyin Hydropower Plant

left upgrade side, it was in phyllite.

Each round required more blastholes
in the phyllite, together with up to six
102 mm cut holes.
The final stretch of tunnel, from
Lake Torolmen to the draw off point in
La ke Tyi n, was d r iven f rom an
adit using an excavator loader and
dumptrucks. The first 226 m was
downgrade, followed by 2.4 km slightly
upgrade at 20 sq m section. The face
was drilled using an Atlas Copco
Rocket Boomer L2C, using ANFO as
the blasting agent.

Surge shaft
At a position known as Tora Bora be-
cause of its remoteness, the 9,000 cu m
surge chamber was excavated early in
the project using an Atlas Copco 322
twin-boom drill rig and ANFO. Poor
access limited the size of equipment
that could be used, which included an
ST1000 Scooptram.
The 436 m-long x 4.04 m-diameter
surge shaft was raise bored from the
surge chamber by Skanska raiseboring
AB using its Robbins 97RL C. This is
a high power and low profile raise drill
specially designed for working on sites
with size and weight restrictions, and
is one of the strongest ever produced
for up to 600 m-long raises in the dia-
meter range of 2.4 m-5.0 m. The con-
version of the 13 year-old machine to
computer control was undertaken by the
raiseboring department at Atlas Copco
in Orebro, Sweden, who upgraded
the entire system using RCS technol-
ogy, and added a new power pack and
electrical cabinet. The upgrade made
the control system more reliable and
easier to use, and the raise drill easier to
assemble at site, because of the reduc-
tion in cabling. Technical data can be
logged and downloaded onto a PC card,
and the whole system is programmable,
making it easier to add new features.
Indeed, a catch-rope feature was added
and programmed into the machine after
it had been delivered and set up. With
this feature installed, if the reamer
loosens, it is restrained by a wire rope
inside the drillstring, and a red light
appears on the panel.
Due to weight restrictions and size
limits of the access road along the
Robbins 97RL C set up and drilling at Tora Bora.
mountainside, the machine had to be
dismantled and hauled in by tractor.
It took Skanska nine trips to get the
raise drill into place, and an additional
30-40 helicopter trips for transporta-
tion of drill rods and accessories. Site
preparation and assembly took around
three weeks.
During winter, it was impossible to
keep the road open due to snowstorms,
and the raise drilling crew had to rely
on helicopter or snowmobiles for tran-
sportation. To avoid a cumbersome
commuting situation, night-quarters
were fitted in the warm and snow free
tunnel, close to the working site.
Drilling of the 15 in pilot hole start-
ed in December, 2002 and took three
months to complete. A drift from the
power tunnel reached the lower level
of the pilot hole by March, 2003, and
reaming of the 4.04 m-diameter shaft
commenced the following month and
was completed by the end of June, 2003.
Summary
The Tyin project began in September,
2001 and was completed in late-2004.
A total of 4,500 rounds were blasted to
remove 680,000 cu m of rock. Some
27,086 rockbolts and 15,100cu m shot-
crete were installed.
Selmer Skanska and its subcontrac-
tors had a total of 160 employees on
site, of which 50 lived at the intermedi-
ate adit location, with the remainder at
a camp in rdal, next to the site area.
Everybody worked the North Sea system
of two weeks on and one week off.
Excavation was completed during
2003, with the final blast in the tailrace
taking place in the last week in May,
and the headrace from Biskopsvatn to
the powerstation breaking through on
10th July. The draw-off tunnel at Torol-
men was finished at the end of July,
with the lake tap left ready drilled for
blasting in mid-2004. The piercing of
Ardalsvatn from the tailrace was car-
ried out in Spring, 2004.
Selmer Skanska is justifiably proud
of this project, which involved drilling
and blasting nearly 21 km of tunnel and
excavating 45,000 cu m of powersta-
tion in just 19 months. This part of the
project was completed without a single
serious accident during the course of
600,000 manhours.
Acknowledgements
Atlas Copco is grateful to Magnar
Myklatun, project manager for Selmer
Skanska at Tyin for his assistance with
this article.

raiseboring 81
 ROBBINS raise drill specification
34RH
H
Standard 34RH
with optional
ground loading
pipeloader
W D
The Robbins 34RH is a low profile and small diameter
raise drill, ideal for slot raises, back filling and narrow
vein mining applications. The multipurpose and light
weight raise drill can be used for conventional raise-
boring, downreaming as well as upward boxhole boring
depending on the configuration of the various options
available. This makes the Robbins 34RH the most
versatile raise drill on the market.
Features and benefits
The single power pack hydraulic drive features variable Width 1,700 mm 1,700 mm 2,200 mm
speed and good torque limiting control.
Rigid columns provide efficient torque reaction,
extending the service life of the thrust cylinders.
Telescopic thrust cylinders provide high thrust in low
profile.
The entire drive train features a hollow centre,
enabling efficient transmission of any flushing media Dip adjustment
to clear the pilot hole.
A choice of different types of worktables is available.
The slide open worktable facilitates downreaming or * Depending on machine version and rock conditions
boxhole applications while the horseshoe fork
worktable wrench, as well as the worktable wrench,
are available for conventional raiseboring only.
The optional ground loading pipeloader offers maximum
flexibility in terms of pipe handling. It is capable of
installing all the drillstring components as well as the
reamer*** (*** Max. diameter 1060mm).
The optional high rev/min version offers almost twice
the production for downreaming applications.
82 raiseboring
Main specifications
Frame Low Standard Wide
Raise diameter
Nominal 1.2 m 1.2 m 1.2 m
(4 ft) (4 ft) (4 ft)
Range* 0.6-1.5 m 0.6-1.5 m 0.6-1.5 m
(2-5 ft) (2-5 ft) (2-5 ft)
Raise length
Nominal 340 m 340 m 340 m
(1,115 ft) (1,115 ft) (1,115 ft)
Maximum* 610 m 610 m 610 m
(2,000 ft) (2,000 ft) (2,000 ft)
Drillpipe
Diameter 203 mm 203 mm 254 mm
(8 in) (8 in) (10 in)
Optional diam. 254 mm 254 mm 203 mm
(10 in) (10 in) (8 in)
Length, s/s** 750 mm 1,219 mm 1,219 mm
(2.5 ft) (4 ft) (4 ft)
Pilot hole
Diameter 229 mm 229 mm 279 mm
(9 in) (9 in) (11 in)
Optional diam. 279 mm 279 mm 229 mm
(11 in) (11 in) (9 in)
Torque and force
Reaming torque 64 kNm 64 kNm 64 kNm
(47,500 lbf ft) (47,500 lbf ft) (47,500 lbf ft)
Reaming thrust 1,285 kN 1,285 kN 1,285 kN
(289,000 lbf) (289,000 lbf) (289,000 lbf)
Installed power 110-160 kW 110-160 kW 110-160 kW
(150-215 hp) (150-215 hp) (150-215hp)
Main drive Hydraulic Hydraulic Hydraulic
Dimensions
Height extended 2,900 mm 3,250 mm 3,350 mm
(115 in) (128 in) (132 in)
Height retracted 2,900 mm
(115 in)
3,250 mm
(128 in)
3,350 mm
(132 in)
(67 in) (67 in) (87 in)
Depth 1,650 mm 1,800 mm 2,250 mm
(65 in) (71 in) (89 in)
Weight
Derrick 7,200 kg 7,600 kg 11,100 kg
(15,870 lb) (16,755 lb) (24,470 lb)
from horizontal 90 - 60 (45) 90 - 60 (45) 90 - 60 (45)
** Shoulder to shoulder
Visit www.raiseboring.com for more information

