Atlas Copco

Raiseboring
in Mining and Construction

Printed matter no. 9851 2575 01

Raiseboring in Mining and Construction

Atlas Copco Rock Drills AB

2008

www.atlascopco.com

First edition 2008

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
33 Modern boxhole boring with BorPak
36 Selection of raiseborer drive system
38 Computers improve rock excavation productivity
40 Site preparation
47 Operating the raiseborer
51 Bailing considerations
56 Cutter and reamer design
64 Raiseboring drillstring components

Case studies
67 Boxhole boring at El Teniente
73 Raiseboring for production at McArthur River
78 Replacing Norways Tyin hydropower plant

Product specifications
82
91
96
99
101
102
103
104
108

Robbins raiseboring machines

Pilot bits from Atlas Copco Secoroc
Drill string components
Power packs
Drill pipe handling equipment
Transporters
Tools
Raiseborer system upgrade kits
Conversion table

Front cover: Robbins 34RH C at the Kvarntorp

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

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 capabilities 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 proving 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

raISEBORING

Talking Technically

Rock drillability
Fracturing rock
Drillability is the ability to fracture or drill rock using mechanical
means, and is governed by a number of factors. Some of these are
related to the rock formation, and
others to the forces applied, and
the geometry of the drilling equipment. Rock properties, rock failure mechanisms, and drilling parameters all relate to drillability, and
are helpful in evaluating drilling
efficiency, trouble shooting problems, and estimating cutter performance.
General rock boring principles
and their practical application are
the basis of modern raiseboring.
Two basic principles are used together in full face boring - these
are cratering and kerf breaking.
The objective when boring is to
crush the rock until tensile cracking 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 experience counts, and nobody has
more knowledge about raise boring than Atlas Copco Robbins.

Zone of triaxial
crushing

Radial
cracks

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 performance without additional information.
The average UCS for selected formations 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 fingernail can scratch up to about 2 Mohs,
a copper coin up to about 3 Mohs, and
raISEBORING

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 drillability are:
Abrasiveness abrasiveness of a formation 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 erosion, 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
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 pressure 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 applications: kerfed carbide insert cutters;
rowed cutters; and randomly-placed carbide insert cutters.

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 demonstrates 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 depending 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

Table 2: Moh hardness numbers for selected common minerals and rock.

Mineral or Rock

Moh Hardness

Mineral or Rock

Moh Hardness

Amphibolite

6.2

Gypsum

1.5

Andalucite

7.5

Limestone

3.3

Andesite

7.2

Magnesite

3.5

Basalt

7.0

Magnetite

4.2

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

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 somewhere between the kerf-type cutter and
the random insert-type cutter. The rowed
cutter design has multiple rows of inserts, 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 formation with less power consumption.
The staggered insert location and multiple 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 insert cutters employs a random pattern
of inserts on the cutter shell to provide
Figure 3: Random pattern on rock face.

raISEBORING

Talking Technically

Zone of tensile failure

Rock chip

Figure 4: Rock failure occurs between insert pressure bulbs.

a fairly dense axial coverage in a complete revolution of the cutter. This design
has shown significant increases in drilling rates, while reducing drilling torque,
which has proven beneficial for situations where the length of the raise, and
the formation characteristics, have proven equal or greater than a machines
capabilities. The random insert cutter
tends to spall out circular chips of approximately 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 phenomenon known as tracking. Tracking
occurs when the insert slips into an existing 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

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 independent of kerf spacing.

Drilling parameters
Three drilling parameters have a significant 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 parameters.
Cuttings removal can have a significant effect in down reaming operations, 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 profile of the cutting structure in conjunction 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

a problem. However, rock accumulation

on the cutter head can affect drilling
performance.
Thrust force on the cutter is the parameter 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 relationship Drill Rate = Function (force
to the power of n) where n varies from
1.2 for low-strength rock, to approximately 1.8 for hard rock.
As an example, if a hard rock is drilling 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
5

Talking Technically

Penetration Rate Vs. UCS

Penetration Rate

n = 1.8

n = 1.6
n = 1.4

n = 1.2

1
0
0

10000

20000

30000

40000

50000

60000

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 closer estimate.
The reduced life is even more pronounced when the cutters are considered 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 cutters 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 formation (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 rates linearly. For example, a 10% increase
in rotary speed should produce a 10%
increase in drilling rate. The traditional
approach to rotary speed recommendations has been to limit the peripheral
6

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 peripheral 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 directly beneath the contact area of the
cutter edge, which is usually a chisel
shaped tungsten carbide insert. As increased 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
drilling machine, with the consequence
being increased power consumption.
Insofar as drilling torque is concerned, capacities of equipment often
dictate the load that can be applied to the
cutters. Several factors influence torque
requirements, such as load per cutter,
reamed diameter, formation, and angle
of the raise. Additionally, the torque requirements tend to fluctuate radically,
with peak torque more important than
average torque.
All things being equal, the torque required 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 requirements. However, in general, the softer
the formation, the deeper the insert penetrates, and the higher the torque requirement. This relationship can be
altered considerably if the rock fails
readily through shear, as in some vertically 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 between the two cutter kerfs. Kerf breaking 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 reamer 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 spacing ratio is reached for the particular
rock type being bored, chipping occurs
between the kerfs, and the rock face
can be systematically excavated.

raISEBORING

Talking Technically

History of raiseboring
Forty five years on
It is now 45 years since Atlas Copco Robbins built the worlds first
successful raiseboring machine,
and launched a worldwide revolution 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 underground.
The latest innovation is the application of Atlas Copcos CAN-bus
control technology to raiseborers,
using components that are common to other new generation products 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 learning 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 produced in total to date, giving it a +60%
market share.
In all, some 35 models have been
introduced, with reaming diameters of
0.6 m to 6.0 m.
Of the models produced, the 73RM
is the most sold, with a reaming diameter
of 1.8 m-3.1 m.
Nearly all of these Robbins raise
drills are still available for work. So,
despite always requiring high capital
investment, raise drills have given an
exceptional return to their owners while
retaining solid residual value. This sums
up the raiseboring story.
Apart from mechanizing the singularly most dangerous job in mining,
these machines have proved to be a
wise investment all round.
raiseboring

Figure 1: The Robbins 41R, first of a long line of raise drills.

Built for life

When James Robbins built the first raise
borer in 1962, little would he have
thought that it would still be working
45 years later. However, the fact is that
the very same 4 ft-diameter machine,
the original Robbins 41R as shown in
Figure 1 with pinned drill tubes and
steel cutters, was recently reported as
working in Morocco.
By 1966, rapid development on the
part of Robbins had established industry

standards for tungsten carbide cutters,

and a float box to reduce stresses in
the main bearing and drill string of the
raiseboring machine. Connectors using
API-standard 7-inch tapered threads
were introduced to connect the drill
tubes on the second machine built by
Robbins and was in use in various sizes
until the DI-22 thread was invented in
1969. This proved to be a well functioning and reliable connection.
In 1967, Robbins upped its game
with the introduction of the Robbins
7

Talking Technically

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 approaching 3,280 ft (1,000 m) in length.
Raiseboring machines have proved superior and more economical when compared 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 shattered. 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 boring 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 2: Robbins 63RM was predecessor to the worlds most sold raise drill, the Robbins 73RM .
Figure 3: Atlas Copco Jarva raiseborer.

61R, capable of reaming a 6 ft-diameter

hole. This became the most-sold machine 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 excavating raises where there is limited or
no access to the upper level. The raiseborer is set up at the haulage level and
a full-diameter raise is bored upward,
8

with the cuttings gravitating down the

hole for removal. Within ten years, the
Robbins BorPak was launched, facilitating boxhole boring without a drill
string, making the operation vastly more
efficient and easy to set up.

Improved methodology
Since Robbins introduced to the mining industry the first machine built
exclusively for raiseboring, the advantages 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
raiseboring

Talking Technically

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 acknowledged as the best available. Robbins
immediately switched from Reed cutting tools to those of its own manufacture, and has since supplied them with
every raiseborer produced. Ingersoll
Rand had itself built some 30 raise boring 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 machines were built in 1982-1983 as shown
raiseboring

in Figure 3, with variable speed drives

and computer control as shown in Figure 4. These machines are today operated by Dynatec in North America.

Future trends
The current trend is towards computerization of the raiseboring operation
using Atlas Copcos patented Rig Control 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

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 control 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 operator can now control all functions on a
raiseborer, including rod changing.

Marcus Eklind
9

Talking Technically

The raiseboring concept

Particular
terminology
The raiseboring concept involves
terminology that is a little different from normal mining language.
Raiseboring, also called raise drilling, is the process of mechanically
boring, drilling, or reaming a vertical or inclined shaft or raise between two or more levels. All levels 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 successful method became known as
raiseboring.
Today, raiseboring is accepted
as the world standard for mechanical raise excavation, and the
name of Atlas Copco Robbins is
synonymous with the technique.

Raiseboring process
In raiseboring, the machine is set up at
the surface or upper level of the two
levels to be connected as shown in Figure 1. A small pilot hole is then drilled down to the lower level using a drill
bit attached to a series of cylindrical
drill pipe pieces, which form the drill
string. Upon completion of the pilot hole,
a reamer with a diameter larger than
the pilot hole is attached to the drill

Figure 1: Raiseboring process.

string at the lower level. Using the reamer, the small pilot hole is reamed back
to the machine on the upper level. The
cuttings excavated by the reamer fall
to the lower level and are removed by
any convenient method.

