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Drilled Casings When using a drill casing, soil, rock and other debris is removed within the protection of a steel tube and brought to the surface. For foundations during the concreting process the pile support is transferred from the temporary drill casing, which is gradually withdrawn, to the concrete forming the pile shaft. Likewise, the casing may be left in place to be used as additional structural support and/or protection of the pile itself. For exploration and well drilling, the casing itself can become the conduit for bringing the bounty to the surface.
Symmetrix Advantages
Straight holes always without deviation due to changing ground formations! Quick set-up and high production rates ! Less torque is required to drill through all formations than other methods! Easy to unlock/ Easy to relock! Drilling is easy at any angle! Effective internal flushing! Safe and controlled! Significant economic savings! Reaming for casing is done by concentric ring bit with no eccentric components! Simple foolproof structure equals no jamming and no lost bits!
1. Symmetrix STD
SYMMETRIX
THE SOLUTION IN OVERBURDEN DRILLING
1. Symmetrix STD
Pilot bit has two shoulders; one at the ring bit; one at the casing shoe Has a wire or ring connection between the ring bit and the casing shoe For drilling medium to deep holes when the casing is left permanently in the hole For temporary casings it is used without the connection between the ring bit and the casing shoe resulting in the ring bit to be left in the hole
Example 1, casing is used as a protective casing in the overburden part of the hole, after the overburden has been drilled through, the drilling is continued in bedrock without casing advancing. Using a normal rockbit (hammerbit).
Step 1: Casing is drilled through overburden and seated into bedrock. Step 2: The pilot bit is unlocked from the ring bit and withdrawn. Step 3: Drilling is continued with a smaller rock bit to complete the task (i.e. water wells, rock sockets, or rock anchors) the casing and ring bit are left in place
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THE SOLUTION IN OVERBURDEN DRILLING
Example 2. Casing is drilled through the overburden to the bedrock. Drilling is not continued but the casing is filled with concrete and or load bearing steel for piling purposes.
Step 1: Casing is drilled through overburden and seated into bedrock Step 2: The pilot bit is unlocked from the ring bit and withdrawn Step 3: The casing, either a thick walled casing or thin walled with additional reinforcement, is filled with concrete to be used as a foundation pile. All Symmetrix systems include the pilot bit, casing shoe to pull the casing (except some shoeless models for double rotation rigs) and the reaming ring bit, which makes the space for the casing. The pilot bits are mainly done for DTH hammers but most small sizes are available also for top hammer drilling. All major shanks are provided according the make and the type of the DTH hammer.
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THE SOLUTION IN OVERBURDEN DRILLING
In Symmetrix well drilling, the wells have either steel or PVC casing drilled through the overburden layers. The pilot bit is then unlocked from the ring bit and withdrawn. The casing is then grouted to seal it to the bedrock thus preventing surface water from contaminating the well. The lower part of the well is then drilled with standard rock bits and drilling methods. The Symmetrix Method has been extremely well received by well drillers worldwide who, thanks to Rotex and Symmetrix, can considerably shorten the work time necessary for overburden drilling.
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THE SOLUTION IN OVERBURDEN DRILLING
Klemm KR 807 drilling 16 inch permanent casings for a railway bridge in Finland
Piling with drilled casing is a fairly common practice in most parts of the world. The selection between friction piles and end bearing piles as well as best methodology and construction technique will depend on the local ground conditions. In areas with varying ground conditions, boulders, extreme hard ground or the need for rock sockets, Symmetrix Casing Advancing System will prove to be the quickest and most economical tool.
Operators of small drill rigs really appreciate the ease of drilling and the small torque required when using Symmetrix. A small drill rig can easily match the productions of larger drill rigs with the same feed length when Symmetrix is used and get productions of 200% or more in comparison to other methods.
Small drill rig using Symmetrix does the work of a big rig in Hong Kong
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THE SOLUTION IN OVERBURDEN DRILLING
Three additional floors were excavated below an old building after underpinning using Symmetrix
This is very evident in railway works where quick non-obtrusive methods are a must. Here, at a railway realignment project in the UK, 1860 steel casings were drilled through overburden and voids (including old mines) to bedrock to a new railway track foundation.
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THE SOLUTION IN OVERBURDEN DRILLING
New W-systems have longer casing shoe sleeves over the casing to allow better guidance and the use of additional plug welds.