44RH
H Diameter 203 mm (8 in)
W D
Building on the proven design of our low profile and
light weight raise drills, the Robbins 44RH adds higher
torque and thrust to a small diameter raise drill. The 44RH
is a versatile and high production raise drill, for raise
requirements in the smaller diameter range.
Features and benefits
The single power pack hydraulic drive features variable
speed and good torque limiting control. The well
proven RCS system adds reliability and user
friendliness.
Rigid columns provide efficient torque reaction
extending the service life of the thrust cylinders.
Telescopic thrust cylinders provide high thrust in
low profile.
The entire drive train features a hollow centre, enabling
efficient transmission of any flushing media
to clear the pilot hole.
The sturdy worktable is available with insert or horse-
shoe fork wrench for fast and reliable pipe threading.
The sideloading pipeloader offers safe and efficient
pipe handling.
raiseboring 83
ROBBINS raise drill specification
Main specifications
Raise diameter
Nominal 1.5 m (5 ft)
Range* 1.0-1.8 m (3.5-6 ft)
Raise length
Nominal 340 m (1,115 ft)
Maximum* 610 m (2,000 ft)
Drill pipe
Optional diam. 254 mm (10 in)
Length, s/s** 1,219 mm (4 ft)
Pilot hole
Diameter 229 mm (9 in)
Optional diam. 254 mm (10 in)
Torque and force
Reaming torque 75 kNm (55,000 lbf ft)
Reaming thrust 2,000 kN (450,000 lbf)
Installed power 160 kW (150 hp)
Main drive Hydraulic
Dimensions
Height extended 3,400 mm (134 in)
Height retracted 3,400 mm (134 in)
Width 1,750 mm (69 in)
Depth 1,600 mm (63 in)
Weight
Derrick 8,000 kg (17,636 lb)
Dip adjustment
from horizontal 90 - 60 (45)
* Depending on machine version and rock conditions
** Shoulder to shoulder
Visit www.raiseboring.com for more information
 ROBBINS raise drill specification

53RH
Main specifications

Models 53RH 53RH-EX

Raise diameter
Nominal 1.8 m (6 ft) 1.8 m (6 ft)
Range* 1.2-2.4 m (4-8 ft) 1.2-2.4 m (4-8 ft)

Raise length
Nominal 490 m (1610 ft) 490 m (1610 ft)
Maximum* 650 m (2130 ft) 650 m (2130 ft)

H Drill pipe
Diameter 286 mm (11-1/4 in) 286 mm (11-1/4 in)
Length, s/s 750 mm (2.5 ft) 1524 mm (5 ft)

Pilot hole
Diameter 311 mm (12-1/4 in) 311 mm (12-1/4 in)
Optional diameter 349 mm (13-3/4 in) 349 mm (13-3/4 in)

Torque and force

Reaming torque 156 kNm 156 kNm
(115,000 lbf ft) (115,000 lbf ft)
Reaming thrust 3,350 kN 3,350 kN
(754,000 lbf) (754,000 lbf)
Installed power 255 kW 255 kW
D (340 hp) (340 hp)
W Main drive Hydraulic Hydraulic

The Robbins 53RH is a unique multi-purpose raise drill,
able to perform upwards boxhole boring as well as con-
ventional raiseboring, without any modifications to the
drive assembly. The Robbins 53RH is of low profile design
which gives it the most application flexibility in restricted
environments.
Dimensions
Height extended 2,700 mm (106 in) 4,000 mm (158 in)
Height retracted 2,700 mm (106 in) 3,650 mm (144 in))
Width 1,900 mm (75 in) 1,900 mm (75 in)
Depth 2,150 mm (85 in) 2,150 mm (85 in)
Weight
Derrick 14,000 kg (30,865 lb) 14,000 kg (30,865 lb)

Dip adjustment
Features and benefits from horizontal 90 - 60 (45) 90 - 60 (45)
The hydraulic drive features variable speed and good * Depending on machine version and rock conditions
torque limiting control. The well proven RCS system ** Shoulder to shoulder
adds reliability and user friendliness.
Rigid crosshead guide columns provide efficient torque
reaction extending the service life of the thrust
cylinders.
Telescopic thrust cylinders provide high thrust in low
profile.
Unique design with dual drive chucks heads for easy
change between boring mode.
A removable swivel enables efficient flushing in both
boxhole boring and raiseboring.
A sliding fork worktable wrench in combination with
the optional semi-automatic drive head wrench,
eliminates the need to handle heavy wrenches
(optional).
The sideloading pipeloader offers safe and efficient
pipe handling both in boxhole and raiseboring mode.

Visit www.raiseboring.com for more information

84 raiseboring

73R
H
D (12-1/4 in) (11 in) (13-3/4 in)
W
With more units sold worldwide than any other raise
drill model in production, the Robbins 73R has become
the reliable workhorse for virtually any raiseboring
application. The 73R is a medium size raise drill, ranging
from 1.5 m to 3.1 m (5-10 ft) in diameter.
Features and benefits
The AC version offers a fixed four speed drive with
high durability and maintainability.
The hydraulic and VF drive features variable speed and
good torque limiting control.
The well proven RCS system adds reliability and user
friendliness.
A patented, two piece swivel float box prevents
transfer of bending moments to the gearbox, and a
replaceable threaded insert lowers maintenance costs.
Rigid crosshead guide columns provide efficient torque
reaction extending the service life of the thrust cylinders.
A simple in-line drive system provides balanced thrust
loads to improve cutting action.
A sliding fork worktable wrench in combination
with the optional semi-automatic drivehead wrench,
eliminates the need to handle heavy wrenches
(optional).
Small footprint requires a smaller drilling pad and
fewer tie down bolts.
raiseboring 85
ROBBINS raise drill specification
Main specifications
Models 73RAC 73RH 73RVF
Raise diameter
Nominal 2.1 m 2.1 m 2.1 m
(7 ft) (7 ft) (7 ft)
Range* 1.5-2.4 m 1.5-3.1 m 1.5-3.1 m
(5-8 ft) (5-10 ft) (5-10 ft)
Raise length
Nominal 550 m 550 m 550 m
(1,800 ft) (1,800 ft) (1,800 ft)
Maximum* 700 m 700 m 700 m
(2,300 ft) (2,300 ft) (2,300 ft)
Drill pipe
Diameter 254 mm 286 mm 286 mm
(10 in) (11-1/4 in) (11-1/4 in)
Optional diam. 286 mm 254 mm 254 mm
(11-1/4 in) (10 in) (10 in)
Length, s/s** 1,524 mm 1,524 mm 1,524 mm
(5 ft) (5 ft) (5 ft)
Pilot hole
Diameter 279 mm 311 mm 311 mm
(11 in) (12-1/4 in) (12-1/4 in)
Optional diam. 311 mm 279 mm 349 mm
Torque and force
Reaming torque 173 kNm 225 kNm 225 kNm
(128,000 lbf ft) (166,000 lbf ft) (166,000 lbf ft)
Reaming thrust 4,159 kN 4,159 kN 4,159 kN
(935,000 lbf) (935,000 lbf) (935,000 lbf)
Installed power 215 kW 305 kW 305 kW
(290 hp) (400 hp) (400 hp)
Main drive Electric (AC) Hydraulic Electric (VF)
Dimensions
Height extended 5,550 mm 5,250 mm 5,900 mm
(219 in) (207 in) (232 in)
Height retracted 3,800 mm 3,600 mm 3,850 mm
(150 in) (142 in) (152 in)
Width 1,600 mm 1,600 mm 1,600 mm
(63 in) (63 in) (63 in)
Depth 1,900 mm 1,900 mm 1,900 mm
(75 in) (75 in) (75 in)
Weight
Derrick 12,000 kg 11,500 kg 13,000 kg
(26,455 lb) (25,350 lb) (28,660 lb)
Dip adjustment
from horizontal 90 - 60 (45) 90 - 60 (45) 90 - 60 (45)
* Depending on machine version and rock conditions
** Shoulder to shoulder
Visit www.raiseboring.com for more information
 ROBBINS raise drill specification

83RH
Main specifications

Raise diameter
Nominal 4.0 m (13 ft)
Range* 2.4-4.5 m (8-15 ft)

Raise length
Nominal 500 m (1,640 ft)
Maximum* 1,000 m (3,280 ft)

Drill pipe
H Diameter 327 mm (12-7/8 in)
Length, s/s** 1,524 mm (5 ft)

Pilot hole
Diameter 349 mm (13-3/4 in)

Torque and force

Reaming torque 407 kNm (300,000 lbf ft)
Reaming thrust 6,124 kN (1,376,700 lbf)
Installed power 455 kW (600 hp)
Main drive Hydraulic

Dimensions
Height extended 6,000 mm (236 in)
Height retracted 4,350 mm (171 in)
D Width 1,650 mm (65 in)
W
Depth 2,150 mm (85 in)

Weight
The ruggedly built, large diameter and high torque Derrick 20,000 kg (44,100 lb)
Robbins 83RH, is one of the toughest raise drills going Dip adjustment
for the widest applications throughout the mining from horizontal 90 - 60 (45)
industry. The 83RH is recommended for reaming shafts
and raises from 2.4 m up to 4.5 m (8-15 ft) in diameter.
* Depending on machine version and rock conditions
** Shoulder to shoulder
Features and benefits
The hydraulic drive features variable speed and good
torque limiting control. The well proven RCS system
adds reliability and user friendliness.
A patented, two piece swivel float box prevents
transfer of bending moments to the gearbox, and a
replaceable threaded insert lowers maintenance costs.
Rigid crosshead guide columns provide efficient torque
reaction extending the service life of the thrust
cylinders.
A simple in-line drive system provides balanced thrust
loads to improve cutting action.
A sliding fork worktable wrench in combination with
the semi-automatic drivehead wrench, eliminates the
need to handle heavy wrenches (optional).
Small footprint requires a smaller drilling pad and
fewer tie down bolts.