Applications
Raiseboring machines have been used
in both mining and civil projects for
holes in the range 0.6-6.0 m-diameter
and up to 1,000 m-long. Some specific
applications of bored raises are:
Mining: materials transport; ventilation;
manriding; mineral production.

Civil: hydro penstocks and surge chambers; redirection and retrieval of hydro
water; petroleum, pressurized gas, and
nuclear waste storage; road and rail tunnel ventilation; stormwater storage and
drainage; access for pipes, hoses, and
cables; water inlets and outlets for fish
farms.

Horizontal and low angle

raiseboring
Standard raiseboring machines are capable of boring raises at angles from
vertical to 45 degrees from horizontal.
Raises from 45 degrees to horizontal

Figure 2: Low angle raiseboring.

10

raiseboring

Talking Technically

have been completed with the addition

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

Figure 3:
Boxhole boring.

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 raises 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 proposed 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 system 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 vertical boring. A reverse circulation system, 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 enlarging it to the final raise diameter by
reaming from the upper level to the lower level as shown in Figure 5. Larger
raiseboring

11

Talking Technically

diameters can be achieved by conventionally reaming a pilot raise, and then

enlarging it by down reaming.
During reaming, the cuttings gravitate 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 gearbox driven by the drill string. Upper and
lower stabilizers ensure proper kerf cutting, and reduce drill string oscillations.

Pilot down, ream down

This method, also known as hole opening, is used to enlarge an existing pilot
hole with a small-diameter reamer. The
operation is similar to pilot hole drilling, 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
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 5: Down reaming.

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, climbing up the raise as it bores. Cuttings pass
through the centre of the machine, falling down the raise and launch tube
onto a conveyor. This revolutionary machine 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 provides 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.
Figure 4: Blind shaft boring.

12

Roberto Lopez

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 instruments used to control and monitor the raiseboring process.
The RBM is composed of five
major assemblies described in the
sections below. These are: derrick;
hydraulic system; lubrication system; electrical system; and control console supplied with each
machine.

Derrick assembly
The derrick assembly supplies the rotational 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 components. These are: base plates; mainframe; columns; headframe; hydraulic
cylinders; and drive train assembly.

Base plates
The base plates, left-hand and righthand, provide the structure for supporting 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 anchored 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 foundation pads and the rock formation.

Mainframe
The mainframe is the major load bearing structure of the derrick assembly.
It is mounted and secured on the base
plates with removable turnbuckles and
expansion pins. Each turnbuckle consists of two threaded eyes screwed into
a turnbuckle body. The turnbuckles
raiseboring

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 equipped 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 remains perpendicular to the axis of the
drill string at all dip angles.
All worktables are equipped with, or
are used in conjunction with, a worktable wrenching system. This reacts the
machine torque into the mainframe for
threaded connection makeup and breakout. 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 mounting for various accessories necessary
for raiseboring machine setup and
13

Talking Technically

Main Drive

DC

Hydraulic

AC

Crosshead

Headframe

Hydraulic cylinders

Drivehead

Gearbox

Columns

Hydraulic
cylinder

Mainframe
Machine
worktable

Turnbuckles

Expansion pins

Turnbuckles
Expansion pins

Baseplates

Figure 2: Exploded view of derrick assembly.

operation, such as the pilot hole starter

bushing, the outlet housing of the blooie system, the drivehead installation
and removal tools, and the ram assembly, if fitted.

Columns

and shares the boring torque between

columns. The headframe is most commonly secured to the columns by use of
a bolted crown gear coupling system.

Hydraulic cylinders

Chrome plated cylindrical columns provide torque transfer from the drive train
assembly into the mainframe. These columns 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.

The hydraulic cylinders supply the thrust

required for raising and lowering the
drill string in relation to the raise boring 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.

Headframe

Drive train assembly

The headframe is mounted atop the

derrick assembly columns, linking them
together. This dampens column vibration,

The drive train assembly supplies to the

drill string and cutting components
the rotational power necessary for raise

14

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 raiseborer columns.
Most Atlas Copco Robbins raise boring 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.
raiseboring

Talking Technically

Main drive motor system

The main drive motor system of the
derrick assembly supplies the rotational
power necessary for raiseboring. Four
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 design, lowest cost, and highest reliability
of all raise drill drive motor systems.
It features fixed speed and fixed torque, and is best suited to competent
ground, where minimum motor stalling
will be encountered.
DC drive is variable speed and variable torque, and is best suited for larger raise diameters in mixed ground
conditions.
Hydraulic drive, employing variable
speed and good torque limiting control,
is suited for use in all ground conditions and has high reliability.
The VF drive system, developed inhouse by Atlas Copco, combines the
simplicity of the AC drive motor system with exact motor speed, torque,
and positioning control.
The VF system circuitry controls the
speed, torque, and position of its AC
motor by first converting the incoming
Figure 4: Pilot drilling and reaming.

Drivehead
capscrew
Splined
connection

Axial
float
Floating box with
patented spherical
design and replaceable
threaded insert

Swiveling
action

Figure 3: Cross-sectional view of the drivehead.

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, torque,
and positioning control.

Gearbox
The gearbox mounts directly to the main
drive motors at its input end, and reduces motor input speed to a speed
compatible with raiseboring at its output end.
Most gearboxes use a planetary reduction 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 ratios 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

The floating box can be housed internally within the gearbox, or mounted
to the output end of the gearbox as a
separate component. When mounted separately 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/removal tools are required when installing or removing the drivehead from
the gearbox.

Hydraulic system assembly

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 floating box to drift axially when threading
or unthreading drill string components.
Axial free f loat permits the threading 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.

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 spherical 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 hydraulic system supplies hydraulic 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 hydraulic reservoir. These are used as mounting platforms for the majority of the
components making up the hydraulic
system. Included in these components
are the motors and pumps used to power 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 system assemblies varies according to the
type and size of machine. The service
manual should be consulted for specific hydraulic system setup, operation,
and maintenance procedures.

Lubrication system
The lubrication system assembly ensures 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, thermometer, and breather; pump drive motor;
and lubricating oil pump, filter, heat
exchanger, and flow meter.
Most Atlas Copco Robbins raise boring machines employ the crosshead of
the drive train assembly as the lubrication reservoir, and as the housing for
the lubrication pump drive motor and
16

raiseboring

Talking Technically

Figure 7: Robbins 73RH C with RCS control panel.

pump. Some machines are designed with

the lubrication system reservoir and components located separately from the derrick assembly, usually to permit the derrick 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 comprises 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 system. Lifting eyes are provided on this
cabinet for hoisting and positioning.
Power and control cables are included in the electrical system assembly.
Most of these cables are of the quickcoupler type, with all the plugs and
raiseboring

receptacles identified for ease in making

proper connections during system
setup.
Because of varying site power supplies, 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 system setup, operation, and maintenance
procedures.

Control console
The modern rig control system from
Atlas Copco features a Control Area Network (CAN) for digital communication
between all modules connected to the
Bus wire.
The entire system features various
I/O (In/Out) modules for communication with all machine sensors and

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, specially designed for outdoor and underground use.
Manufactured and delivered to over
400 units since 1998, this proven, standardized control system is modular, with
all major parts interchangeable with
other similarly-controlled Atlas Copco
products.

Jan Forsberg
17

Talking Technically

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 restrictions. 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.

Side loading pipeloader in operation.

Robbins 73RM-DC under installation.

Reaming the Henty ventilation shaft.

18

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 transporter capable of 1.5 km/h and positioned on a speciallydesigned 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 fourrow 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 customer expressed satisfaction with the project.

raiseboring

Talking Technically

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 Robbins 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 borers now at work developing ventilation shafts in the arduous 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 torque 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

and pilot hole drilling in the 0 30 rev/min range. At constant 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.

19

Talking Technically

Computer based training

for raiseboring
Latest version
Atlas Copco Secoroc recently introduced version 4.0 of its Computer-Based Training (CBT) package as being of paramount importance in achieving the highest
level of competence in rock drilling 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 profitability for all, and adds to competitiveness. Atlas Copco Secoroc believes that the CBT package
for rock drilling tools is the most
comprehensive interactive training tool available in the industry
today.

Expert knowledge

Main menu. This is the first picture shown when you start the CBT. From this main
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
Secoroc personnel over many years and
conveys expert knowledge in the use
of modern rock drilling products.

CBT Rock Drilling Tools version 4.0

was released after six years of patient
development. Computer based training
transfers knowledge about raiseboring

Course menu. View picture for the course Raiseboring. Under the text Introduction you find two
buttons, Learning objectives will explain what you are expected to learn. Introduction will give
you an overview by running pictures and a speaker talking. Under Lessons you choose chapters.

and drill string products, and their use,

in a simple and efficient way.
Aided by 3-dimensional animations,
photographs, film sequences and interactive lessons, the training course explains how the markets leading raise
boring and drill string products can
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
corner you find four buttons. X will finish the actual step. Number two will
take you back one step. The third button allows you to scroll through the course.

Lesson. There are three buttons for presentations. Video camera

button: running pictures and speaker text. Photo camera button: pictures
from more important or difficult parts. Text button: pictures and text.

Step player. When pressing the step player button you will find film
sequences or animations. At the end of every lesson you can also go through
a test, Focus test, to check your knowledge.

