Week 12 - Microwave Roadheader Excavation

Microwave Assisted Roadheader Excavation of
Rock Caverns in Singapore Granite
USPF Project
Developing Low-Power Microwave Tools to Assist Rock Excavation for
Underground Caverns
15 August 2019 – 31 December 2020
Zhao Jian, Monash University, Australia
Microwave Assisted Roadheader Excavation
Rock Cavern Construction and Project Objectives

Development of Microwave Focusing Antennas
Field Tests on Gali Batu Granite Blocks and Wall
Laboratory Tests on Gali Batu Granite
Excavation Rate and Energy Comparative Analysis
Microwave Machine and Roadheader Operation
Conclusions and Recommendations
2
Cavern Construction and Project Objectives
Rock Excavation and Cutting Methods

• Mechanised methods:
Tunnel boring machine, roadheader, mobile
Charging
miner, impact breaker, ripper. Drilling
Shotcreting
Usually continuous process. Surveying
Marking
Blasting
Mapping
• Drill-and-blast method:
Drilling, charging and explosion. Bolting
Usually cyclic process. Ventilation

Scaling
• Other methods:
Mucking
High pressure waterjet, chemicals, © Atlas Copco

+ modifications
electromagnetic waves.
3
Hard Rock Cavern Excavations

Multi-stage multi-face excavation.
• Drill-and-blast method:
Drilling, charging and explosion.
Cyclic excavation process,
excavation stops during blasting.
• Mechanised excavation methods:
Roadheader, mobile miner.
Continuous excavation process,
machines working independently.
© Atlas Copco
4
Roadheader Rock Excavation Machines

Primarily for low to moderate strength rocks, up to 140 MPa. In highly
fractured low RQD rocks, can cut rocks up to 180 MPa.
Cutterhead Roadheader Cutterhead Standard Maximum Rock

Roadheader
Weight Power Cutting Area Strength
Class
(ton) (kW) (m2) (UCS MPa)
Boom Light 8-40 50-170 25 60-80

Muck conveyor
Medium 40-70 160-230 30 80-100
Heavy 70-110 250-300 40 100-120

Loading apron
Crawler chassis Extra heavy >100 350-400 45 120-140
Transverse roadheader ©Sandvik
Limitations of Roadheader Excavation in Hard Rocks

• Rock strength limited to
140 MPa in massive rock.
• Low excavation rate in
high strength rocks.
• High cutting tool
consumption in high
abrasive rocks.
© sydneymetro.info
6
Cavern Construction in Singapore

• Large caverns for various underground
space.
• Caverns mostly in granite, excavated by
blasting.
Potential cavern
• Urban environment, great concerns on construction site
at Gali Batu
blasting safety and vibration.
Cavern construction may be constrained by
blasting. Alternative excavation technology is
required. © Google Maps
Cavern Construction by Roadheader in Singapore Granite

• Singapore granite is of very high strength, average 186 MPa and
maximum 300 MPa. Currently no roadheader technology is available to
excavate massive rocks >140 MPa.
• Microwave treatment can reduce rock strength, enable roadheader to
excavate very strong granite.
• Microwave assisted roadheader excavation method is believed to be a
viable alternative to drill-and-blast method.
8
Microwave and Microwave Rock Weakening Technology

Microwave is an electromagnetic wave with a frequency in the range of
300 M to 300 G Hz. When rocks are subjected to microwave irradiation,
electromagnetic energy is converted to thermal energy through
increased agitation of water molecules and/or charged ions in minerals.
Microwave rock weakening
involves (i) differential
temperature raising and (ii)
differential thermal expansion, of
different minerals, leading to
thermal induced cracking.
Microwave Rock Weakening Research and Findings

Laboratory tests using confined microwave irradiation shows that with
microwave intensity of about 100 W/cm2, granite and some hard rocks
can be substantially
weakened with cracking.
Peak strength can be reduced
Up to 45% after 2 minutes
Irradiation.
10
10
USPF Project Scopes