Visitwww.surfacedrilling.com
Visit www.raiseboring.com forformore
moreinformation
information

86 raiseboring
 ROBBINS raise drill specification

91RH
Main specifications

Raise diameter
Nominal 5.0 m (17 ft)
Range* 2.4-5.0 m (8-17 ft)

Raise length
Nominal 600 m (1,640 ft)
Maximum* 1,000 m (3,280 ft)
H
Drill pipe
Diameter 327 mm (12-7/8 in)
Length, s/s** 1,524 mm (5 ft)

Pilot hole
Diameter 349 mm (13-3/4 in)

Torque and force

Reaming torque 450 kNm (330,000 lbf ft)
Reaming thrust 6,700 kN (1,510,000 lbf)
Installed power 500 kW (670 hp)
Main drive Hydraulic

Dimensions
D Height extended 5,100 mm (201 in)
W
Height retracted 4,050 mm (160 in)
Width 2,300 mm (91 in)
Depth 2,500 mm (99 in)

Weight
The Robbins 91RH is the latest addition to the Robbins Derrick 24,000 kg (53,000 lb)
low profile series that brings the advantage of raise-
Dip adjustment
boring to more underground mine locations. Its modular from horizontal 90 - 60 (45)
design allows it to be disassembled into relatively small
components for easy transport through smaller haulage
ways, yet the powerful hydraulic drive of the 91RH * Depending on machine version and rock conditions
makes it ideal for large raises up to 5.0 m (17 ft). ** Shoulder to shoulder

Features and benefits

The hydraulic drive features variable speed and good
torque limiting control. The well proven RCS system
adds reliability and user friendliness.
A gearbox incorporated in a barrel allows the drive
train to be disassembled into smaller components
without losing the preload of the main bearings.
This saves time during maintenance and transportation.
Rigid crosshead guide columns provide efficient torque
reaction extending the service life of the thrust cylinders.
A simple in-line drive system provides balanced thrust
loads to improve cutting action.
A sliding fork worktable wrench, in combination with
the semi-automatic drivehead wrench, eliminates the
need to handle heavy wrenches.

Visit www.raiseboring.com for more information

raiseboring 87
 ROBBINS raise drill specification

97RDC
Main specifications

Raise diameter
Nominal 5.0 m (17 ft)
Range* 2.4-5.0 m (8-17 ft)

Raise length
Nominal 600 m (1,640 ft)
Maximum* 1,000 m (3,280 ft)

Drill pipe
Diameter 327 mm (12-7/8 in)
H
Length, s/s** 1,524 mm (5 ft)

Pilot hole
Diameter 349 mm (13-3/4 in)

Torque and force

Reaming torque 450 kNm (330,000 lbf ft)
Reaming thrust 6,845 kN (1,538,200 lbf)
Installed power 375 kW (500 hp)
Main drive Electric (DC)

Dimensions
Height extended 4,400 mm (173 in)
Height retracted 4,400 mm (173 in)
D Width 2,250 mm (89 in)
W
Depth 3,300 mm (130 in)

Weight
Derrick 24,000 kg (53,000 lb)
The Robbins 97RDC is a high power and low profile raise
drill specially designed for mines with size and weight Dip adjustment
restrictions. Despite its low profile, the 97RDC is one of from horizontal 90 - 60 (45)
the largest raise drills ever produced. Recommended
diameter range is 2.4 m up to 5.0 m (8-17 ft). * Depending on machine version and rock conditions
** Shoulder to shoulder

Features and benefits

The digital DC drive incorporates the latest electric
technology. The well proven RCS system adds
reliability and user friendliness.
A patented, two-piece swivel float box prevents
transfer of bending moments to the gearbox, and
a replaceable threaded insert lowers maintenance
costs.
Rigid crosshead guide columns provide efficient torque
reaction, extending the service life of the thrust
cylinders.
The low profile layout employs an offset drive line with
underslung motors, planetary gearing and telescopic
cylinders.
A sliding fork worktable wrench, in combination with
the semi-automatic drivehead wrench, eliminates the
need to handle heavy wrenches.

Visit www.raiseboring.com for more information

88 raiseboring

123R
H
D (2,000,000 lbf) (2,000,000 lbf)
W Installed power 500 kW 525 kW
Designed for large diameter and long hole raiseboring
applications, the Robbins 123R is a very powerful raise
drill. The 123R is designed for large diameter raises,
ranging from 3.1 m up to 6.0 m (10-20 ft), making it
the preferred choice for raising shafts in mining or
civil engineering applications.
Features and benefits
The hydraulic or VF drive features variable speed
and good torque limiting control. The well proven RCS
system adds reliability and user friendliness.
A gearbox incorporated in a barrel allows the drive
train to be disassembled into smaller components
without losing the preload of the main bearings.
This saves time during maintenance and transportation.
Rigid crosshead guide columns provide efficient torque
reaction extending the service life of the thrust
cylinders.
A simple in-line drive system provides balanced thrust
loads to improve cutting action.
A sliding fork worktable wrench, in combination with
the semi-automatic drivehead wrench, eliminates the
need to handle heavy wrenches.
raiseboring 89
ROBBINS raise drill specification
Main specifications
Models 123RH 123RVF
Raise diameter
Nominal 4.0 m (13 ft) 5.0 m (17 ft)
Range* 3.1-5.0 m (10-17 ft) 3.1-6.0 m (10-20 ft)
Raise Length
Nominal 920 m (3,020 ft) 920 m (3,020 ft)
Maximum* 1,100 m (3,610 ft) 1,100 m (3,610 ft)
Drill pipe
Diameter 327 mm (12-7/8 in) 352 mm (13-7/8 in)
Optional diameter 352 mm (13-7/8 in) 327 mm (12-7/8 in)
Length, s/s 1,524 mm (5 ft) 1,524 mm (5 ft)
Pilot hole
Diameter 349 mm (13-3/4 in) 381 mm (15 in)
Optional diameter 381 mm (15 in) 349 mm (13-3/4 in)
Torque and force
Reaming torque 450 kNm 540 kNm
(330,000 lbf ft) (398,000 lbf ft)
Reaming thrust 8,923 kN 8,923 kN
(670 hp) (700 hp)
Main drive Hydraulic Electric (VF)
Dimensions
Height extended 5,700 mm (224 in) 5,800 mm (228 in)
Height retracted 4,050 (160 in) 4,050 (160 in)
Width 2,300 mm (91 in) 2,300 mm (91 in)
Depth 2,500 mm (99 in) 2,500 mm (99 in)
Weight
Derrick 25,400 kg (56,000 lb) 25,400 kg (56,000 lb)
Dip adjustment
from horizontal 90 - 60 (45) 90 - 60 (45)
* Depending on machine version and rock conditions
** Shoulder to shoulder
Visit www.raiseboring.com for more information
 ROBBINS raise drill specification

191RH
Main specifications

Raise diameter
Nominal 5.0 m (17 ft)
Range* 4.5-6.0 m (15-20 ft)

Raise length
Nominal 1,000 m (3,280 ft)
Maximum* 1,400 m (4,590 ft)

Drill pipe
H Diameter 375 mm (14-3/4 in)
Length, s/s** 1,524 mm (5 ft)

Pilot hole
Diameter 381 mm (15 in)