Product selection exercises. At the end you also have the possibility
to go through some real exercises, where you will have the background for a
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 drilling tools can be estimated at three
weeks.
CBT enables efficient training whenever the need arises. For instance, a new
raiseboring

employee can start the learning process

right away, and learn about how the product is manufactured, its characteristics,
wear limits and much more.
A modular structure enables users
to study lesson by lesson, or in a selective 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 teaches you to find the right tool for any
given rock drilling application at any
time of the day. Similar to its experience with CBT version 2.0, Atlas Copco

Secoroc has found good market acceptance of version 3.0, which has been advising key customers and technical
schools on its use, as well as its own
sales team.
The new version of CBT 4.0 is expected 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

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 Portugal. However, recent legislation
following a tunnel fire at Guadarrama in Spain completely changes
the picture. At the Guadarrama
twin railway tunnels, the TBMs
were well ahead of the cross passage development when a fire occurred near the face. As a result,
the fire crews were denied access
to the face along the parallel tunnel, and had to stand off. All future twin tunnels in Spain will now
have to develop cross passages
close to the face. Because these
tunnels are mainly TBM-driven,
and blasting would be risky to hugely expensive equipment, the
cross passages will have to be developed mechanically. Horizontal
raiseboring is possibly the only
currently available alternative.

Modifications
There are many different applications
that require horizontal or low angle
drifts. Raiseboring is a non-explosive
method, so the vibration effect on surrounding rock, and on buildings close
to the drill site, are kept to a minimum.
Hydropower projects, urban sewerage

Robbins raise drill in front of the face.

projects, and service drifts in mines are

a few examples where horizontal raiseboring has advantages over drill/blast
methods. The latter methods are not
even an option in the 0.7-1.2 m-diameter
range, because men and equipment are
simply not available to safely work such
small openings.
The raiseboring method does not
change when the angle is lowered to
horizontal. However, transporting the
rock cuttings from the face becomes
a challenge, because gravity does not
help in the same way as for steeper
holes. Hitting the target with the pilot
bit also requires more skills than in a

vertical raiseboring application, because of the downward pull of the drill

string.
However, most types of raiseboring
machines can be modified to pull horizontal and low angle raises. These modifications generally include an altered
gearbox lubrication routing, a modified base plate, and the addition of a
rear support for the guide columns.

Handling rock cuttings

A reamer used in a horizontal application employs scrapers to remove cuttings from the rock face. These clean

Low angle raiseboring.

22

raiseboring

Talking Technically

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 required 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 sealing system around the drill string, equipped with an intake valve, is necessary with this method. This is similar
to the blooie system, which uses air as
the flushing medium for pilot hole drilling. 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 needed to keep the rock face clean.
For smaller diameter raises close to
horizontal, mucking methods are more
raiseboring

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 attached 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 convey the cuttings out of the raise. This
method occasionally requires people inside the raise to extend pipe, route power to the pump, and remove any oversize cuttings.
Another method is to use a nonrotating 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 mixture of air and water supplied through
the drill string cleans the face. The increased pressure inside the sealed area
ensures that cuttings are blown out

through the pipe, which has to be extended 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 deviation of the pilot hole in a horizontal 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
23

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 companies, Somague, Moniz da Maia Serra
& Fortunato (MSF) and Mota, was formed to complete the civil works of the
Checking the raiseborer drillstring in the 110 m shaft.

Venda Nova project situated on the river 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 raisebored 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 ventilation and escape system.
Drillcon Iberia Lda, a subsidiary of
Drillcon AB of Sweden, used an Atlas
Copco Robbins 73R raiseboring machine 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 process, from training drillers on the Robbins unit, to helping install new cutters
on the reamer. When the hole was finished, 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 tunnel system came into operation in 2004
to provide much needed generating capacity for the national grid. Venda Nova
will also act as a pumped storage station serving its companion dam Paradela further downstream. When electricity demand is low, water that has
passed through the powerhouse for storage 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.

24

raiseboring

Talking Technically

Development of boxhole boring

Safe and efficient
The boxhole borer concept emerged in the early 1970s, and the
current models of dual-purpose
raiseborers are a combination of
the engineering skills and experience 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 preparation and setup time. Most of
the machines ever built are still
working, releasing miners from
the thankless task of manual raising, 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, primarily 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 torqued up so much during reaming that it
belled on the box ends and welded at the
shoulder, and each length had to be cut
off as it was removed. The pilot hole was
drilled using a Mission DTH hammer, and
Security designed and built the reamer.
Since those early days, some 600 raiseboring machines have been sold worldwide.
The first Robbins 34R units were
made for Falconbridges Kidd Creek
mine in Timmins, Ontario, Canada,
and have been in continuous use since
they were commissioned.
raiseboring

Figure 1: The Robbins 34R raiseboring machine was the predecessor to the versatile Robbins 34R.

The mine uses the machines to bore

1.2 m-diameter slot raises, and for downreaming 710 mm-diameter holes, which
are used for dumping backfill into empty
stopes.
The Robbins 34R has a number of
special advantages: it is small, compact
and powerful; it can operate with as little
clearance as 3.4 m while drilling or reaming; and the hydraulic drive provides

variable speed control which helps the

operator to maximize machine performance in varying rock conditions.
In addition, with a number of automatic features, the Robbins 34R can be
operated by one person. These features
include a sensor that automatically shuts
down the boring cycle at the end of a
cylinder stroke, or at a pre-determined
level of torque.
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 timeconsuming to install, and have since
been replaced by a drilling platform that
uses leveling jacks combined with stinger
cylinders in the derrick columns, eliminating 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 excavation and considerably safer and better
work environment; smooth wall needing 300% less power for air ventilation;
cost/metre decreases as raise length
increases, allowing more flexibility in
mine design and planning; and a significant 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 control feeding of ore by gravity into haulage cars. The raise going up from this
chute box or base is therefore known
as a boxhole.
The Robbins 34RH-HT can drill boxholes, 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 carried by gravity down the hole, and deflected 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 boxhole borer. The raises were to be 90 mlong, 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 torque was 95,000 ft lb. The drill pipe was
4 ft-long with 3 radial fins for stabilization. The rig weighed only 28,000
lbs and could be transported through a
2 m x 2 m drift.
The 51R was later rebuilt as a 55R,
which was the prototype of the 52R.
The 52R was more compact, used 24 indiameter flanged pipe, had many hydraulic and drive train improvements, a
built-in water spray, and non-rotary drill
string with in-hole cutterhead drive.
Some 22 units of 52R with hydraulic and
electric drive were built, many of which
are still operating.
In 1982, Robbins launched a project
to design a new machine, the 53R with
derrick drive and rotary drill string. The
machine was designed so that site preparation work was limited to only a basic
pad. The reaming torque was 80,000
lbs ft and thrust was 620,000 lbs.
The Robbins 53R was ready for
South African gold mining, and the first
machine went to Vaal Reefs 8 Shaft in
1984, where the first 42 m-long hole was
pre-piloted. All subsequent holes were
drilled blind, achieving penetration
raiseboring

Figure 4: The Robbins 51R raiseboring machine, first produced in 1973.

rates of 2 m/hr to 2.5 m/hr with a 5 ftdiameter head, which in 25,000 psi
quartzites was considered excellent. As
a result, the Robbins 53R became popular in the South African gold fields. The
muck chute was improved, and further
work was done on stabilizers.

An important advantage with the

dual-purpose machine is that both
boxhole boring and raiseboring can be
carried out. The conversion between
drilling modes is relatively quick and
easy. The 34R is turned upside down
and a float box spring is added, whereas

Dual purpose machines

Figure 5: Robbins 53RH set up underground.

The Dual Purpose 34R is a low profile,

small diameter machine developed on
the basis of the 32R. The High Thrust
HT version was developed in the 1980s
with 47,500 ft lbs torque and 289,000
lbs thrust. It allows quick conversion
from raiseborer to boxholer. It is also
used around the world at places such
as: Brunswick Mine, Canada; Toyoha
Mine, Japan; Leinster Mine, Australia;
Western Metals (ARD), Australia; and
EI Teniente Mine, Chile.
27

Talking Technically

the 53R has top and bottom chucks into

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

Boxhole reaming
Initially, the reamer for boxhole boring
machines was installed overhead, a cumbersome procedure which also entailed
extra time and expense for the preparation 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 hydraulic cylinders opened it wide enough
to allow the passage of the reamer. This
feature increases the footprint of the machine, but does not increase its height,
and produces a more functional system.
The remote controlled, hydraulically
operated slide-opening worktable enables the entire drill string, including
boxhole stabilizers and reamer, to pass
through the worktable of the machine.
Depending on model and frame width
of the 34RH-HT, reamers of diameters
from 692 mm to 1,060 mm can pass
through the worktable.
Over the years, Atlas Copco engineers have designed many reamers,
both standard and specialized. Concern
about the possibility of ground squeezing during boxhole boring was overcome by fitting a set of gauge housings
and cutters, which are installed on the
underside of the reamer. In the event of
the ground squeezing during boring
operations, the RCC Duro cutters would
cut their way out as the reamer is withdrawn from the completed boxhole.
All Robbins 34R units are designed
so that the machines full torque and
thrust are available in either the pushing or pulling mode. The 34RH-HT was
modified to use stronger 10 in (254 mm)
28

Figure 6: The remote controlled and hydraulically operated muck collector is fully integrated into the
derrick assembly, and remains on the machine even during transportation.

drill pipe, to better stabilize the reamer,

and to transmit the full torque and thrust
of the machine.