(a) To design, fabricate and modify wave focusing antennas for single
and grouped irradiation microwave heads;
(b) To conduct field tests on selected Singapore site (or granite) with the
designed and modified microwave tools.;
(c) To conduct laboratory tests on Singapore rocks to quantify rock
properties with microwave treatment;
(d) To study and compare costs for underground cavern construction in
Singapore granite.
11
11
USPF Project Organisation and Milestone Timelines

The project is undertaken by Prof Zhao Jian of Monash University,
supported by Dr Zhang Qianbing (Monash U) and Dr Wu Wei (NTU), and
engaged 2 post-doc (Dr Zou Chunjiang, Dr Liu Kai) and several PhD
students (Jack Wu, Sun Tingwen, Ma Zhongjun, Zhao Qinhua).
External organisations
Proposal Submitted May 2018
were involved in rock
preparation, tool design Proposal Accepted December 2018
and fabrication, and field JTC-Monash Agreement Signed 15 August 2019
testing.
Project Completed 31 December 2020
12
12
Project Reports
Preliminary Laboratory Experiments, Observations and Measurements on Fracturing and Damage of the Bukit
Timah Granite by Low Power Microwave Treatment, 2019/11/30.
Large-Scale Field Experiments of Microwave Treatment on Large Granite Rock Blocks and Wall, Part 1: Test
Preparation and Plan, 2020/2/25.
Large-Scale Field Experiments of Microwave Treatment on Large Granite Rock Blocks and Wall, Part 2: Initial
Phase Test Report, 2020/7/20.
Laboratory Measurements and Observations on Microwave Heating Characteristics of Granite and Igneous
Rock Composition Minerals, 2020/7/25.
Design and Manufacturing of Low-Power Converging Microwave System for Rock Fracturing, 2020/11/15.
Laboratory Measurements on Strength and Indentation Hardness of the Bukit Timah Granite after Microwave
Treatment, 2020/11/30.
Large-Scale Field Experiments of Microwave Treatment on Large Granite Rock Blocks and Wall, Part 3: Final
Phase Test Report, 2020/12/4.
Analysis and Comparison Studies on Specific Energy, Excavation Rate and Excavation Cost of Microwave
Assisted Roadheader Excavation of Singapore Granite, 2020/12/15.
Interim reports, progress reports, supplementary notes and materials.
13
13
Technical Requirements and Possible Solutions

Technical requirements: to achieve microwave intensity > 100 W/cm2 on
rock surface, in open space.
Possible solutions: to design wave
focusing antennas.
Testing: to test on Singapore
granite at field scale.
14
14
Wave Focusing Antennas and Initial Designs

Converging waveguide: reduces waveguide dimension
in electric field direction (height) while magnetic field
Size: 109 x 55 x 400 mm
direction (width) is kept unchanged. Power intensity is
inversely proportional to opening size.
Metal plate focusing lens: uses two sets of
parallel metal plates at a right angle to work
as a lens to focus the microwave power at its
focal point. With large size, it can be used for
single point irradiation, but not in group. It is
discontinued for further testing. Size: 1200 x 1200 x 2000 mm
15
15
Converging Waveguide Improvements

Converging waveguide with dielectric filling:
low-loss dielectric is filled the interior of the
waveguide, to gradually reduce dimensions in
both E-plane and H-plane, to improve wave
directionality and further increase microwave Size: 109 x 55 x 180 mm
power intensity. Length reduced to 180 mm,

and width (109 mm) can be further reduced by
30 mm. Alum inum oxide
Both waveguides are tested.
16
16
Microwave Waveguide Development and Testing

Testing of waveguides are organised in 2 phases associated with 2
stages of waveguide developments.
Phase 1: to test the initial waveguide design (unfilled), and to provide
suggestions for modifications.
Phase 2: to test the modified waveguide (dielectric filled).
17
17
Field Tests on Gali Batu Granite
Field Testing Objectives

• Proof of waveguide design
• Microwave operation in open
space condition (field test)
• Engineering scale of rock
weakening (medium and
large blocks)
• Simulation of excavation
(rock wall)
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18
Granite Blocks from

Gali Batu
Granite blocks are
collected, transported
and cut into large size
and medium size
blocks for testing.
Additional samples are
supplemented by
similar local granite.
19
19
Phase 1 Testing Summary