Torque and force

Reaming torque 814 kNm (600,375 lbf ft)
Reaming thrust 11,600 kN (2,607,800 lbf)
Installed power 950 kW (1,290 hp)
Main drive Hydraulic

Dimensions
Height extended 6,500 mm (256 in)
Height retracted 4,600 mm (181 in)
D
Width 2,300 mm (91 in)
W
Depth 2,700 mm (106 in)

Weight
Designed for large diameter and long hole raiseboring Derrick 45,000 kg (99,200 lb)
applications, the Robbins 191RH is the most powerful Dip adjustment
raise drill in the Atlas Copco Raiseboring series. The from horizontal 90 - 60 (45)
191RH is designed to meet the requirements for very
long, large raises, ranging from 4.5 m to 6.0 m (15-20 ft) * Depending on machine version and rock conditions
to a depth of 1,400 m (4,500 ft) ** Shoulder to shoulder

Features and benefits

The hydraulic drive features variable speed and good
torque limiting control. The well proven RCS system
adds reliability and user friendliness.
A gearbox incorporated in a barrel allows the drive
train to be disassembled into smaller components
without losing the preload of the main bearings.
This saves time during maintenance and transportation.
Rigid crosshead guide columns provide efficient torque
reaction, extending the service life of the thrust
cylinders.
A simple in-line drive system provides balanced thrust
loads to improve cutting action.

A sliding fork worktable wrench, in combination with

the semi-automatic drivehead wrench, eliminates the
need to handle heavy wrenches.

Visit www.raiseboring.com for more information

90 raiseboring
 Secoroc pilot bits

Raise your productivity with pilot bits from

Atlas Copco Secoroc

As part of its ongoing commitment to the mining and construction industries, Atlas Copco Secoroc provides
a complete range of pilot bits. Bits designed to meet the most demanding performance and service life
expectations. Whatever rock conditions youre working in, we have the bits to meet the challenge.

Lower cost per metre drilled
Our industry leadership is the direct result of unwavering
dedication to lowering your overall drilling cost. As part
of this effort, our pilot bits not only give you outstanding
service life, the range of different designs provides a
selection of cutting structures for different rock formations
to be drilled. Furthermore, you can rest assured that both
the manufacturing processes and products are certified
in accordance with API and ISO 9001 technology quality
standards.
At your service wherever you are
No matter how great our products are theyre only a
start. To secure your investment, you need technical
support. Thanks to Atlas Copco Secorocs global
presence, qualified support is never more than a phone
call away. We have skilled personnel on hand across the
world to offer assistance, advice, training, service and
maintenance whenever and wherever you need it.

raiseboring 91
 Secoroc pilot bits

The right bit for the job

For any raise bore piloting operation accurancy, bit selection and carbide wear rate are all key in keeping costs down
and efficiency up. Missing the target area and numerous trips to change bits are just two common, potentially costly
problems.

Select your bit carefully Pilot bit manufacturer comparison

Atlas Copco BMHT Smith Sandvik Security
Before starting on a raise project, collect as much infor-
Secoroc MH BI-V - - M84F
mation about the site as possible. Find out about the
typical formations, their compressive strengths and Secoroc H BI-X Q7JS SCM M87F
abrasive qualities. Secoroc VH BI-XX Q9JS SCH H100F

Then pick your bit. The right one is the one that ultimately A guide to our pilot bits and the equivalent products from other manufacturers.
yields the lowest cost per metre drilled. As youll
discover, with Secoroc you cant go wrong.

Selection guide

Soft/Medium hard rock Hard rock Very hard rock

Secoroc MH

Secoroc H

Secoroc VH

10,000 psi 30,000 psi 50,000 psi 70,000 psi

70 MPa 210 MPa 350 MPa 480 MPa

92 raiseboring
 Secoroc pilot bits

Pilot bits three designs to cover your needs

Secoroc MH extra long life in medium hard and
abrasive formations
Conical-shaped carbide buttons and very little cone
offset allow this bit to drill for long hours in formations
of high compressive strength, including hard limestone,
dolomite and shale. Heavy cutter set for full bottom hole
coverage.
Secoroc VH very hard formation drilling
Tough ovoid carbide buttons, zero offset and full b
ottom
hole coverage combine to allow long hours of drilling in
weighty, hard rock applications. Positioned to cover the
bottom of the h
ole, the nose and inner row buttons are
ovoid-shaped with low projection.

Secoroc H for hard rock formations

Tough, fracture-resistant, ovoid and ogive-shaped
carbide buttons and reduced offset make this bit ideal
for heavyweight, hard rock applications. Good load
distribution thanks to heavy cutter set and full bottom
hole coverage.

Size Prod No. Product Code Product Formation IADC Pin Conn.
7 7/8" 91000924 117-3200-73-RB-07 Bullseye H Hard 7-3-7 4 1/2" API Reg

9" 91000361 117-3228-73-RB-07 Bullseye H Hard 7-3-7 4 1/2" API Reg

9 /8"
7
91000296 118-3250-73-RB-07 Bullseye H Hard 7-3-7 6 5/8" API Reg

9 7/8" 91000297 118-3250-83-RB-07 Bullseye VH Very Hard 8-3-7 6 5/8" API Reg

11" 91000290 118-3279-61-RB-07 Bullseye MH Medium Hard 6-1-7 6 5/8" API Reg

11" 91000313 118-3279-83-RB-07 Bullseye VH Very Hard 8-3-7 6 5/8" API Reg

12 1/4" 91000269 118-3311-73-RB-07 Bullseye H Hard 7-3-7 6 5/8" API Reg

12 /4"
1
91000314 118-3311-83-RB-07 Bullseye VH Very Hard 8-3-7 6 5/8" API Reg

13 3/4" 91000294 118-3349-63-RB-05 Bullseye MH Medium Hard 6-3-5 6 5/8" API Reg

13 /4"
3
91000370 118-3349-73-RB-05 Bullseye H Hard 7-3-5 6 5/8" API Reg

15" 91000383 132-3381-73-RB-05 Bullseye H Hard 7-3-5 7 5/8" API Reg

17 /2"
1
91001026 132-3445-73-RB-05 Bullseye H Hard 7-3-5 7 5/8" API Reg

raiseboring 93
 Secoroc pilot bits

A pilot study in bit design

Tungsten carbide buttons in

different designs

Bearing type
Bit sizes: 12"
o-ring sealed journal bearing
Bit sizes: 13"-15"
o-ring sealed roller bearing

Gauge bevel protection

flat top

Lug/shirttail protection
hardfacing on shirttail

94 raiseboring
 Secoroc pilot bits

12 ways to get the most out of your pilot bits

1 Use a bit gauge to check that the gauge diameter is 8 Do not over torque the pilot bit during makeup.
within recommended tolerances. Recommended torques given by API manufacturers
should be followed. Slow rotation speed during
2 If the pilot bit is used, check that the carbide buttons makeup is advised.
are in good condition and the cones are free to turn
without excessive play. Furthermore, make sure that 9 During bit breakout, raise the pilot bit and drill string
all flushing passages are clear. component high enough to allow the bit to drop into
the bit breaker box.
3 Make sure that the design of the pilot bit complies
with the geological formation youre drilling in as 10 Do not drop the pilot bit with the drill string weight
well as the flushing fluid used. attached.

4 If flushing with compressed air, check that nozzles 11 After removing the pilot bit and bit reamer stabilizer
are installed and of the correct size. from the drill string after breakthrough, lubricate the
cones of the bit with light oil prior to storage.
5 If flushing with water, check that nozzles have been
removed from flushing passages. 12 Any time the pilot hole is open, make sure you dont
drop anything in it. But if you do, be sure to remove
6 Clean up and inspect the threads and mating the object before you resume drilling.
shoulders of the pilot bit and drill string component.
Liberally coat with lubricant approved by the bit
manufacturer.

7 To avoid damaging the threads of the pilot bit and

drill string component, thread the bit by hand onto
the drill string component before installing the
component in the floating box of the machine.