Muck collection
To prevent the cuttings from covering the
machine as they fall down the bored raise,
a muck collector is installed between
the bored hole and the machine.
Atlas Copco have designed a muck
collector that connects to the head frame
of the Robbins 34RH HT, with extension bars that can be adjusted to raise
or lower the muck collector by pushing
it with the drive head.
The muck collector unit is fitted with
a rubber seal, which assists in containing muck and dust. This is designed in
two halves, to be opened by remotecontrolled hydraulic cylinders for the
reamer and stabilizers to pass. It also features a cone-shaped seal to clamp around
the drill pipe to prevent muck and water

from entering the drive box area of the

machine.
The collector also incorporates a
muck chute, which deflects the muck
away from the machine to the rear end
in a 90-degree working range. Furthermore, this remote controlled and hydraulically operated muck collector is
fully integrated into the derrick assembly, and remains on the machine, even
during transportation.
The design of the 34RH-HT continues to evolve, as customer requirements change, resulting in 360-degree
drilling, no concrete pad requirement,
reamer and stabilizer installation under
the head frame, and an integral muck
collector.
Close cooperation between Atlas
Copco engineers and customers is resulting in the continued development of
this most versatile raise drill.

Roberto Lopez
raiseboring

Talking Technically

Down reaming
Increased safety
Down reaming is a type of raise
boring where a pilot hole is reamed 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 smalldiameter 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 reaming due to the necessity to stabilize the reamer and drill string
when reaming. Removing cuttings
from the face requires more effort
than a standard raisebored shaft.
Down reaming is mainly used
when the lower level is unsafe or
if access to the lower level is financially not viable. One advantage for the down reaming method is that all work is done at
machine level further increasing
safety over competing methods.

Figure 1: Part of the down reamer used on the San Giacomo project in Italy.

as described above. When the first reamer

completes and is removed from the
raise, the second, larger reamer is collared into the top of the hole. The front
of this reamer follows, and is stabilized

in the raise using drill string stabilizers

of the same diameter. Weight stacks have
historically been used on the reamer to
increase the thrust capacity in the downreaming system, as shown in Figure 3.

Figure 2: Down reaming, one step.

Down reaming, one step

In the working sequence below, the reamer needs to either pass through the
machine work table or be assembled to
the drill string in a pit underneath the
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 procedure as shown in Figure 2.

Pilot down

Ream down

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 profile 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 downwards. 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 flushed 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 nonrotating 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 nonrotating stabilizer consists of a special
drill pipe with four arms mounted on a
bearing bushing. This design runs quieter, 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 Robbins 34RH and 53RH Raiseborers.
These machines are designed for raise
reaming, down reaming and boxhole
boring.
Figure 3: Down reaming, large diameter.

30

Roberto Lopez and

Mikael Bergman
raiseboring

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, resulting 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 employs approximately 800 people.

Robbins 34RH set up for down reaming at Brunswick Mine.

Secoroc RDI 720 reamer in the hole.

raiseboring

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 indiameter 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 conventional 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 switched to down reaming.
Unlike in conventional reaming, the complete downreaming operation can be handled at machine level, and
securing of the lower level is no longer necessary.

31

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 twocutter counterpart, the reamer can be loaded higher, and
rotated faster, without transmitting excessive stress or

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 threecutter design, and the customers save money by doing
the work themselves.

RDI 720.

32

raiseboring

Talking Technically

Modern boxhole boring with

BorPak
Effective solution
The Robbins BorPak offers a novel
concept in the mechanical excavation of hard rock. A steerable
blind boring machine, it operates
without a pilot hole, without drill
pipe, and, most importantly, without a man inside the excavation.
BorPak is an effective solution for
traditionally difficult areas of mine
excavation or underground construction, particularly where top
access is unavailable. It is suitable for a wide variety of mining
and construction projects, such as
drilling from one level to another,
or from tunnel to surface. It is especially attractive when flexibility 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
boring of orepasses, ventilation
drifts, and slot raises. These can
be from 20 m to 200 m-long, as
low as 30 degrees from horizontal,
and up to 90 degrees vertical.

Innovation at work
BorPak gets its name from the expandable packer unit that absorbs the torque
and thrust of the rotating cutterhead.
Cuttings gravitate down a guidance tube
and onto a conveyor. Operated from a
panel outside the raise, BorPak improves worker safety and lowers labour
costs. A hydraulic power system advances the cutterhead, and steering is continuous, using a laser as a guide. Safety
grippers prevent the unit from sliding
down the raise between strokes or in the
event of power failure.
Atlas Copco engineers will work
with clients to design BorPak to specific requirements of the job. The system can be fully automated, and is
capable of around-the-clock operation.
Site preparations are minimal, and no
concrete pad is needed. The launch
raiseboring

BorPak on site.

tube housing the cutterhead is braced

against the rock face, and drilling can
commence immediately. Preparation and
set-up takes less than two hours under
normal conditions.
To begin boring, the machine extends from its starting tube, which is
anchored to the rock face by hydraulic
jacks. The expandable rubber packer
holds the machine in position and
reacts forward thrust and torque during
boring. Adjustments by the operator at
his console direct steering shoes at the
front of the unit, controlling the boring
direction. Each time the machine completes its half-metre stroke, the expandable packer releases, and the operator
shifts the steering shoes to hold mode.
The packer is deflated, moved forward
in the hole, and reinf lated. A new
stroke can then commence, the whole
regripping process having taken less
than two minutes. This regripping sequence can be computer controlled using
Atlas Copcos well-tried and tested
Rig Control System, now in its third
generation.

When the hole is complete, the

BorPak is automatically retracted and
lowered to its crawler frame, ready to
be moved to its next job.
These features of the current BorPak add up to greater availability, less
downtime, and improved production.

Boring unit
BorPak comprises two major assemblies: the boring unit; and the carrier
and launcher.
The boring unit has a cutterhead
at the front, or top. This is supported
by the body of the machine, with steering pads for directional control. The
packer anchors the main body in the
raise during boring, while the safety
grippers hold the boring unit when the
packer is not pressurized. The drive
train for cutterhead rotation is mounted
within the main body, and a cuttings
outlet is incorporated.
Also within the body are the thrust
cylinders, electrical and hydraulic circuits for powering and controlling the
33

Talking Technically

BorPak in transport mode.

machine, and water circuits for cooling

and dust control.
These circuits are hooked up to trailing 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 arrangement is included to ensure long life of
the important drivetrain components.
The hydraulic system supplies sufficient 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

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 boring.
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 packer or the steering pads are not pressurized because of power cut, or in the
case of a malfunction.

Carrier and launcher

For ease of movement to the underground raise location, the BorPak system can be mounted on a diesel-powered 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 outriggers 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 cutterhead 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, cutterhead rotation and thrust are halted for
regripping. The thrust cylinders are
raiseboring

Talking Technically

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 automatic 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 raises 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 collaring, with a maximum of 4.8 m/h.
This machine featured four 380 mmdiameter single disc carbide insert cutters
raiseboring

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 cutterhead, 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-diameter 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 development. This BorPak has a cutterhead
equipped with four twin-cutter assemblies and four single disc cutter assemblies, all 15 in-diameter. Rotary power
is supplied by three 52 kW, watercooled, three-phase electric motors
through a gearbox and final drive. The
drive system has a closed pumped
lubrication circuit with filter and heat exchanger. Four main hydraulic cylinders

provide the thrust to the cutterhead,

while eight expandable packers grip the
body. The operator can steer the machine using steering shoes located at
its front end.
BorPak has proved its value in meeting the challenges of blind shaft boring 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 crosspassages on major projects. The compact
dimensions of BorPak, and the nondisruptive 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

35

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 systems can be used with Robbins
raiseboring machines, each suited
to different conditions. These systems 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, environment, ground conditions, and
Customers capability and available maintenance and troubleshooting skills.
Atlas Copco experts will advise
on the choice of most suitable
drive for specific conditions.
Electrical system assembly.

AC drive

DC drive

The alternating current AC drive motor

system uses a two-speed squirrel cage
induction motor. This type of motor provides 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 design, 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 stalling will be encountered.
For best performance, the power
source and supply cable to the motor
should be able to handle the locked rotor power demands of the motor, such
as when tightening a threaded connection, without excessive voltage drop.
State-of-the-art soft start units are used
for bigger models. Considerable developments in this field are allowing the
design and manufacturing of simpler
compact units with relatively simple
maintenance requirements.

The direct current DC drive motor system 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 variable speed main drive systems. DC drive
has proven performance on larger raises
where low revs/min must be accompanied by high torque, and in areas of
broken ground where repeated reamer
stalling occurs. Because of the variable
rev/min and good torque limiting control, DC drive is best suited for larger
raise diameters in mixed ground conditions. 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

36

sufficient resources and tecanical knowledge.