Block Size Quantity Tests and Measurements Total Test Numbers
Single-point single duration radiation, 1-4 min 24
Thermal imaging 48
Medium 24 (8+16) Schmidt hammer hardness 312
Ultrasonic velocity 552
Impact drilling 24
Multi-points single duration radiation, 1-4 min 48
Thermal imaging 48
Schmidt hammer hardness 524
Large 11(1+10)
Impact drilling 36
Rotary drilling 12
20
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Phase 2 Testing Summary

Block Size Quantity Tests and Measurements Total Test Numbers
Single-point single duration radiation, 1-2 min 23
Thermal imaging 46
Medium 23 (12+11)
Single/multi point single duration radiation, 2 min 61
Thermal imaging 122
Large 11 (7+4)
Multi point single duration 77
Wall 1 (9) Thermal imaging 154
21
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Field Test
Set-Up and
Measurements
22
22
Test Results: Waveguide Designs

The initial designed converging waveguide
worked well when it is at close distance of
Performance of
less than 1.5 cm to the rock. dielectric filled
converging waveguide
The improved dielectric filled converging (blue) at 3 kw.min
irradiation.
waveguide has smaller size, higher
microwave intensity and better
directionality.
At high power, the tool is still efficient in
breaking rocks at distance up to 5 cm.
23
23
Field Test Temperatures increase with radiation power and

Temperature scan
Results: duration, 770 degrees with 6 kW and 4 min.
Microwave Crack numbers and lengths increase with
Heating and Crack observation radiation power and duration, extended beyond
15-20 cm.
Cracking
Velocities decrease with radiation power and
Ultrasonic wave
duration, decrease with distance from radiation
velocity
centre to about 15 cm.
Hardness decrease with radiation power and
Schmidt hardness duration, decrease with distance from radiation
centre to about 15 cm.
Breakability and drillability increase with
Rock breakage
radiation power and duration.
24
24
Field Test Results: Microwave Damage Zone and Size

• Visible cracks can extend to 15-20 cm to
the free boundary. Sonic velocity
measurements and Schmidt hammer
tests also imply the damage zone is up to
15-20 cm radius.
• Inside the rock, visible crack length is
about 8 to 10 cm.
• For systematic microwave treatment,
suggested optimal irradiation spacing is
15-20 cm.
25
25
Laboratory Testing Objectives

• Determine dielectric properties
of rock forming minerals.
• Confirm microwave rock
Loading Microwave Test
weakening mechanism. Test type
condition condition numbers
Uniaxial
• Determine rock strength changes compressive Quasi-static
2 kW,
1, 3, 5 min
12
strength
with microwave.
Brazil tensile 2 kW,
Quasi-static 12
strength 1, 3, 5 min
• Quantify roadheader cutting
6 kW,
indentation parameters. Indentation Quasi-static
0.5, 1, 1.5 min
12
hardness
index 6 kW,
Dynamic 23
0.5, 1, 1.5 min
26
26
Laboratory Tests Conducted

• Mineral dielectric and heating tests: 14 minerals are tested, in
powders and in pieces, with measurements of dielectric properties
and heating characteristics.
• Compressive and tensile strength tests: uniaxial compressive strength
and Brazil tensile strength at different microwave
treatment.
• Indentation hardness tests: Static and dynamic
impact indentation tests to characterize rock
cutting and drilling performance.
27
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Test Results on Dielectric Properties of Key Minerals

Loss factor
Granite is of high microwave Minerals Dielectric constant Loss factor
category
fracturability due to mineral Albite (plagioclase) 5.62 0.039 a
composition mix. Almandine (garnet) 9.91 0.056 a
Augite (pyroxene) 6.80 0.182 b
80 Quartz Othoclase
Plagioclase
Biotite
White mica
Biotite #2
Biotite (mica) 7.48 0.456 b
70 Biotite #3 Hornblende #1
Hornblende #2
Hedenbergite #1
Hypersthene
Hedenbergite #2 Calcite 8.46 0.025 a
60
Heating rate (℃/min)
Diopside Forsterite
50
Diopside (pyroxene) 6.77 0.012 a
40 Hornblende (amphibole) 14.45 0.324 b