Operating parameters

Size Design Makeup Weight-on-bit Bit Rotary

(in) torque range weight speed (rev/min)

7 7/8 Secoroc H 16,270-21,015 nm 10,630-21,260 kg 30 kg 50-90

12,000-15,500 lbf ft 23,625-47,250 lb 67 lb
9 Secoroc H 16,270-21,015 nm 12,150-24,300 kg 35 kg 50-90
12,000-15,500 lbf ft 27,000-54,000 lb 76 lb
9 7/8 Secoroc H 37,963-43,386 nm 13,330-26,660 kg 64 kg 50-90
28,000-32,000 lbf ft 29,625-59,250 lb 140 lb
9 7/8 Secoroc VH 37,963-43,386 nm 13,330-26,660 kg 64 kg 40-80
28,000-32,000 lbf ft 29,625-59,250 lb 140 lb
11 Secoroc MH 37,963-43,386 nm 14,850-29,700 kg 77 kg 50-120
28,000-32,000 lbf ft 33,000-66,000 lb 170 lb
11 Secoroc VH 37,963-43,386 nm 14,850-29,700 kg 77 kg 40-80
28,000-32,000 lbf ft 33,000-66,000 lb 170 lb
12 1/4 Secoroc H 37,963-43,386 nm 16,540-33,075 kg 101 kg 50-90
28,000-32,000 lbf ft 36,750-73,500 lb 224 lb
12 1/4 Secoroc VH 37,963-43,386 nm 16,540-33,075 kg 101 kg 40-80
28,000-32,000 lbf ft 36,750-73,500 lb 224 lb
13 3/4 Secoroc MH 37,963-43,386 nm 18,560-37,125 kg 130 kg 50-120
28,000-32,000 lbf ft 41,250-82,500 lb 285 lb
13 3/4 Secoroc VH 37,963-43,386 nm 18,560-37,125 kg 130 kg 40-80
28,000-32,000 lbf ft 41,250-82,500 lb 285 lb
15 Secoroc H 35,000-45,000 lbf ft 20,250-40,500 kg 168 kg 50-90
48,400-62,200 nm 45,000-90,000 lb 370 lb
The recommended weight-on-bit and rotary speed operational specifications are shown above. The rule of thumb for best rock engagement is: the greater the
weight-on-bit the lower the rotary speed, the larger the bit the lower the rotary speed.

raiseboring 95
 ROBBINS

Drill string components

8 pipe using 9 pilot hole size
Raise drill string description Box Pin
OD* OD* S/S* S/S* Wrench Wrench Weight Weight
connection connection
in mm in mm flat (in) flat (mm) lb kg
DI22 DI22
Raise drill rod, integral 8.000 203.2 48 1,220 6.750 6.750 7 175 385
Raise drill starter sub (short) 8.500 215.9 12 305 6.750 6.750 7 175 170 77
Raise drill starter (short) 8.500 215.9 21 533 6.750 6.750 7 175 297 135
Raise drill starter (long) 8.500 215.9 48 1,220 6.750 6.750 7 175 513 234
Raise drill stabilizer,
9.000 228.6 48 1,220 6.750 6.750 175 480 218
6 rib, T.C.I.
Raise drill stabilizer, 6 rib, hardface 9.000 228.6 48 1,220 6.750 6.750 7 175 480 218
Raise drill stabilizer, model 60, DI22
9.000 228.6 48 1,220 6.750 4.500 175 620 280
pin x reg box
Lifting bail, 6" DI22 box, 20,000 lb
8.000 203.2 6.750 7 175 44 20
capacity
Lifting bail, 6" DI22 pin, 20,000 lb
8.000 203.2 6.750 7 175 58 26
capacity
Saver sub 8.000 203.2 20 508 6.750 6.750 7 175 161 73
Drill pipe, standard strength 8.000 203.2 29.5 749 6.750 6.750 7 175 390 178
Stabilizer, 6 ribs 9.000 228.6 29.5 749 6.750 6.750 7 175 390 178
Stabilizer, bit reamer 9.000 228.6 29.5 749 6.750 4.500 7 175 400 180
Starter pipe, long 8.500 215.9 29.5 749 6.750 6.750 7 175 305 139
Starter bit sub 8.500 215.9 29.5 749 6.750 4.500 7 175 395 180

8 pipe using 978 pilot hole size

Raise drill string description Box Pin
OD* OD* S/S* S/S* Wrench Wrench Weight Weight
connection connection
in mm in mm flat (in) flat (mm) lb kg
DI22 DI22
Raise drill rod, integral, 8" OD pin
8.000 203.2 48 1,220 6.750 6.750 7 175 385 175
x box
Raise drill starter sub (short), 8"
8.500 215.9 12 305 6.750 6.750 7 175 170 78
OD box
Raise drill starter (short), 8" OD 8.500 215.9 21 533 6.750 6.750 7 175 206 94
Raise drill starter (long), 8" OD 8.500 215.9 48 1,219 6.750 6.750 7 175 470 214
Raise drill stabilizer, model 60, DI22
9.875 250.8 37 940 6.750 6.625 7 175 510 230
pin x reg box
Raise drill stabilizer, 6 rib, hardface,
9.875 250.8 48 1,220 6.750 6.750 7 175 475 215
9.875H.S x box
Lifting bail, 6" DI22 box, 20,000 lb
8.000 203.2 6.750 44 20
capacity
Lifting bail, 6" DI22 pin, 20,000 lb
8.000 203.2 6.750 58 26
capacity

*OD = outer diameter

*S/S = shoulder to shoulder

96 raiseboring
 DRILL STRING COMPONENTS

10 pipe using 11 pilot hole size

Raise drill string description Box Pin
OD* OD* S/S* S/S* Wrench Wrench Weight Weight
connection connection
in mm in mm flat (in) flat (mm) lb kg
DI22 DI22
Raise drill starter (short) 9.500 241.3 20 508 8.250 8.250 8 200 220 100
Raise drill bit sub 9.500 241.3 12 305 8.250 6.625 8 200 200 91
Raise drill starter 9.500 241.3 60 1,525 8.250 8.250 8 200 550 250
Raise drill rod, standard strength 10.000 254 60 1,525 8.250 8.250 8 200 550 250
Raise drill rod, high strength 10.000 254 60 1,525 8.250 8.250 8 200 860 390
Raise drill stabilizer, 6 rib, hardface
11.000 279.4 60 1,525 8.250 8.250 8 200 1150 522

Raise drill stabilizer, model 60,

11.000 279.4 60 1,525 8.250 6.625 8 200 1025 465
DI-22 pin x , reg box
Lifting bail, 8" DI-22 box, 30,000 lb
10.000 254 8.250 73 33
capacity
Lifting bail, 8" DI22 pin, 30,000 lb
10.000 254 8.250 66 30
capacity
Bit sub DI-22 pin x reg box 8.250 209.6 9.5 241 6.625 8.250 8 200 440 200
Saver sub, 6 ribs 11.000 279.4 23 584 8.250 8.250 8 200 1023 465
Drill pipe, STD 10.000 254 29.5 749 8.250 8.250 8 200 440 200
Starter pipe, long 9.370 238 29.5 749 8.250 8.250 8 200 422 192
Bit sub, 6 ribs mod 11.000 279.4 16.75 425 8.250 6.250 8 200 341 155
Starter sub 9.500 241.3 48 1,220 6.625 8.250 8 792 360