Hydraulic drive
The hydraulic drive motor system consists of one or more hydraulic motors
coupled to a multiple speed gearbox.
Hydraulic power is supplied to the hydraulic motors by one or more highpressure 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 particular raiseboring machine. Latest design of higher efficiency motors, combined with the use of proportional displacement systems are the preferred
option for raiseboring machines. With
variable speed and good torque limiting control, hydraulic drive can be used
in all ground conditions and has high
reliability when normal hydraulic preventive maintenance systems are in
place, and heat generation, and space
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 simplicity of the AC drive motor system with
exact motor speed, torque, and positioning 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 incoming 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, torque, and positioning control.
The VF drive motor system offers
several advantages over conventional
AC drive as follows:
1. Adjustment of motor speed and
torque, automatic motor braking
to prevent thread damage or over torque of drill string threaded
connections during connection
starting, and makeup.
2. System built-in diagnostics and
fault indications, simplifying motor
maintenance and troubleshooting.
3. Lower Costs. The VF system uses
less electrical energy than AC drive
systems because of its higher power
factor, requires normal mainte nance, and utilizes specially desig ned and manufactured main drive
AC motors.
4. Conversion of a standard AC drive
motor system to a VF system.
This conversion can transform an
older four-speed AC system into a
versatile state-of-the-ar t raise
borer.
Inherited into the VF drive technology is the considerable amount of space
required to handle heat dissipation.
Since standard types of AC motors are
not recommended for use in VF drives,
a new Atlas Copco Robbins specification AC motor should be installed
with every VF drive conversion.
raiseboring

Hydraulic system assembly.

Control console
Controls on the console assembly are
for both electrical and hydraulic functions. Drive train assembly controls
in-clude those for reversing rotation
and selecting drivehead speed.
Other electrical controls are provided
for rapid crosshead traverse, electrical
motor starting, and hydraulic cylinder
thrust pressure control. Hydraulic controls are provided for oil flow rate and
thrust pressure regulation. Controls for
an optional Pipeloader are commonly
housed in a portable pendant station
that is located at the control console
assembly.
Control consoles on more raise boring machines have meter readouts of
main drive motor amperes or main drive
motor pressure, depending on the type
of main drive motor, and drivehead revs/
min. Additionally, actual force applied
to the rock face by the pilot bit or reamer is displayed by use of a bit force
computer. Indicators for various hydraulic pressures are also displayed.

The latest now-available RCS control console assembly contains all the
controls and readouts necessary for raise
boring system operation. A modern compact rig control system from Atlas Copco
features a Control Area Network (CAN)
for digital communication between all
modules connected to the communication wire (bus). The entire system
features various I/O modules for communication with all sensors and meters
involved, and a master module for computing and processing of operational
data, as well as a display module for
presenting of calculated data (graphical
user interface). The new control system
is the proven Atlas Copco standard
CAN-bus control panel, manufactured
and delivered to over 140 units since
1998. It features a solid shell specially
designed for outdoor and underground
usage under severe conditions. All components involved are deve oped and long
term tested for the same conditions.

Roberto Lopez

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 borers. This represents a quantum
leap forward with respect to drilling accuracy, equipment reliability, logging capabilities, reduction
of manpower, and serviceability.
CAN-bus technology, well proven
in the automobile industry, is an
integrated part in the computerization. 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 excavation 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, including raiseborers.
The latest generation of raiseborers
requires less operators to supervise them,
while offering improved working environment and high production with reliability.
Atlas Copco has a great interest in
what raiseboring can do to improve
the rock excavation process as a whole,
and continually monitors the performance of machines working for customers around the world.
The PLC system, installed on drill
rigs for many years, uses a large radial
network to connect the central computer with the various sensors and processors. It handles analog high-speed
signals, while hosting many processors
for advanced digital communication
and man-machine communication. This
38

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 probably still a good solution. However,
as control systems become larger and
more complicated, the mix of highprecision and high-speed signals becomes more difficult to optimize in PLC
systems, and the radial networks involved require intense cabling.

CAN-bus raiseborers
With the introduction of the CAN-bus
system on the new generation of Atlas
Copco Robbins raiseborers, completely 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 builtin diagnostic procedure for the electronic system, making it easy to find
and repair faults. The electronic components on the CAN-bus rigs are common and interchangeable, thus requiring fewer spares at site.
CAN-bus can be adapted to the
type of application, whether surface or
raiseboring

Talking Technically

Rig control systems

Monitoring module condition.

underground, the pilot and reamer sizes,

the level of automation, and the introduction 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 improvements 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 organization does not require a deep knowledge of digital or computer technology.

RCS promotes quieter and more spacious 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 diagnostic and fault finding facility. Once
he has programmed the hole, the computer takes over, optimizing the pilot
drilling or reaming process, and leaving 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 rampup 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 increase in rotation pressure, which immediately causes boring to stop, avoiding unnecessary torsional stresses in the
machine and drill string.

Future trends
Automation products are already available to connect a raiseborer to a customers communication network.
Once the raiseborer is connected to
the network, the project control and
management systems will receive vital

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 teleremote operation, navigation and autonomous operation. They also have a
customer application interface to standardize 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 PCbased 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

RCS applied to raiseboring.

Monitoring of the rock characteristics is possible

Using the MWD (Measuring While
Drilling) function, rock parameters can
be logged during pilot drilling and reaming, without extra input. This is valuable in interpreting the results of parameter monitoring.
Rod changing is automated
Using radio remote control, the operator 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

Talking Technically

Site preparation
Improved efficiency
Correct site preparation eliminates major delays and adds noticeable efficiencies to the raiseboring operation. The site planner
needs to know the geology and
layout of the hole so that a correct 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 changing 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.

Clearance for derrick

erection from the
transporter system

Overhead
clearance
for complete
derrick
extension

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 scheduled 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
40

Overhead clearances.

Derrick mounting systems

Concrete pad mounting

The derrick must be positioned and mounted at the site before the raiseboring
operation can begin.
The two most commonly used mounting 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 qualified 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 location of the pilot hole collaring point and
base plates, must be indicated on the
site layout drawing.

This mounting system is constructed by

casting a concrete pad at the raise boring site on which the derrick base plates 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 running 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 relatively 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
raiseboring

Talking Technically

Derrick

Base plates

Concrete pad
Rock bolts

Sloped sunken channel

Concrete pad mounting system.

derrick and concrete pad from slum ping into the hole upon completion.
2. It is extremely important that the con crete pad be poured to solid bedrock
to ensure the best foundation possible.
3. The concrete pad must be of sufficient
quality and thickness to positively re 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
away from the working areas at the
front of the machine.
5. The upper concrete pad surfaces on
each side of the recessed channel must
be smooth, absolutely horizontal, and
level with one another.
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
each raiseboring machine.
raiseboring

Steel beam mounting

With the steel beam mounting system,
the base plates are secured to a steel
structure, which can be bolted to a

concrete pad or directly to the invert

rock, or to reinforced concrete pads at
opposite ends of a sunken pit.
Advantages of steel beam mounting
systems include:

Steel structure concrete pad mounting.

Bolts fastening the

base plates to the
steel structure

Concrete pad

Rock bolts

Steel structure

Rock bolts

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.

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 - concrete pad; steel structure - direct rock;
and steel structure traversing a sunken
pit.

Steel structure - concrete pad

Design considerations for the steel structure include: the upper surfaces must be
made horizontal and level with one another, 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, spacing, and hole pattern of the base plates
42

raiseboring

Talking Technically

Robbins 97RL at work in a typical cavern with good overhead clearance.

or sub bases. The concrete pad must be

designed to accommodate the dimensions 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, competent, and of sufficient strength to positively react the maximum load transmitted from the steel structure during
the raiseboring operation.

Steel structure traversing a

sunken pit

With this type of system, the steel structure traverses the sunken pit and is secured to reinforced concrete pads at opposite ends of the pit.
Design considerations for the sunken 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

circular pit must be competent, or be lined

with concrete in softer, structurally unreliable 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 permit stinger clearance for complete reamer
borethrough. Design of the steel structure 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 incorporated 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

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 influence 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 components can be rolled to the raiseboring
machine pipeloader. Sometimes a rail
43

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 Derrick Assembly in the particular machine
service manual. If a transporter system is to be used for derrick erection,
adequate overhead clearance is required
above the positioned transporter to swing
the derrick from its horizontal transport position to its boring position on
the mounted base plates.
The raiseboring site must have sufficient floor space for locating and correctly positioning all necessary equipment. This equipment typically includes
the following: derrick and mounting system; hydraulic system; electrical system; control console; pipeloader; drill
string components; tool boxes; auxiliary
44

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 everything to be positioned for all electrical
cables and hydraulic hoses to be interconnected. The service manual provided with each machine lists its cable
and hose lengths. Extra floor space is
required to allow the derrick transporter, where used, to be properly positioned for derrick erection.

Site services
Compressed air is required at site to
power pneumatic tools and to provide
a bailing medium during pilot hole drilling. Also, some crawlers are driven by
compressed air.
Clean water is required at the raiseboring 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, antifreezing precautions should be taken.
The electrical power supply required by the raiseboring machine at the
site is dependent upon the individual
machine being used. Additional electrical 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 raiseboring site and the breakthrough site to
enable installation and collaring-in
raiseboring

Talking Technically

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 cuttings 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 telephone system can be used, or a compatible 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 comfortable for the operating crew and acceptable for machine operation. Excessively
high air temperatures can lead to the
overheating of hydraulic and lubrication
oils, and damage of electrical and hydraulic equipment. Furthermore, high
dust and fume levels promote frequent
raiseboring

electrical cabinet air filter replacments.

Upon completion of planning and the
layout drawing, the site must be surveyed and excavated to the required
dimensions.

Site survey
Upon complete construction of the derrick mounting system, a site survey must
be carried out to ensure the base plate
mounting surfaces are absolutely horizontal. 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 perpendicular 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.