Rotex Oy has patented the manufacturing method of the W systems a method allowing the models to be made in large quantities
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THE SOLUTION IN OVERBURDEN DRILLING
2. Symmetrix Econ
Symmetrix Econ is used for the same purposes as STD. The only obvious difference is that the ring bit (reamer) is not attached to the casing shoe with wire locking but instead is locked to the pilot bit only. The pilot bit is the same as in the STD System The ring bit and casing shoe are not mechanically connected Designed especially for shallow holes with permanent or temporary casings
Econ Set
STD Set
Step 1: Casing is drilled through overburden into sufficiently firm till or seated in bedrock Step 2: The pilot bit is unlocked from the ring bit and withdrawn Step 3: The casing is filled with concrete and, if needed, with reinforcement
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THE SOLUTION IN OVERBURDEN DRILLING
When a large number of piles is needed to be installed in fair to medium-difficult conditions, Symmetrix Econ is the right tool. Easy drilling, fast hole-to-hole movements and adaptation of new casing are the elements of efficiency in the Econ bit.
Symmetrix Econ can also be used for temporary casings, especially where it is difficult to pull out the casing. The casing is drilled through the overburden and seated into bedrock or to the designed tip elevation. The pilot bit is unlocked from the ring bit and withdrawn. Rebar or a structural beam is inserted with concrete to form a pile. The casing is then extracted leaving the ring bit behind.
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THE SOLUTION IN OVERBURDEN DRILLING
3. Symmetrix SE
Symmetrix SE is a new ring bit design made especially where there is no need to continue drilling beyond the bottom of the casing. When the ring bit ID is not a critical concern, strong shoulders can be built into the pilot bit and ring bit.
The SE type is specified according to the casing OD as in SE applications the drill through diameter is regarded as insignificant.
SE Set Principle: Simple casing shoe and ring bit are very economical yet still strong enough for deep holes and difficult rock conditions. The ring bit thickness is the same as the pilot bit groove width with a deep striking shoulder giving it excellent wear resistance and long pilot bit life. This system is perfect for drilled foundations where the casing is brought to the bottom of a rock socket (in which case additional drill through is not necessary).
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THE SOLUTION IN OVERBURDEN DRILLING
SE is designed to be the most costeffective solution for single-use drilling allowing the casing to be drilled to the bottom of the rock socket SE is designed for drilled foundations where there will be no additional drilling beyond the tip of the casing SE system consists of the SE pilot bit, SE ring bit, and SE casing shoe SE type is specified according to the casing OD as the drill through diameter is insignificant The ring bit thickness is the same as the pilot bit groove width The impact shoulder is deep giving excellent wear resistance and long pilot bit life Simple ring bit and casing shoe are strong enough for deep holes and difficult rock conditions Maintenance welding of worn impact shoulders is easy to perform when necessary
Symmetrix SE is a family of products designed for applications where drilling is not necessary beyond the tip of the casing.
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4. Symmetrix N System
Symmetrix N Version is designed for temporary casings. The ring bit is integrated with the casing shoe and designed to allow the casing to be pulled out from great depths. N-type pilot bit Designed for applications where casings are retrieved and the same ring set is used multiple times N-type multi-use ring sets; ring bit and casing shoe are connected by a strong mechanism System also suitable for thick wall casings
Step 1: Casing is drilled through overburden to the required depth Step 2: The pilot bit is unlocked from the ring bit and extracted Step 3: Reinforcement, in the form of a rebar cage or structural beam, and concrete is place in the casing Step 4: The casing is extracted (even from great depths) leaving a suitable friction pile
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THE SOLUTION IN OVERBURDEN DRILLING
Symmetrix N352 for 406 mm (16) casing pulled out to be used again
Symmetrix N in Anchoring
A typical application for the Symmetrix N-system is in the construction of ground anchors. Temporary casings with the Symmetrix N-system are extracted after the anchors have been completed. Quick and economical installation of ground anchors is possible especially in the case where the anchor length is working as the bonding unit.
Different anchor applications, such as ground anchors and rock anchors, have different bonding lengths. Both anchors can easily be installed with the N-system. The resund Bridge between Denmark and Sweden required the Symmetrix N109 to drill 2200 anchors.
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THE SOLUTION IN OVERBURDEN DRILLING
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DT in normal drilling mode drilling through the ring bit and being retrieved though the ring bit
The use of drill-through in piling operations where a separate rock socket is required brings about tremendous savings in cost and time by avoiding the need of an additional drill rig and/or the use of a crane for handling additional tools and switching out the hammer and drill strings. The reduction of time equals an increase of 100% over methods in which the rock socket is drilled separately. Anchoring is another application for Symmetrix DT systems as a separate rock bit is no longer needed for the rock socket saving both time and cost.
N-DT
W-DT
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THE SOLUTION IN OVERBURDEN DRILLING
Piling Applications
For end bearing piles: the casing is drilled through overburden to the required elevation; the pilot bit is unlocked from the ring bit and withdrawn: the casing is filled with concrete (and when necessary additional steel reinforcement). In most cases the casing, typically thick walled, is left in place and acts solely or, along with the steel reinforcement, partially as the load bearing member.