11 pipe using 12 pilot hole size

Raise drill string description Box Pin
OD* OD* S/S* S/S* Wrench Wrench Weight Weight
connection connection
in mm in mm flat (in) flat (mm) lb kg
DI22 DI22
Starter pipe, short 11.000 279.4 30 760 9.250 9.250 9 230 800 364
Raise drill starter sub 11.000 279.4 36.5 927 9.250 6.625 9 230 850 386
Starter sub 11.000 279 48 1,219 6.625 9.250 9 230 1060 482
Raise drill starter (long) 11.000 279.4 60 1,525 9.250 9.250 9 230 1400 636
Raise drill rod, integral, standard
11.250 285.8 60 1,525 9.250 9.250 9 230 1060 484
strength
Raise drill rod, integral,
11.250 285.8 60 1,525 9.250 9.250 9 230 775 350
high strength
Drill pipe, standard strength 11.250 285.8 29.5 749 9.250 9.250 9 230 775 350
Stabilizer, 6 ribs 12.250 311.2 30 762 9.250 9.250 9 230 655 297
Stabilizer, 6 ribs 12.250 311.2 36 914 9.250 9.250 9 230 985 467
Stabilizer, 6 ribs 12.250 311.2 60 1,524 9.250 9.250 9 230 1500 680
Stabilizer, bit reamer 12.250 311.2 26 660 9.250 6.625 9 230 728 331
Starter pipe, short 11.250 285.8 29.5 749 9.250 9.250 9 230 572 260
Lifting bail, pin 11.250 285.8 9.250 93 42
Lifting bail, box 11.000 279.4 9.250 213 97

raiseboring 97
 DRILL STRING COMPONENTS

1278 pipe using 13 pilot hole size

Raise drill string description Box Pin
OD* OD* S/S* S/S* Wrench Wrench Weight Weight
connection connection
in mm in mm flat (in) flat (mm) lb kg
DI22 DI22
Raise drill rod 12.875 327 60 1,525 10.500 10.500 10 250 1400 635
Starter pipe (long) 12.875 327 60 1,525 10.500 10.500 10 250 1550 705
Starter pipe (short) 12.750 323.9 30 760 10.500 10.500 10 250 878 399
Starter sub, DI22 pin x 6 API box 12.750 323.9 53.75 1,365 10.500 6.625 10 250 1725 784
Raise drill stabilizer, model 60, DI22
13.750 349.3 48 1,220 10.500 6.625 10 250 1500 682
pin x 6-reg box
Raise drill stabilizer, 16 rib, hard-
13.750 349.3 60 1,525 10.500 10.500 10 250 1605 730
faced, Robbins wrench squares
Saver sub 13.750 349.3 25 635 10.500 10.500 10 250 655 297
Saver sub 13.750 349.3 36 914 10.500 10.500 10 250 942 428
Lifting bail, 10" DI22 box, 70,000 lb
12.875 327 10.500 139 64
capacity
Lifting bail, 10" DI22 pin, 70,000 lb
12.875 327 10.500 149 68
capacity

1278 pipe using 15 pilot hole size

Raise drill string description Box Pin
OD* OD* S/S* S/S* Wrench Wrench Weight Weight
connection connection
in mm in mm flat (in) flat (mm) lb kg
DI22 DI22
Raise drill rod 12.875 327 60 1,525 10.500 10.500 10 250 1400 636
Starter pipe (long) 12.750 323.9 60 1,525 10.500 10.500 10 250 1550 705
Starter pipe (short) 12.750 323.9 30 760 10.500 10.500 10 250 878 399
Starter sub, assembly DI22 pin x 6
12.750 323.9 53.75 1,365 10.500 6.625 10 250 1725 784
reg Ibox
Raise drill stabilizer, Model 60, DI22
15.000 381 48 1,220 10.500 7.625 10 250 1200 545
pin x reg box
Raise drill stabilizer, 6 rib,
15.000 381 60 1,525 10.500 10.500 10 250 1750 795
hardfaced
Lifting bail, 10" DI22 box, 70,000 lb
12.875 327 10.500 139 64
capacity
Lifting bail, 10" DI22 pin, 70,000 lb
12.875 327 10.500 149 68
capacity

1378 pipe
Raise drill string description Box Pin
OD* OD* S/S* S/S* Wrench Wrench Weight Weight
connection connection
in mm in mm flat (in) flat (mm) lb kg
DI22 DI22
Raise drill rod 13.880 352 60 1,525 11ST 11ST 11 279 1685 764

*OD = outer diameter

*S/S = shoulder to shoulder

98 raiseboring

Power packs
Main drive pack
On a hydraulic driven machine the hydrostatic drive
provides hydraulic power to the hydraulic motor(s).
It consists of a fully enclosed, skid equipped mounting
frame with an oil pan, a hydraulic reservoir and a 3-phase
motor equipped with strip heaters driving one variable
displacement pump. Mounted in the pack are return line
filters, heat exchanger, breather and manifold assembly.
The power pack may also be equipped with a built-in fire
suppression system. The electrical cabinet is accessed
separately on one side of the unit. It contains most of the
electrical control components such as circuit breakers,
earth fault relay, under/over voltage relay and control
transformer.
On an electric driven machine (AC, DC or VF) the main
drive pack contains the power and control distribution
hardware and circuitry for the entire raiseboring system.
The cabinet is fully enclosed and may incorporate heaters
for humidity control. A simple and reliable softstart
provides the control for the AC motor.
The latest digital DC drives ensure the best possible
performance of the DC motor. State of the art VF
drives are available upon request. Included are also
components such as circuit breakers, earth fault relay,
under/over voltage relay and control transformer.
raiseboring 99
powering the raise drill
Thrust pack
The thrust pack provides hydraulic power to the derrick
assembly auxiliary components. It consists of a fully
enclosed, skid equipped, mounting frame with an oil
pan, a hydraulic reservoir and a 3-phase motor equipped
with strip heaters driving two variable displacement
pumps, one for the fast traverse circuit and one for the
high thrust system. It also drives one gear pump for the
auxiliary and cooling circuits.
Features and benefits
Compact and lightweight enclosure for protection in
underground environment.
Lifting lugs and fork lift provisions for easy lifting and
positioning.
Thanks to the use of integrated technology, the number
of components and wiring in the cabinet can be kept to
a minimum.
Modern proportional valves in the hydraulic system
allow for safe and smooth operation.
Service lights inside the units are turned on
automatically when doors are opened.
Can be equipped with optional service receptacles for
connecting additional equipment.
 powering the raise drill

L
W

Specifications
Depending on machine specification and type of drive,
the number of power packs and the dimensions of the
power packs may vary. Most Robbins raise drills use two
packs. One for the main drive system for rotation and
one for thrust. Each unit is built to withstand the harsh
environment in underground mining and uses standard
Atlas Copco components.

Power pack Length Height Width Weight

metric imperial metric imperial metric imperial metric imperial
34RH Low Single pack 3,300 mm 130 inch 1,450 mm 57 inch 1,550 mm 61 inch 5,500 kg 12,125 lb
34RH Standard Single pack 3,300 mm 130 inch 1,450 mm 57 inch 1,550 mm 61 inch 5,500 kg 12,000 lb
34RH Wide Single pack 3,300 mm 130 inch 1,450 mm 57 inch 1,550 mm 61 inch 5,500 kg 12,000 lb
44RH Single pack 3,300 mm 130 inch 1,450 mm 57 inch 1,550 mm 61 inch 5,500 kg 12,000 lb
53RH Drive pack 2,800 mm 111 inch 1,450 mm 57 inch 1,500 mm 59 inch 4,250 kg 9,400 lb
Thrust pack 2,200 mm 87 inch 1,450 mm 57 inch 1,300 mm 2,400 kg 5,300 lb
53RH-EX Drive pack 2,800 mm 111 inch 1,450 mm 57 inch 1,500 mm 59 inch 4,250 kg 9,400 lb
Thrust pack 2,200 mm 87 inch 1,450 mm 57 inch 1,300 mm 52 inch 2,400 kg 5,300 lb
73RH Drive pack 2,800 mm 111 inch 1,450 mm 57 inch 1,500 mm 59 inch 4,250 kg 9,400 lb
Thrust pack 2,200 mm 87 inch 1,450 mm 57 inch 1,300 mm 52 inch 2,400 kg 5,300 lb
73RAC Drive pack 1,900 mm 75 inch 1,300 mm 52 inch 800 mm 32 inch 900 kg 2,000 lb
Thrust pack 2,200 mm 87 inch 1,450 mm 57 inch 1,300 mm 52 inch 2,400 kg 5,300 lb
73RVF Drive pack TBA TBA TBA TBA TBA TBA TBA TBA
Thrust pack 2,200 mm 87 inch 1,450 mm 57 inch 1,300 mm 52 inch 2,400 kg 5,300 lb
83RH Drive pack 3,000 mm 119 inch 1,450 mm 57 inch 1,600 mm 63 inch 4,800 kg 10,600 lb
Thrust pack 2,200 mm 87 inch 1,450 mm 57 inch 1,300 mm 52 inch 2,400 kg 5,300 lb
91RH Drive pack 3,300 mm 130 inch 1,450 mm 57 inch 1,600 mm 63 inch 8,700 kg 11,000 lb
Thrust pack 2,400 mm 95 inch 1,450 mm 57 inch 1,300 mm 52 inch 3,300 kg 7,300 lb
97RL Drive pack 2,550 mm 101 inch 1,500 mm 59 inch 1,300 mm 52 inch 1,800 kg 4,000 lb
Thrust pack 2,400 mm 95 inch 1,450 mm 57 inch 1,300 mm 52 inch 3,300 kg 7,300 lb
123RH Drive pack 3,300 mm 130 inch 1,450 mm 57 inch 1,600 mm 63 inch 8,700 kg 11,000 lb
Thrust pack 2,400 mm 95 inch 1,450 mm 57 inch 1,300 mm 52 inch 3,300 kg 7,300 lb
123RVF Drive pack TBA TBA TBA TBA TBA TBA TBA TBA
Thrust pack 2,400 mm 95 inch 1,450 mm 57 inch 1,300 mm 52 inch 3,300 kg 7,300 lb
191RH Drive pack x 3 3,500 mm 138 inch 1,450 mm 57 inch 2,000 mm 79 inch 7,500 kg 16,500 lb
Thrust pack x 3 2,400 mm 95 inch 1,450 mm 57 inch 1,300 mm 52 inch 3,300 kg 7,300 lb

100 raiseboring
 Drill pipe handling equipment

Pipeloader

Ground loading pipeloader on a Robbins 34RH C.