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 dimensions for the base plates are given
in the section Site Preparation and
Equipment Setup of each machine's service 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 mounting surfaces. If the raise is to be angled
from vertical, the template must be offset 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
45

Talking Technically

The excavation must be large enough

to allow both the reamer to be positioned and to accommodate the rock cuttings produced by the boring operation.
The site must also be accessible to loading and transport equipment.
Direct communication between the
breakthrough site and the machine operator 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 purpose.
A supply of water and compressed
air is necessary at the breakthrough site.
Water is required for cutter changes,
hosing down the reamer during preparation, and when any necessary examination of the reamer is to take place.
Compressed air is required for the operation of pneumatic hand tools.
Additional preparations include setting 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.
Concrete pad with bailing trench and pump pit.

Rikard Erlandsson
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 drilling 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 necessary 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

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 repairs become necessary. If the derrick
has to be dismantled for transport, lifting eyes must be located directly over
the final assembly positions of each
major component.

Breakthrough site
preparation
The breakthrough site must be excavated to size to permit removal of the
pilot bit and reamer-stabilizer, and to
install the reamer.

Oil trap under hydraulic power pack.

raiseboring

Talking Technically

Operating the raiseborer

Machine manual
Proper operation of the raiseborer
can be summarized in the methods and sequence required to
complete the raise safely, keeping in mind reliability, cost effectiveness, and maximum performance 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 instructions on how to maximize its utilization.
While the operational details
are specifically defined by the
model and function, the fundamental 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 setup of the specific machine, pilot
drilling, reaming, and removal of
the in-hole equipment.

Worksite preparation
The first stage of the raiseboring operation is the preparation of the worksite, keeping in mind the layout required for the
machine, power units, drill pipe, and accessories. 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 provided 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
raISEBORING

Robbins 34RH C.

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 operation. Poor anchoring of the base may
cause displacement of the equipment.
This will move its centreline and cause
loss of direction, inducing bending moments 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 equipment, ground conditions and local
services.

Anchoring and aligning the equipment 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 formation. The drilling characteristics of
these materials are different, so excess
force and speed must be avoided, otherwise deviation of the hole may result.
Correct pilot drill bit configuration for
the expected rock conditions and flushing medium are crucial.
Used pipes should be checked for
condition, and handled and stored carefully. A file can be used to smooth down
47

Talking Technically

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

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 concrete 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 collared deep enough to accommodate the
bit sub and stabilizers just behind the
bit and establish their direction. Collaring 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 drilling accuracy. In soft, blocky ground,
or when drilling low angles, additional
stabilizers may be used at intervals between 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

A liberal coating of general purpose

grease is applied to the collaring components, after assuring there are no protruding 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 purpose.
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 collared 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 instructions 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 backflow 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 stabilizers, until at least two stabilizers are
in the hole. Three stabilizers may be
needed to guide long holes.
Exercise care to prevent foreign material, 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. Because rock is not usually homogenous,
continuous monitoring and adjustment
will be required to maintain the optimum cutting rate, feed rate, rotation
speed, and bit force. Refer to the instructions 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.
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 failure to the mating part, so pipes should
always be handled and treated as precision items.
Because of the high torque and tension 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 drillingLikewise, these may loosen during the
reaming process.
Raiseboring operations require high
tension and torque in all of the pipe connections, and these must be tightened
properly to ensure a uniform coefficient of friction and prevent galling
raISEBORING

Talking Technically

during unthreading. Only thread lubricant 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 maximum 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 accidentally bumped, they should be repaired before use. A drill string is as
strong as its weakest pipe or connection.

Efficient drilling
Drilling can be controlled by speed or
bit force. The choice of method is based 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 penetration rate should be limited to a maximum of 2 in/min (50 mm/min) to minimize 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
rate controls. This method will achieve
a faster pilot hole. Whatever method is
used, the maximum weight on the bit
is the ruling consideration, limited by
the rotational speed of the machine and
the capacity of the bailing system to
remove the cuttings from the hole.
Before changing rods, it is essential
to clear the cuttings from the hole, otherwise they may settle, cementing the
string. Given the depth of the hole and
the annulus area, the bottom-up-time
can be calculated. This is the minimum
flushing time required to ensure all the
raISEBORING

Surface commissioning of a Robbins 73RH C.

cuttings have been removed from the

face before turning off the bailing, at
least theoretically. Operators have to be
prepared to make control adjustments
during the drilling process, since different
rock types, formations and characteristics may be encountered. Penetration
speed should be regularly monitored to
ensure it stays within the required range.
The bit force indicator will show changes
in rock hardness. The cuttings being discharged can be inspected to for chip size.
Small chips indicate efficient cutting,

while sandy discharge indicates insufficient load on the bit or inappropriate

bailing volume. Both promote regrinding
of the cuttings, and are detrimental to
the drilling process. If voids are encountered, the returning medium will
be lost, and the drill string should be
withdrawn. Attempting to drill without
returning medium can cause a stuck
drill string, with loss of both equipment
and hole. Cementing the hole may be
necessary to seal the voids and stabilize
the hole.
49

Talking Technically

Additives such as bentonite may be

used to seal fissures and prevent excessive losses of return fluid. When drilling 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 drillstring 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, characterized 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 reaming or to lower the reamer for inspection. 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, together 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 stabilizers 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 components 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 breaking the stem, which is expensive and
tedious to remove, a saver sub can be
50

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 experiences 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 assistance should be sought about methods
and techniques for retrieval.
The golden rule is to never work under 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 cleaning at the lower level, reaming must be
stopped for rectification.
Once the reamer head is connected,
communication with the machine operator must be established. Proper lubrication and alignment of the reaming
attachments is required to prevent crossthreading 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 breakages. 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 reinstall a reamer than to tighten the connections correctly.

Collaring the reamer

Starting the reamer is a slow process until all of the cutters are in contact with
the face. The force used varies with the
number of cutters in contact at a specific 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 Service 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 completed, the raise can continue at normal
drilling rates.
The cutters are loaded to the optimum 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 limestone formations may produce huge
boulders which make reaming very
difficult.
The objective is safe, effective cutting within the scale of maximum permissible load/cutter.
Continuous monitoring and adjustments may be required to maintain the
optimum cutting rate, feed rate, rotation
speed, and cutter force. The drilling record 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 reamer, 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 reamed 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

raISEBORING

Talking Technically

Bailing considerations
Importance of
bailing
It is important during pilot hole
drilling to provide a bailing medium such as water, compressed air,
or compressed air with water. This
should be of sufficient quantity
and pressure to ensure that all material being cut is removed immediately from the bottom of the
hole and exhausted up the annulus between the drill string and the
pilot hole walls. Adverse effects
of inadequate bailing are: shortened bit life due to the abrasive
effect of reground cuttings; bailing 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 penetration rate; rougher drilling operation; 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 surface to seal off the annulus. The cuttings and dust are directed away from
the machine through an abrasive resistant line to a convenient discharge
point.
If compressed air with water is used
as the bailing medium, a blooie system
may or may not be used. It is important that the water being injected into
the air stream be controlled carefully.
The approximate amount of water for
this mode is 20 lit/min (4.5 gal/min).
Too little water may create sticky mud,
which can severely limit bailing action,
due to caking around the drill string
raiseboring

Part of the site set up cavern blocked off to create a water and settling tank.

and increased friction on the pilot hole

surface.
Too much water will also reduce bailing action. An important fact to remember is that it takes approximately
1 psi of air pressure to lift water 1 ft in
the annulus. If water alone is used, a
blooie system is not required. There is
no dust to contend with, and the velocity of the return water is much less than
with compressed air.

When drilling with air, the pilot bit

should be air-cooled. This type of bit
utilizes a portion of the air to cool its
bearings. When drilling with water, bits
having sealed bearings should be used
for longer bearing life.
After adding drill pipe, the bit should
be raised off the bottom of the pilot
hole and rotated with bailing applied
to flush the bit bearings and bottom of
the hole.
51

Talking Technically

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 cuttings are removed from the pilot hole
prior to shutting off the bailing air after
drilling each pipe-length. This is particularly important at increased depths.
Manufacturers assume that the air supply will cool the bit bearings. Therefore, it is necessary to provide sufficient backpressure through the bit to ensure 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 cutting face.

Drilling with water

Drilling with water as the bailing medium generally requires 570 lit/min
(150 gal/min) at a pressure of 552-690
kPa gauge (60-100 psi). This will provide a bailing velocity of approximately 50 m/min (160 ft/min). This, of
course, is dependent on the same factors 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

Raiseborer set up with trench for bailing pump.

Drilling with compressed air

The general consensus of bit manufacturers is that at least 23 cu m/min (800
cu ft/min) of air supply through the annulus at 414-552 kPa gauge (60-80 psi),
with a minimum velocity of 1,500 m/min
(5,000 ft/min), is necessary when drilling with compressed air. This velocity
52

ensures that cuttings are being removed

from the bottom of the hole. The approximate bailing velocity can be calculated using the equations overleaf.
Velocity of bailing air will be decreased under the following conditions:
if water is encountered during drilling,
or added into the air supply; if heavier
material is encountered; as hole depth

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 because of its ease of handling and dust
suppression qualities. For this reason,
bailing fluid selection is usually dependent 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
raiseboring

Talking Technically

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 compressed air are given under the heading
Bailing System in the Description section 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/compressor output, depending on which
value is known, can be calculated using
the following equations:

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 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)

Water

raiseboring

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 checked 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 recommended 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. Failure to check the bit design against the
bailing fluid type can result in premature bit failure.
Provisions must be made for the discharge of bailing fluid and cuttings.
After the bailing system has been decided and designed, its dimensions and
location should be recorded on the site
layout drawing.