30 Magnetite 47.57 1.870 c
20 Microcline (K-feldspar) 5.55 0.118 b
10
Muscovite (mica) 6.50 0.136 b
0
500 600 700 800 900 1000 Olivine 6.26 0.006 a
Power (W) Quartz 4.72 0.014 a
28
28
Test Results on Compressive and Tensile Strengths

Tensile strength reduction is more than compressive strength reduction
due to cracking.
Highest reduction is on indentation hardness index.
Input energy, Duration (at 2 Average UCS, Average Average BTS, Average
kW.min kW), min MPa reduction, % MPa reduction, %
0 0 107 0 8.5 0
2 1 104 3 8.2 4
6 3 93 13 4.8 44
10 5 71 34 3.2 62
29
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Test Results on Static and Dynamic Indentation Hardness

Input energy, Duration (at Average Reduction, Average Reduction, Average
kW.min 6 kW), min Static IHI % Dynamic IHI % reduction, %
0 0 57.8 0 814 0 0
3 0.5 50.3 13 763 6 10
6 1.0 32.8 43 368 55 49
9 1.5 13.2 77 199 76 76
30
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Excavation Rate and Energy Analysis
Objectives and Scopes of Rate and Energy Studies

• Analyzing of roadheader excavation specific energy and cutting rate
for Singapore granite before and after microwave treatment.
• Comparing of energy and rate for microwave assisted roadheader
excavation options.
• Estimating cost implications on using microwave in rock cavern
excavation.
• Enabling compatibility between microwave treatment and roadheader
excavation operations.
31
31
Rock Mechanics Parameters and Energy and Rate Analysis

Roadheader Energy and Comparing Comparing Quantitative
Microwave specific rate are excavation excavation measures
treated energy and functions of energy and rate and and
granite cutting rate UCS, BTS, rate with overall cost comparison
models RQD fresh granite with blast
Input Input Including Based case

Direct rock RQD UCS and case studies studies in
breaking and from BTS on effects of different
drilling tests field from lab rock rocks and
tests tests parameters parameters
Qualitative Energy and rate Energy and rate Energy and rate
only;
Insufficient
to excavate vs to excavate + to microwave
quantitative original rock microwaved rock rock
32
32
Test Results on Strength Reduction and Damage Zone

• Granite blocks from Gali Batu have lower average 𝛔c (UCS) of 107 MPa
(due to weathering). The general fresh Singapore granite has average
𝛔c at 186 MPa, with highest at 300 MPa.
• Gali Batu granite is weakened by 10 kW.min microwave with strength
reductions between 30 to 70 % (𝛔c 34%, 𝛔t 62%, and IHI 80%).
• Visible crack extension up to 30 cm to free boundary and 15 cm within
infinite boundary. Damage zone within rock block is taken as 15-25 cm
diameter. Optimal microwave heating point spacing is about 15-20 cm.
33
33
Rock Mechanics Parameters of Gali Batu Granite (107 MPa)
Microwave 𝛔c (MPa) 𝛔t (MPa) RQD (%)

Treatment
(kW.min) Range Average Reduction Range Average Reduction Range Average
0 93-118 107 6.8-9.6 8.5 100 100
3 101 6% 7.4 13% 95-98 97
6 87-97 93 13% 4.7-5.1 4.8 44% 90-93 91
9 76 29% 3.6 58% 83-87 84
10 70-72 71 34% 2.4-4.0 3.2 62% 83
34
34
Rock Mechanics Parameters of Singapore Granite (186 MPa)
Microwave Treatment
𝛔c (MPa) 𝛔t (MPa) RQD (%)
(kW.min)
Average Reduction Average Reduction Average
0 186 11.4 100
3 175 6% 9.9 13% 97
6 162 13% 6.4 44% 91
9 132 29% 4.8 58% 84
10 123 34% 4.3 62% 83
35
35
Roadheader Excavation Specific Energy and Cutting Rate