For drill pipe handling a pipeloader is used.

This device is manually controlled and hydraulically
operated. It is designed for placing and removing drill
string components into and out of the derrick during
the boring operation. The drill pipe handling equipment
can be mounted on either side of the derrick main frame.

The pipeloader picks the drill pipe up from the side of

the derrick and swings it into position to be mated
with the drill string and float box. The drill pipe is held
frictionally by jaws plates mounted on a moveable arm.
The pipeloader is remotely controlled by the operator,
either from a handheld control pendant or the operating
panel.

Side loading pipeloader.

raiseboring 101
 Raise borer transporters

Transporters
Transporters are used for getting the derrick to and
from the boring site. Additionally the transporters are
equipped with hydraulic cylinders for derrick erection
during system setup and derrick take-down after
completion of the raise. Atlas Copco offers different
types of transporters to suit different needs.

Diesel crawler
The diesel powered crawler is equipped with integrally
suspended twin crawler tracks, separately powered by
hydraulic motors. The diesel engine drives two hydraulic
pumps, one for the tracks, and one for the fan/erection.
The track drives are driven by a variable displacement
pump and controlled by two proportional valves, each
valve controlling a dual displacement motor, which in
turn are mounted to planetary-type final drive units. Diesel crawler

These final drive units are mounted inside of the rear

track drive sprockets. The diesel engine also provides
power to the erection system, making the crawler an
independent unit. Controls are either radio remote
or via an umbilical cord. The high and low speed in
combination with proportional controls makes the
crawler easy to control and the powerful diesel
engine ensures adequate manoeuvrability.

Air crawler
The air crawler is equipped with twin crawler tracks,
integrally suspended and separately powered by a
hydraulic motor in each track with dual displacement,
mounted to planetary-type final drive units The hydraulic
pump is driven by an air motor. In order to operate, the
crawler must be supplied with compressed air at max.
6 bar (90 PSI) and minimum 15 m3/min (500 ft3/min) air
supply. The air motor also drives a hydraulic pump for Air crawler
powering the erection system. There is also an air-
driven 24 V generator on the crawler for supply of its
electric circuits. The erection system comprises two
proportionally controlled hydraulic cylinders. Controls
are either radio remote or via an umbilical cord.

Sled
The sled is the simplest form of transporter. Skids
are provided on the sled to enable the derrick to be
transported and positioned by use of an independent
mine transport source. The hydraulic erection cylinders
of the sled must be connected to the hydraulic system of
the raiseboring machine for derrick erection and derrick
take-down. An optional electrical powered power pack
can be supplied.

Sled

102 raiseboring

Tools
Makeup and breakout tool (MBT)
This assembly consists of mechanical clamps attached
to a hydraulic ram and a hand- or air operated hydraulic
pump. The ram is connected to the pump by a flexible
hose for convenience. This tool is used primarily for
removal of the bit reamer-stabilizer/pilot bit from the
drill string after a breakthrough. This tool is also used
to tighten the reamer to the drill string to assure proper
torqeing of the connection. See picture above.
Blooie assembly
The blooie system provides a controlled exit for return
bailing fluid and cuttings flowing from the pilot hole
during drilling. This system consists of three major
components: the outlet housing, the lower housing, and
the blooie seal. The outlet housing of the blooie system,
which houses the blooie seal, bolts to the underside
of the machine worktable and provides a flange on its
bottom end to which the lower housing can be fastened.
The lower housing, which is grouted firmly into the
concrete and/or bedrock below the raiseboring machine,
is available in extended lengths to accommodate for
increased distances to the concrete pad or bedrock
resulting when boring angled raises. During pilot hole
drilling, the drill string is routed through both housings
and the blooie seal and into the pilot hole. The blooie
system provides a controlled exit for the bailing fluid
and cuttings by effectively sealing the drill string in
the outlet housing.
raiseboring 103
Ancillary Tools
Starter bushing
The starter bushing is used during pilot hole start up, to-
gether with the starter sub and starter pipe to initiate an
accurately aligned pilot hole. The starter bushing is in-
stalled at the machine worktable when drilling of the pilot
hole begins. The inner diameter of the bushing is machined
to provide a snug interaction with the outer diameter
of the starter sub and starter pipe. The reason for this is
to decrease the pilot hole deviation. See picture above.
Accumulator charging kit
This kit is used to charge the pipeloader clamp accumu-
lator and the drive motor accumulators with dry nitrogen.
Included in the kit is a special fitting compatible with
those commonly found on dry nitrogen bottles and
a regulator or pressure reducing valve with gauge
assembly. The outlet hose of the regulator connects to
the charging nozzle on the accumulator. The regulator is
used to adjust the charging pressure.
 Upgrades
Raiseborer system upgrade kits
Robbins 73RH C with RCS control panel.
There are over 250 Robbins raiseboring systems, built
before 2000, in operation for which Atlas Copco can
provide service support. We know that the derrick of
the machine will normally last in excess of 25 years
in operation, but predicting the efficiency of other
components is not so straightforward. The capacities of
these com-ponents with regards to information read-out,
control, thrust, power and torque are greatly reduced as
the equipment ages.
A large number of these raise drills in the field have worn
out or malfunctioning systems, whilst others are in need
of upgraded capacities with regard to information read-
out, thrust, torque and power.
With this in mind, Atlas Copco Rock Drilling Equipment
has developed a number of upgrade kits that, depending
on the model and customer needs, can include upgrading
of the rig control system (RCS), hydraulic drive (or electric
drive replacement), drive pack, thrust pack, electrical pack,
control console and pipe handling. These upgrade assem-
blies are designed in accordance with the state-of-the-art
technology featuring standard Atlas Copco components
and the well-proven CAN-bus control system. As customers
will expect, all kit components are to Atlas Copco standard,
and are easily available worldwide through all Atlas Copco
Customer Centers.
104 raiseboring
Features and benefits
More compact and lightweight enclosures
Less components and wiring in the cabinet due to
integrated technology, translating into a more reliable
operating system
New systems allow simple replacement of the hydraulic
system with modern proportional valves, etc.
Easy-to-read control features permit safer and faster
production
Can be easily upgraded or customized later due to the
modern RCS
Proven Atlas Copco panel features a compact, watertight
enclosure. It is identical to those in the Atlas Copco
underground equipment
Programmable controls make future software upgrades
easy
Improved motor control and performance with program-
mable soft-start system for optimum results
Soft-start facility has built-in parameters (e.g. motor
voltage and current) and built-in diagnostics
Modern technology will increase system performance
and availability of parts, as well as reducing
maintenance costs