Two water systems are commonly used

for bailing: non-recirculated and recirculated.

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 system should be designed to conform to
the natural layout of the raiseboring
site. This, and the design of the derrick
mounting system, will usually determine 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 collaring 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 derrick, direct the discharge to the reservoir from the derrick, and pump the
bailing discharge from the reservoir to
the cuttings handling area.
53

Talking Technically

Recirculation reservoir arrangement.

Bailing discharge must be directed

to an area at or near the raiseboring
site with ample storage space for cuttings 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 storage required, use the following equations:
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 cuttings at the raiseboring site is to direct
the bailing discharge onto the site floor
54

and utilize the cuttings as site floor fill.

If this method is to be used, proper
floor drainage is required. If floor drainage is inadequate, bailing water can
be pumped to a drain or into a transport car with a screen liner and drainage holes.

Recirculation
Guidelines for transporting bailing discharge when using recirculated bailing
water are similar to those shown above.
For water recirculation, the cuttings handdling 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 compressed air and water mixture is used
raiseboring

Talking Technically

Bailing discharge
Compressed air

Abrasive
resistant pipe
Blooie
system

Drill pipe
Nozzle
Compressed air and cuttings

Water injection elbow

Blooie system and exhaust pipe.

for pilot hole bailing. The pipe system

connects to the outlet housing of the
blooie system, and can be designed to
direct the bailing discharge to the cuttings handling area.
The bailing fluid and cuttings must
be discharged into an area with ample
storage space and accessibility to personnel and transport equipment if the
cuttings are to be removed from the
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 reduces noise and dust levels for the crew,
and eliminates any danger posed by high
velocity cuttings discharge.

given previously in the section Compressed Air and Water.

High viscosity water (mud)

When additives such as bentonite are
used with water to form a high viscosity
bailing fluid for reducing bailing losses,

the bailing water should be recirculated

for reasons of economy.
Site planning considerations for
the transport of bailing discharge and
the handling of cuttings are the same
as those given earlier.

Roberto Lopez

Water circulation.

Compressed air
Site planning considerations for the
transport of bailing discharge and the
handling of cuttings when using compressed 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 components 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 comprising pipe, stabilizers, various subs
and roller reamer stabilizers for the
pilot hole, the stinger, the reamer, and
the cutters. Only the cutters come into
contact with the formation for the purpose of fracturing the rock. The cutters
are mounted on the reamer using saddles. The stinger connects the drill string
to the head. Thrust and torque are transmitted from the machine, through the
drill string and stinger, to the reamer
cutters and the rock formation.
Since the cutter interface with the
rock is very important to the performance of the raiseboring application, the
design of the cutters is important.

Cutters
Cutters are used to excavate rock when
reaming or boxhole boring upward, or
shaft sinking downward. These are mounted on cutter housings positioned and
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. However, since most raiseboring occurs in
medium to hard rock formations, the
56

Figure 1: The cratering and kerf breaking mechanism.

remainder of this chapter addresses

multi-row carbide cutters.
A carbide cutter has multiple cutting
rows machined into an integral steel
cutter hub. Tungsten carbide inserts are
placed in each of the cutting rows to
increase cutter life.
Multi-row carbide cutters are designed in the shape of a truncated cone.
The larger diameter end of the cutter
is designed to be mounted outboard of
the smaller diameter.

Main cutter types

There are at least four types of cutter
geometry used for raiseboring applications. These are disc cutters, kerfed

carbide insert cutters, rowed cutters and

randomly placed carbide insert cutters.
Each of these cutters employs a crushing mechanism in which adjacent rows
of steel, carbide or adjacent inserts induce cracks that propagate between
each other and spall out a kerf, or fragment of rock (figure 1).
Disc cutters have gradually fallen out
of favour due to the increased diameters being drilled, the increased demands
on the cutters, and the introduction of
new types of cutters more suited to the
current challenges. A disc cutter originally employed steel rings with different shapes on the outer diameter of
the ring depending on the hardness of
the rock (figure 2). Generally, the harder

Figure 2: Disc cutter, cutting ring profiles.

raiseboring

Talking Technically

Figure 3: Steel ring disc cutter.

the rock, the blunter is the outer diameter of the disc cutter (figure 3). Tungsten 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 changes, along with the shape of the outside diameter of the disc cutter, relative
to the hardness of the rock and the location on the head. Disc cutters and
domed reamers in combination served
the industry adequately in the early
years of raiseboring in soft and medium 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

Figure 4: Domed reamer.

design is generally difficult to work with,

difficult to measure, and difficult to expand. 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 cutters. When properly spaced kerfs are
combined with sufficient cutter force,
very efficient drilling results, since the
kerf maintains almost continuous contact with the formation. Interaction between 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, almost circular chips, depending on the
formation and the loading (figure 5).

They produce a pattern of grooves on

the drilled rock face relative to the spacing between the cutter rows.
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 load and torque are available. Grooves 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 cutter 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

Figure 6: Rock face, worked by a kerf cutter reamer.

57

Talking Technically

Figure 7: A pair of Magnum kerf cutters.

cutters because the latter can be rearranged individually for each cutting row.
The kerf cutter is generally employed in flat or barrel-shaped profiles,
rather than in domed profiles. It is generally less expensive to operate, since
fewer saddles are required to cover diameters in medium to hard rock conditions, and the bearing component is not
required for each row of carbide as for
a disc cutter.
Each kerf cutter design provides certain benefits to the application. The RCC
cutter design, for instance, provides a
Figure 8: A RCC11 cutter.

cutting structure with more relief within

the rows for better cuttings removal,
and can provide true 50 mm row spacing. 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 cutters required on larger heads, and increase 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 enhance the crushing action.
The Magnum cutter design is longer
and flatter than the RCC cutting structure, 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 cutters employ insert rows spaced 25 mm
apart, either on the gauge (MKC55G) or
the nose (MKC55N) (figure 7). This
cutting structure allows for extra coverage 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 stressed 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 pattern within each row is designed to reduce the incidence of tracking by employing an increasing or decreasing pitch
between inserts. This patented insert location has proven to physically reduce
tracking.
The kerf cutter has become the industry 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 somewhere between the kerf cutter and the
random insert cutter (figure 8). Eleven
distinct rows can be seen on this cutting structure, hence the nomenclature
RCC11. The nose and gauge of this cutting 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 multiple rows of inserts, but no steel kerfs.
The lack of kerfs allows more room for
cuttings removal, affords less opportunity for abrasive formations to wear
away the cutter shell, and facilitates
58

raiseboring

Talking Technically

greater penetration of the inserts into

the formation, with less power consumption.
The staggered insert location, lighter
insert coverage on the inner rows, and
multiple rows, tends to decrease the torque 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 cutting structure design also employs the
method of skip pitch on inserts within
the row. The pattern on the rock formation is somewhere between the pattern
left by the kerf type cutting structure
and that of the random insert location
cutting structure.

Random insert cutters

Random insert cutters offer a fairly
dense axial coverage in a complete revolution by placing inserts in a random
pattern on the cutter shell.
This design has shown significant increases in drilling rates, while reducing
drilling torque, which is beneficial where
the length of the raise or the rock formation are outside the scope of a machines capabilities. The random cutter spalls out small circular chips of
approximately 1.5 in diameter (figure 9).
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
Figure 10: Random cutter cutting structure.

raiseboring

Figure 9: Cuttings produced with random cutters.

pressure bulbs. No discernable pattern

or row is evident on the cutting face,
except at the nose and gauge of the
cutter. An additional benefit of the random insert location is a reduction in
tracking. Tracking occurs when the insert slips into a pressure bulb crater
created by the previous pass of the cutter. It can wear the edge of the insert
prematurely and result in shear failure
of the carbide, reducing the penetration
rate. Tracking can be reduced in nonrandom cutters by varying 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,
independent of kerf spacing. Figure 10
shows a random cutter cutting structure.

Bearing and seal design

Bearing designs have evolved into two
distinct types, known as preloaded tapered roller and roller-ball-roller.
Examples of both of these designs are
shown in figure 11.
The tapered roller bearing uses off
the shelf bearings with integral bearing
races. This type is preloaded using spacers between the bearings and is very
impact resistant.
The roller-ball-roller utilizes carburized races, which are machined into the
journal and shell along with roller and
ball bearings made from high quality
bearing steel. Unlike the tapered bearing, this approach does not require a
preload.
Special greases are used that enhance
the seals, while additives provide high
load carrying capacity to the bearings.

Figure 11: Preloaded tapered bearing and roller-ball-roller bearing systems.

59

Talking Technically

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 normally expected at the corners of these
transition areas.

Head design
Reamers or heads are designed in different ways for several different requirements. Some of the standard head designs
are integral heads, expandable or modular heads, downreaming heads and
boxhole heads. Other heads are generally modifications of one of these four
designs.

Integral heads
Figure 12: 1.8 metre integral head.