Empirical equations calculating specific energy (SE) and Instantaneous
Cutting Rate (ICR) are established based on field and laboratory tests.
SE = 0.027 (𝛔c 𝛔t) + 0.675
SE = 1.98 e0.0182 𝛔c
ICR = k (P / SE), k=0.8-0.9
ICR = 260･0.974RMCI, RMCI = 𝛔c(RQD/100)2/3
ICR = 510600 𝛔c-2.18
(Equations 4 and 5 are for P=300 kW)
36
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Estimated SE and ICR for Gali Batu Granite (107 MPa)

Microwave Average 𝛔c, Average 𝛔t, Average Average SE, Average
Treatment, kW.min MPa MPa RQD, % kW.h/m3 ICR, m3/h
0 107 8.5 100 19.6 16.0
3 101 7.4 97 16.6 18.8
6 93 4.8 91 11.7 24.2
9 76 3.6 84 8.0 38.1
10 71 3.2 83 7.0 43.7
Cutter power 300 kW
37
37
Estimated SE and ICR for Singapore Granite (186 MPa)

Microwave Average 𝛔c, Average 𝛔t, Average Average SE, Average
Treatment, kW.min MPa MPa RQD, % kW.h/m3 ICR, m3/h
0 186 11.4 100 58.2 3.9
3 175 9.9 97 47.6 4.8
6 162 6.4 91 33.1 6.6
9 132 4.8 84 19.8 12.0
10 123 4.3 83 16.8 14.6
Cutter power 300 kW
38
38
Microwave Treatment Rate for Different Head Configurations
Head configuration (spacing 17 cm) 4x4 5x5 6x6 7x7 8x8 9x9 10 x 10
Treatment area per head (m2) 0.46 0.72 1.0 1.42 1.85 2.34 2.89
Treatment run depth (m) 0.2 0.2 0.2 0.2 0.2 0.2 0.2
Volume per treatment run (m3) 0.092 0.144 0.200 0.284 0.370 0.468 0.578
Treatment run time (s) 120 120 120 120 120 120 120
Treatment rate (m3/h) 2.8 4.5 6.0 8.6 11.1 14.0 17.1
39
39
Comparisons of Energy and Rate for 186 MPa Granite

Energy and rate to Energy and rate to Energy and rate to
and microwave granite
excavate original granite ? excavate microwaved
(10 kW.min, 17 cm spacing,
(186 MPa) granite (123 MPa)
20 cm depth)
Energy to excavate Energy to excavate Energy to microwave

186 MPa granite > microwaved granite + granite
3.5 MJ/m3 (58.2 kW.h/m3) 1.0 MJ/m3 (16.8 kW.h/m3) 1.7 MJ/m3 (28.8 kW.h/m3)
Rate to excavate Rate to excavate Rate to microwave

Rate ratio
186 MPa granite < microwaved granite approx. 2:1 granite (6x6 points)
3.9 m3/h 14.6 m3/h 6.0 m3/h
5x5 points, 4.5 m3/h, ratio @ 3:1

9x9 points, 14 m3/h, ratio @ 1:1
40
40
General Case for Singapore Granite (186 MPa): From

Impossible to Possible using Roadheader to Excavate
• Granite of strength of 186 MPa is not possible for roadheader (>3.5
MJ/m3, <4 m3/h with excessive cutter consumption).
• Microwave (10 kW.min) reduces strength to about 123 MPa.
• Cutting rate can reach 15 m3/h, combined energy rate is 2.7 MJ/m3.
Requires 2 microwave machine of 6x6 head (or 1 machine with 9x9).
• Rate for 186 MPa granite is theoretical. In practice it is not possible to
excavate.
41
41
Comparisons of Energy and Rate for 107 MPa Granite

Energy and rate to Energy and rate to Energy and rate to
and microwave granite
excavate original granite ? excavate microwaved
(10 kW.min, 17 cm spacing,
(107 MPa) granite (71 MPa)
20 cm depth)
Energy to excavate Energy to excavate Energy to microwave