RCS mounted on a moveable trolley for better
view and position of the operating controls.
Objectives and approach
The main reasons for upgrading are to modernize the
technology used, increase the systems performance,
reduce maintenance costs, and increase the availability
of parts due to the fact that all machines presently
produced will share similar parts.
In-depth knowledge of the existing equipment is a must
since the exact components on the equipment have to
be categorized and identified in order to prepare an
upgrade. Atlas Copco Raiseboring department will help
in every way possible to conclude, together with the
Customer Center, what can be done for the customers
machine. The available upgrade kits are as follows:
RCS upgrade
The new Rig Control System (RCS) follows a well-proven
Atlas Copco standard featuring CAN-bus. It is totally en-
closed in a waterproofed envelope designed for outdoor
and underground use under severe conditions. All com-
ponents involved have been developed and long-term
tested in extreme conditions.
The control is fully electrical, eliminating the need for
pressure hoses and gauges at the console. Optional
functions include hydraulic oil level, oil temperature and
filter monitoring. Function of the pipehandling system
raiseboring 105
upgrades
RCS is a common platform for all Atlas Copco
mining and construction products.
can also be included and operated via a joystick on the
panel. This improves performance and availability as
well as reducing cost.
Power pack upgrade
The hydraulic power pack provides hydraulic power to
the derrick assembly and auxiliary components. It con-
sists of a skid-mounted frame with an oil pan, hydraulic
oil reservoir, and a 3-phase electric motor equipped with
strip heaters. It drives two variable-displacement piston
pumps, one for the fast traverse circuit and one for the
feed system. It also drives one gear pump for the
auxiliary and cooling circuits.
Installed with the power pack are the return-line filter,
heat exchanger, breather and manifold assembly. The
manifold has provision for mounting directional control
valves, relief valves and quick-disconnect couplers used
in the hydraulic system. A combined level gauge and
thermometer is mounted on the reservoir.
The skid-mounted frame has lifting lugs. It can either be
fully enclosed and equipped with gull-wing doors, or
available in a basic open layout (i.e. non-enclosed).
The thrust pack can also be equipped with a built-in
fire suppression system.
 Upgrades

Electrical power unit.

Electrical cabinet upgrade

The electrical cabinet contains most of the electrical
control components, such as a manually operated main
circuit breaker, earth-fault relay, under/over voltage relay,
control transformer, CAN-bus master module and control
relays. A running time meter and an optional multimeter,
showing current, voltage and power consumption, are
mounted on the cabinet. Several fault-indicating lights
and a power-on light are mounted outside the cabinet.

This cabinet is the nerve centre for all wiring to the ma-
chine assemblies and components. A heater inside the
cabinet may be provided for humidity control during
lengthy idle periods. The cabinet is equipped with service
lights inside that turn on automatically when the doors
are opened. It is equipped with a service receptacle for
connecting additional equipment, such as water pumps
or welding machines, and has lifting lugs and fork-lift
apertures to facilitate hoisting and positioning.

Hydraulic drive upgrade

This is the top-of-the-range upgrade for DC electrical-
drive machines. The complete upgrade kit is made up of
RCS control, a new hydraulic power pack, twin hydraulic
drive motors and a new electrical power pack. These are
bound to increase the machines useful operating life.
The twin hydraulic drive motors for rig rotation and the
hydraulic thrust pack also provides sufficient power to
the motor, electrical cabinet and RCS control to give the
necessary rig performance. Hydraulic power unit.

106 raiseboring
 upgrades

Complete rig set up in operation.

Pipe loader upgrade

The pipe loader kit is a hydraulically powered unit,
remotely controlled by the operator from a hand-
held electrical control station. It enables drill string
components to be precisely placed into the derrick,
greatly reducing the risk of damaging the threaded
connection.

Using the pipe loader, drill string components are picked

up from ground-level storage and positioned in the
derrick. Conversely the pipe loader can return these
components to storage on the ground.

These added capabilities eliminate the need for a drill

pipe hosting system at the derrick. Operator fatigue
and time required for handling are also reduced, thus
increasing efficiency.

Ground pipe loader.

raiseboring 107
 MARKET MATERIAL

Conversion table
This unit Times Equals This unit Times Equals

Length Mass
(commonly but incorrectly called weight)
mm (millimetre)........................ x 0.001 (10-3).............= m g (gramme). ............................... x 0.001.................... = kg
cm (centimetre)......................... x 0.01........................= m t (tonnes, metric)....................... x 1 000................... = kg
dm (decimetre).......................... x 0.1..........................= m grain.
.......................................... x 0.0648.................. = g
km (kilometre)........................... x 1 000 (103).............= m oz
(ounce).................................. x 28.35.................... = g
in (inch)...................................... x 25.4........................= mm ozt
(troy ounce)......................... x 31.10.................... = g
ft (feet)....................................... x 0.305......................= m lb
(pound).................................. x 0.4536.................. = kg
yd (yard).................................... x 0.914......................= m ton
(long, US). . .......................... x 1 016.................... = kg
mile............................................ x 1609.......................= m ton
(UK)..................................... x 1 016.................... = kg
ton
(short). . ................................ x 907....................... = kg
Power
J/s (joule/second)...................... x 1.............................= W Speed
(velocity)
Nm/s (newton metre/second)... x 1.............................= W km/h
(kilometre/hour). .............. x 0.2777.................. = m/s
kW (kilowatts)............................ x 1 000.....................= W m/s
(metre/sec)......................... x 3.6........................ = km/h
hk (metric horse power)........... x 735.5......................= W mile/h.........................................
x 0.45...................... = m/s
hp (horsepower UK, US).......... x 745.7......................= W mile/h.........................................
x 1.61...................... = km/h
ft.lbf/s......................................... x 1.36........................= W ft/s
(foot/second)....................... x 18.29.................... = m/min
Btu/h........................................... x 0.29........................= W ft/min
(foot/minute).................. x 0.3048.................. = m/min

Volume Frequency

l (litre)......................................... x 0.001......................= m3 blow/min.
................................... x 0.017.................... = Hz
ml (millilitre).............................. x 0.001......................= l kHz
(kiloHertz)........................... x 1 000................... = Hz
dm3 (cubic decimetre).............. x 1.0..........................= l rev/min.
. ..................................... x 0.01667................ = r/s
cm3 (cubic decimetre)............... x 1.0..........................= ml degree/second.
. ......................... x 0.1667.................. = r/min
mm3 (cubic millimetre) . .......... x 0.001......................= ml
in3 (cubic inch)........................... x 16.39......................= ml Pressure

ft3 (cubic feet)............................ x 28.316....................= l bar..............................................
x 100....................... = kPa
Imperial gallon.......................... x 4.546......................= l bar..............................................
x 100 000 (105)....... = Pa
US gallon................................... x 3.785......................= l kp/cm

2
........................................ x 0.98...................... = bar
Ounce (Imp. fluid oz)................ x 28.41......................= ml atm
(atmosphere)..................... x 1.01...................... = bar
Ounce (US fluid oz)................... x 29.57......................= ml psi
(pounds/in 2
)......................... x 6.895.................... = kPa
Pint (US liquid).......................... x 0.4732....................= l psi.
. ............................................. x 0.06895................ = bar
Quart (US liquid)....................... x 0.9463....................= l
yd3 (cubic yard)......................... x 0.7646....................= m3 Area
mm2 (square mm)..................... x 0.000001 (10-6).... = m2
Force cm2 (square cm)........................ x 0.0001 (10-4)........ = m2
kN (kilonewton)......................... x 1 000.....................= N in2 (square inches).................... x 645....................... = mm2
kp (kilopond)............................. x 9.81........................= N ft2 (square feet).......................... x 0.0929.................. = m2
kgf (kilogramme force)............. x 9.81........................= N yd2 (square yard)....................... x 0.8361.................. = m2
Ibf (pound force)....................... x 4.45........................= N Acre . ......................................... x 4 047.................... = m2
Square mile............................... x 2.590.................... = km2
Torque (moment of force) ha (hectare)............................... x 10 000................. = m2
kpm (kilopondmetre)................ x 9.81........................= Nm
Ibf in (poundforce inch) ........... x 0.11........................= Nm
Ibf ft (poundforce foot)............. x 1.36........................= Nm

Equals Divided This Equals Divided This

by unit by unit

108 raiseboring
 Atlas Copco
No surprises Raiseboring
in Mining and Construction

Raiseboring in Mining and Construction

Service and support.
Two words Atlas Copco has built a reputation on since 1873. 24 hours
a day, 7 days a week we pro-actively support the mining industry with
solutions that work before its too late. Anytime, anywhere in the world
our network of sales companies, mining experts and service program
makes sure your machines and tools are ready to work. After all,
Printed matter no. 9851 2575 01

machines have to be online to make money.

Committed to your superior productivity.

Atlas Copco Rock Drills AB

First edition 2008
2008

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