If stable bedrock is not within feasible piling depth, the casing itself may be used only as additional corrosion protection or as a liner to keep the hole open. The main load is then carried out by an internal casing, pile or beam installed inside the drilled casing. The internal load bearing element would require a length for bonding the pile to the ground through a rock socket.
There are numerous ways to apply the Symmetrix system to foundation piling ensuring that the right tool is available for every possible project.
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THE SOLUTION IN OVERBURDEN DRILLING
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End bearing piles for this bridge were installed prior to rock excavation (accomplished by drilling and blasting)
In the case where the pile is required to have a designated capacity in both bearing and tension, the casing pile will typically require a rock socket with friction pin to take the tension loads.
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THE SOLUTION IN OVERBURDEN DRILLING
Friction Piles
When there is no composite material such as bedrock to seat an end bearing pile, a friction pile is utilized. Casings are typically used when the ground conditions will not allow the hole to stay open and the integrity of the hole and the drilling tools themselves must be protected. When working in areas where the ground conditions require the use of a DTH hammer, Symmetrix N, Econ or SE with temporary casings is the best choice.
Typically the N-system is the prescribed system however if the ground has numerous boulders or the casing is drilled deep through hard rock layers then the use of Econ or SE systems may be more feasible. Sometimes the foundation design for friction piles calls for rock sockets to extend beyond weathered or fractured rock for additional uplift capacity. In such cases a rock socket must be drilled beyond the tip of the casing and the load transfer is based on the bond between the socket element, such as an H pile, and the grouted rock interface.
Friction bars are sometimes welded along the rock socket length of the H pile for extra gripping surface
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THE SOLUTION IN OVERBURDEN DRILLING
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Jet grouting works going on through grout columns done with drilled casings, Sikkim
Phase 1
Phase 2
Phase 3
Phase 4
Phase 5
Phase 1 Casing is drilled with Symmetrix N or Econ system Phase 2 Symmetrix System is lifted out and hole straightness checked Phase 3 Casing is filled with grout in 4-5 meter intervals lifting the casing simultaneously or with packers while casing is lifted out Phase 4, Jet-grouting rods are drilled in to required depth Phase 5, Jet grouting is done
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THE SOLUTION IN OVERBURDEN DRILLING
Secondary piles (2) are then drilled down to tip elevation. Rebar or other reinforcement is set into the casings, the casings filled with concrete and then the casings are extracted. A fully stable rock socketed and reinforced wall is now ready. A secant pile wall requires what appears to be an excessive amount of drilled length however the resulting cost is certainly much less expensive than a grab or mill constructed wall when significant boulders are encountered or when the bottom of the wall must be constructed into solid bedrock.
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THE SOLUTION IN OVERBURDEN DRILLING
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Virtually any crane can be adapted for DTH drilling Nova Scotia, Canada
As the Symmetrix system requires only a minimal amount of torque it ideally suited to gravity fed drilling without a drill rig or leader only a crane is needed. This methodology, in use by several contractors, is the perfect solution for construction of temporary work trestles, temporary bridge foundations or in limited access situation where alternative methods would be costly due to the need for access and/or special equipment.
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THE SOLUTION IN OVERBURDEN DRILLING
Bulk sampling with 28 inch Symmetrix system Drilling is done with dual stage drill rod with cuttings directed to a container
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6. Symmetrix Horizon
Symmetrix Horizon is designed for situations where long horizontal drilling must occur. Due to the high friction levels experienced in horizontal drilling, the impact shoulders have been designed as heavy duty. Because the ring bit is collected from the receiving pit, there is no requirement for drill through and thus there is no limit to the contact surface size and the striking surfaces can be made thick and strong. Designed for long horizontal holes when casing is left permanently in the hole (or for very deep vertical holes) Strong ring bit and casing shoe to guarantee long borings in any soil or rock conditions
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THE SOLUTION IN OVERBURDEN DRILLING
In horizontal drilling, the casing may require pushing in addition to the pulling action of the casing shoe in order to overcome the tremendous friction. Flushing is therefore critical and the use of augers may be necessary to bring out cuttings from the casing.
609mm drill bit and casing breaking through after 240 meters of drilling in Italy
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THE SOLUTION IN OVERBURDEN DRILLING
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Pipe roof constructed for a metro line in Hong Kong (preserving park and trees)
Sometimes interlocked casings are used to allow the casings to form an ideal shape. The example in Hong Kong on the right shows where not only the roof but also the walls were constructed using drilled casings interlocked to keep the structure aligned and deviation to a minimum.