107 MPa granite < microwaved granite + granite
1.2 MJ/m3 (19.6 kW.h/m3) 0.4 MJ/m3 (7.0 kW.h/m3) 1.7 MJ/m3 (28.8 kW.h/m3)
Rate to excavate Rate to excavate Rate to microwave

Rate not
107 MPa granite < microwaved granite compatibility granite (6x6 points)
16.0 m3/h 43.7 m3/h 6.0 m3/h
Requiring 7 microwave machine

to work with 1 roadheader.
42
42
Case for Weathered Granite or Sedimentary Rocks (107 MPa):

Improved Excavation Rate but Limited Cost Benefit
• Rocks of strength 107 MPa, roadheader cutting rate is 16 m3/h, energy
rate is 1.2 MJ/m3.
• Microwave (10 kW.min) reduces strength to 71 MPa, cutting rate can
reach 44 m3/h. Microwave-roadheader combined energy rate is 2.1
MJ/m3.
• Microwave rate is low and not compatible with roadheader rate. It
requires 7 microwave machine (6x6) to work with 1 roadheader.
• Useful only if rate is the main consideration.
43
43
Comparison with Field Curves, Rock Strength and RQD
Singapore granite
before and after
(Thuro and microwave
Plinninger
1999)
44
44
Cost Distribution of Roadheader Excavation of Mine Roadway

• Unit cost for roadheader excavation Expense
Cost per m
Drive (US$/m)
Cost per Volume
(US$/m3)
Cost
Percentage
is low for weak and soft rocks. It is
Roadheader* 312.5 11.2 22%
in fact lower than drill-and-blast
Energy 62.5 2.2 4%
(2111 US$/m).
Cutter
42.5 1.5 3%
• Energy counts only 4% of the cost. consumption
Maintenance,
• The highest cost is manpower. repair & parts
65.0 2.3 5%
Labour 950.0 33.9 66%
Total 1432.5 51.1 100%
*Roadheader cutterhead power 160 kW, excavation cross-

section area 28 m2, in a claystone. (Su and Akkas 2019)
45
45
Microwave Excavation Machine and Multi-Point Head

One complete machine, similar to drilling jumbo, microwave head fitted
with multiple focusing waveguides
(spacing 15-25 cm), remote control, Micro-
wave Waveguide
auto impedance matching, Head
auto positioning and

closing-up.
46
46
Microwave-Roadheader Excavation Operation

1) Mobilise multi-point microwave machine to the rock face. Treat the
whole face, with one or more machines (to match roadheader
excavation rate). Demobilise the microwave machines.
2) Mobilise roadheader to the rock face. Excavate the whole face to the
designed depth. Demobilise the microwave machines.
3) Repeat (1) and (2).
Microwave treatment and roadheader excavation are done by remote
control, in parallel, at different excavation faces.
47
47
Microwave-Roadheader Excavation Operation

Microwave and roadheader can work independently. More microwave
machines can be used to match the excavation rate.
48
48
Matching Microwave and Roadheader Excavation Operation

Microwave treatment faces.
10kw.min., 17 cm spacing.
6x6 points, 1 m2,
2 min, 2 microwave machines.
Total microwave treatment time
= 64÷1×2÷2
= 64 min.
Granite 186 MPa, excavation face 64 m2 (16 x 4 m)
Roadheader excavation face.
cutting depth 20 cm, ICR 14.6
m3/h, 1 roadheader.
Total roadheader cutting time
= (64×0.2)÷14.6
=0.88 h
= 53 min.
49
49
Comparisons with Drill-and-Blast

• Drill-and blast is the most common and indeed the most effective
method to excavate caverns in rock rocks. It can excavate 1,200 m3 per
day for heading and more for benching.
• Whenever blasting is permitted, it should be the preferred method for
cavern excavation.
• Microwave technology is for assisting mechanized excavation, in the
situation where blasting is not permitted.
50
50
Comparisons with Other Excavation Techniques

• Other rock cutting techniques: expansion by chemicals, high pressure
waterjet.
• Both are for small quantity excavation and secondary breaking, not
suitable for tunnel and cavern excavation.
• Chemical expansion cycle: drill holes, pouring chemicals, expansion.
Cycle length is minimum 1 day. Not possible for confined rocks.
• Waterjet cutting depth is up to a few cm. Cut rock not free to be
removed, water consumption and flooding at tunnel site.
51
51
Project Conclusions (I)