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THE SOLUTION IN OVERBURDEN DRILLING
7. Symmetrix T-System
The Symmetrix T-system is designed for small diameter casings used with both top hammer (drifter) and DTH hammer use. The driving shoulders are designed very strong which means a long pilot bit lifetime even through difficult conditions. The drill through passage is small however these bits were not designed to be drilled beyond the casing tip. A standard Symmetrix design ensures that only a small amount of torque is needed allowing these bits to be used with standard tunneling jumbos which have very limited torque. Primarily designed for forepoling in tunnel construction Robust, concentric construction for drilling in fractured and variable hard rock formations Available for both top-hammer and DTH drilling
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THE SOLUTION IN OVERBURDEN DRILLING
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Forepoling is constructed either with standard tunneling jumbos with short 3~4 meter feeds and threaded casings or as a single pass drilling operation with specialty forepoling rigs with long feeds. Forepoling is a ground stabilization technique where the support structure of a tunnel sector is placed ahead of the excavation. The supporting mechanism provided by the forepoling technique stabilizes the tunnel face area in both transverse and longitudinal directions by an arch-like reinforced zone. The Spiling method consists of four different parts: Drilled steel pipe Grout inside the pipes and in voids outside Treated ground by permeation or fracture grouting Steel arch supports (with foot piles when necessary)
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THE SOLUTION IN OVERBURDEN DRILLING
Injection is the crucial part of this system in order to form the arch-like structure. For cement or chemical grouting, perforated casings are used; holes are either open or fitted with oneway valves for double packer grouting.
Fiberglass system
Weak and/or wet conditions may require fiberglass casings at the face of the tunnel for stabilization and longer drainage casings with Sidra/Sidrex systems.
Dewatering slots are protected with a water soluble material and they open automatically within 12 hours after drilling. A patented packing seal located on the outer surface of the drainage element prevents grout from blocking the slots. Symmetrix and Sidra are patented trademarks.
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THE SOLUTION IN OVERBURDEN DRILLING
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Ports Open
Ports Closed
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SimGrout Simultaneous grout injection Available for all Symmetrix STD pilot bits Three injection holes Grout volume and pressure selected according to the application and available grouting equipment Modifications to adopt the method can be made at the work site
Grouting is done either through standard plastic grouting hoses (if double wall drill rods are used) or through steel hosing (water pipes) with simple overlapping joints. Centralizers are not rotating but fixed to the casing and retrieved when the hammer and pilot bit are extracted.
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THE SOLUTION IN OVERBURDEN DRILLING
The Wassara water hammer has many advantages over standard air powered hammers. They can be used in areas with a high ground water pressure; they keep their efficiency in long holes; and drilling with water consumes only 1/3 the energy used in standard DTH drilling.
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THE SOLUTION IN OVERBURDEN DRILLING
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9. System Requirements
Drilling requires: a suitable DTH hammer applicable to the task at hand: compressors to run the hammer; drill rods; and a Symmetrix pilot bit with sets of reamers
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THE SOLUTION IN OVERBURDEN DRILLING
Another possibility is to utilize the reverse circulation principle with dual wall drill pipes. Two swivels, one for compressed air and the other for exhaust air with cuttings and soil need to be installed. One must ensure that the hollow spindle of the rotary head has a passage equal to the inner diameter of the RC pipe. Reverse Circulation Drilling Principle: Cuttings are collected; same rod can be used for several different casing sizes by only changing the rubber liner seal; suitable for sensitive drilling conditions.
The diverter directs the return flushing air into the inner pipe of the dual wall drill rod and up through the rotary head into the collection pit.
In all DTH drilling remember: Grind the casing shoe and casing surfaces before welding Use a proper root weld Ensure you have enough flushing velocity; especially in deep holes (over 30 m) slow flushing increases back pressure thus causing slow penetration and possible shoe breakage Use stabilizers Use air valve to reduce the stress on casing shoe/reamer shoulders after breaking through boulders Maintain your pilot bits Use foam when necessary
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THE SOLUTION IN OVERBURDEN DRILLING
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The casing shoe and casing should have a minimum 2~2.5 mm gap prior to welding to ensure full weld penetration. This also applied to the buttwelded N-version.
When large diameter N versions are welded the first root weld is done from inside with the weld ground smooth from both sides. Subsequently the weld should be inspected and then filled from outside with two or three runs (depending on the type and size of the electrodes and the casing diameter)
Maintenance
When doing repair welds, use hard welding rods and grind the surfaces back to original standards. Keep buttons grinded. Grind them before 1/3 of the button is flat. Especially watch gauge buttons. Good welding rods for hard welding the worn shoulders are: Esab OK 84.58
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SYMMETRIX
Symmetrix STD155
Symmetrix STD165
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THE SOLUTION IN OVERBURDEN DRILLING
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