• A new dielectric filled converging waveguide has developed for
improved performance of microwave heating of rock.
• Rocks at engineering scale are weakened substantially with cracking.
Visible cracks can be 30 cm to free boundary and 15 cm inside rock.
Suggested optimal microwave heating point spacing is 15-20 cm, as
damage zone is about 15-25 cm diameter.
• Current roadheader technology can excavate hard massive rocks up to
140 MPa. Microwave treatment makes very strong and hard rocks from
impossible to possible for roadheader excavation.
52
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Project Conclusions (II)

• For very strong rocks (e.g., >180 MPa), microwave – roadheader
excavation method has advantage in terms of energy and rate.
• For medium and low strength rocks (<120 MPa), there is little
advantage of using microwave to assist roadheader excavation, except
gaining excavation rate.
• Operation to use microwave in excavation also means underground
excavation will be fully automated and remote control, which is in line
with current and future construction trend.
53
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Week 12 - Microwave Roadheader Excavation

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Week 12 - Microwave Roadheader Excavation

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Microwave Assisted Roadheader Excavation of

Rock Caverns in Singapore Granite

Zhao Jian, Monash University, Australia

Microwave Assisted Roadheader Excavation

Rock Cavern Construction and Project Objectives

Rock Excavation and Cutting Methods

Usually cyclic process. Ventilation

High pressure waterjet, chemicals, © Atlas Copco

Cavern Construction and Project Objectives

Hard Rock Cavern Excavations

Roadheader Rock Excavation Machines

Cutterhead Roadheader Cutterhead Standard Maximum Rock

Boom Light 8-40 50-170 25 60-80

Medium 40-70 160-230 30 80-100

Heavy 70-110 250-300 40 100-120

Cavern Construction and Project Objectives

Limitations of Roadheader Excavation in Hard Rocks

Cavern Construction in Singapore

Cavern Construction and Project Objectives

Cavern Construction by Roadheader in Singapore Granite

Microwave and Microwave Rock Weakening Technology

Cavern Construction and Project Objectives

Microwave Rock Weakening Research and Findings

USPF Project Scopes

Cavern Construction and Project Objectives

USPF Project Organisation and Milestone Timelines

Development of Microwave Focusing Antennas

Technical Requirements and Possible Solutions

Wave Focusing Antennas and Initial Designs

Development of Microwave Focusing Antennas

Converging Waveguide Improvements

power intensity. Length reduced to 180 mm,

Both waveguides are tested.

Microwave Waveguide Development and Testing

Field Tests on Gali Batu Granite

Field Testing Objectives

Granite Blocks from

Field Tests on Gali Batu Granite

Phase 1 Testing Summary

Phase 2 Testing Summary

Field Tests on Gali Batu Granite

Test Results: Waveguide Designs

Field Tests on Gali Batu Granite

Field Test Temperatures increase with radiation power and

Field Test Results: Microwave Damage Zone and Size

Laboratory Tests on Gali Batu Granite

Laboratory Testing Objectives

Laboratory Tests Conducted

Laboratory Tests on Gali Batu Granite

Test Results on Dielectric Properties of Key Minerals

40 Hornblende (amphibole) 14.45 0.324 b

Test Results on Compressive and Tensile Strengths

Laboratory Tests on Gali Batu Granite

Test Results on Static and Dynamic Indentation Hardness

Objectives and Scopes of Rate and Energy Studies

Excavation Rate and Energy Analysis

Rock Mechanics Parameters and Energy and Rate Analysis

Input Input Including Based case

Test Results on Strength Reduction and Damage Zone

Excavation Rate and Energy Analysis

Rock Mechanics Parameters of Gali Batu Granite (107 MPa)

Microwave 𝛔c (MPa) 𝛔t (MPa) RQD (%)

0 93-118 107 6.8-9.6 8.5 100 100

3 101 6% 7.4 13% 95-98 97