Both cutters employ metal face seals featuring two metal rings and two elastomer o-rings on either end, to maintain
the resiliency of the seal under operating 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 removable from the reamer, but, in a few instances, it is an integral part.
Cutters are held securely to the reamer 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 assembly. The bolted design enables these
housings to be detached and repositioned 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

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 rechecked 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 template 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 positions located on the template.
Reamers equipped with water spray
systems for cutter cooling and dust suppression are available on request.
The general cutting profile of the
reamer is flat, with a slightly depressed
angle at the stinger, and a standard bevel 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 reaming stability.

Integral heads are designed to drill a

single diameter. They are generally
cheaper, stronger and shorter than expandable or modular designs, because
there is no attachment mechanism required 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 diameter.
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 designed for easy change of diameter, according 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;
raiseboring

Talking Technically

Figure 13a: Mini superbase with 4.0 metre extensions.

Figure 13b: RRS reamer in 2.4 metre mode.

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 mechanism is simple, effective, easy to operate 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 multipliers to hydraulic torque tools depending on the diameter of the bolts and the
torque required. An example of a simple

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 incorporates all of these features. Using hydraulic torque tools, the wings are assembled 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.

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.

Figure 14: Attachment using a simple bolted

connection.

Figure 15: Attachment using dowels for guiding and

a combination of bolts and keys to handle the load.

Figure 16: Attachment using a combination of

wedge, bolts and dowels to handle the load.

raiseboring

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

61

Talking Technically

Stinger designs

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 preferred method of raising because of
poor ground conditions, or because of
its better profile. The most common boxhole diameters range from 1.5 m (60 in)
to 1.8 m (72 in), with a maximum diameter of around 2.1 m (84 in).
Figure 18: 720 mm down reamer.

62

Down reaming heads

Down reaming heads follow down an
existing pilot hole from the raiseboring
machine, employing rotating or nonrotating stabilizers. In general, down
reaming is used when the ground conditions 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 requirements in the market. Historically, down
reamers have utilized two cutters to ream
from the pilot hole out to the final diameter, 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.

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 raiseboring machine to the head under a
great deal of stress. The stinger connects 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 dimensions 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 remains 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 replaceable 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 extended wear resistance, but cannot be
replaced when worn.

Non-standard heads

Weld-in or integral
stingers

There are a number of other head designs based on customer requirements

which include heads adapted to drill at
low angles or completely horizontal, as
well as a number of other specialized applications where access may be limited,
dangerous or unprofitable with standard designs.

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.
raiseboring

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 tapered 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
Taperlok stingers are installed using a
hydraulic injection system, in which a
mating taper in the head is expanded
and the stem is pressed into place. The
mating taper is then allowed to shrink
to its original geometry. The Taperlok
is one of the most reliable stingers, but
its design is very dependent upon exact
geometry and cleanliness, which is not
easy to attain underground. The manufacturing 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.

Figure 19: The Bikon stem connection.

the pilot hole. Pilot bits used in raiseboring are equipped with an API regular threaded pin for connection to either
the starter sub during pilot hole start

up, or the bit reamer-stabilizer during

pilot hole drilling.

Figure 20: Taperlok stem.

Figure 21: Flanged stem.

Steve Brooke

Flanged stinger
Flanged stingers are attached to the head
using bolts and dowels. They have become 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 sufficiently robust to consistently transmit
rotational and thrust forces from
the machine to the pilot bit or reamer, and to provide support for
the reamer in the raise when adding or removing drill string components. The design of the drill
string must always be compatible with the machine on which
it is used. Atlas Copco drill string
components are designed for purpose and manufactured in lengths
that are easy to handle, store, and
transport. Crucially, they are sized
to be readily installed and removed
from the derrick of the raiseboring
machine, making them safe and
efficient in use.

Drill pipe

Six-rib stabilizer

Drill string
Bit reamerstabilizer

The drill string is commonly known as all

the components used for the drilling operation, including the drill pipe, subs, and
stabilizers.

Pilot bit

Bottom pack
Bottom pack is known as the bottom section of the drill string that determines the
pilot hole diameter. These are made of the
tricone bit, roller bit sub, and stabilizers.
These can vary from standard configurations to fit the requirements.

Starter pipe
Starter pipe is required for pilot hole
start up, this pipe is different from regular drill pipe only in that outer diameter are machined. They are available in
various lengths and diameters depending on the application. The starter pipes
64

Reamer

Pilot drilling and reaming.

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 conjunction with the starter pipes.
In addition to the wrenching areas
located near the upper DI-22 threaded
raISEBORING

Talking Technically

pin, the sub is equipped with wrenching 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 table 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 components. 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 raiseboring.
Bit reamer stabilizer
Rib stabilizer

Bit reamer stabilizer

The bit reamer stabilizer is installed adjacent 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 uniformly loaded in the pilot hole. It is the
function of the cutting roller on the bit
reamer stabilizer to maintain the correct 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 stabilizer are added to the drill string after
installation of the pilot bit reamer stabilizer.
These types of stabilizer are manufactured 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 application. The stabilizer can be considered
as the primary guide maintaining direction of the pilot hole.

Shock absorbers
A shock absorber is a specially designed 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
loads generated as the bit cones go over
the higher and lower areas at the base
of the hole.

Drill pipe float valve

The float valve is used during pilot hole
drilling to act as a check valve, preventing reverse bailing fluid flow from entering the drill string through the pilot
bit upon a depressurization of the bailing
fluid in the drill string.
Depressurization is necessary when
adding or removing drill string components at the derrick assembly. Before
pilot hole start up, the float valve is installed into the lower end of the bitreamer stabilizer adjacent to the pilot
hole drill bit

A typical section of raiseborer drill pipe.

Stress or flex modifiers

Reamer

Stress modifiers or flex modifiers are

specially designed drill string components designed to flex the connection
between the reamer head and the drill
string.
Unlike the saver sub the stress or
flex modifiers are designed, to absorb
bending forces without breaking.

The reamer head is used to back ream

the pilot hole. Various design types
of cutters and reamers in a choise of
diameters are available depending on
the specified ground conditions and
customers needs.

Roberto Lopez

Secoroc pilot bits for raiseboring.

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 component is designed to break and protect
the stabilizer connection.
66

raISEBORING

Boxhole Boring at El Teniente

Boxhole boring at El Teniente

The lieutenant
marches on
State owned Codelco is Chiles largest company and the worlds largest producer of refined copper.
The Codelco-owned El Teniente
(The Lieutenant) mine is presently
the worlds largest underground
mining operation. The mine average production rate is currently
126,000 t/day. Boxhole boring between the production and haulage
levels using Atlas Copco Robbins
machines is a major component in
achieving such high outputs.
Recently, two raiseborers modified to suit the El Teniente mine
conditions were commissioned by
Atlas Copco. They were evaluated
for three months, during which
time the crews were trained in
their operation. Both exceeded the
set target performance criteria.

Introduction
Codelco, renowned for its refined copper
output, is also the second ranked world
supplier of molybdenum, as well as being
a major producer of silver and sulphuric
acid, both of which are by-products of its
core copper production.
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
1.9 km-wide, and is 1.8 km-deep, with
proven reserves of some 4,000 million t,
sufficient for a mine life of 100 years.
Approximately 2,800 miners work
seven levels on a 24 h/day, 7 day/ week
operation.
El Teniente production increased significantly in 2005, when its new Esmeralda section came on line, using the
pre-undercut panel caving method. Overall mine output has increased by 31,000
t/day, with 45,000 t/day coming from
the Esmeralda Project, making it the
most important sector in the mine. The
two new boxhole boring systems supplied by Atlas Copco Robbins are a
vital part of this production system.
raiseboring

Basic facts in new operation

Main caving level
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.
Production level
Level: 2,162 m above sea level.
Drifts: 30 m. Sections: 4.0 x 3.6 m.
Draw Bell: 17.3 m

Orebody (narrow cut)

Slot hole
0.7 m diam/15 m long

Loading, LHD
Dumping

Production level
Robbins
34RH
Orepasses

Ventilation shaft,
1.5 m diameter
35 m long
Robbins
53RH

Tapping

Ventilation
shaft, 1.5 m
diameter
45 m long
(max: 75 m)

Transportation level

Ventilation level

Mining method at El Teniente.

The 3.6 x 3.6 m operating limits at

the mine work sites demanded an
extremely low reamer design with
a quickly detachable stinger.
This reamer is bolted onto the
machine when not in use.
When piloting, the stinger is
removed from the reamer, to allow
the drill string to be fed through.
In reaming mode, the stinger is
refitted using the pipe loader,
and the locking bolts are
tightened manually.

67

Boxhole Boring at El Teniente

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 introduced 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 working height. Both machines are selfpropelled, and equipped with efficient
muck collectors, remote-controlled pipe
handling and automatic data logging.

Atlas Copco Robbins 34RH

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 caving 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, comprising 45-50 shafts, are bored annually.
Because drifts have not been developed on the production level, all ventilation raises and ore passes are bored
from the haulage level and upwards
using the boxhole boring technique. The
average length of the vertical and inclined 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 machine design by the size of the underground sections. Work sites measure
3.6 x 3.6 m, and maximum transportation dimensions are 2.5 m-wide x 2.5 mhigh 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 extinguisher system. The mine electrical installations provide power at 575-4,000
68

V, 3-phases at 50 Hz, and 24-220 V, single phase at 50 Hz. Each machine is designed 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 occasional blast vibrations may be experienced. 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 performance 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 available operating time of 15-16 h. The
number of operating personnel required,
set-up and moving time, the rate of penetration 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

The Robbins 34RH is a low profile,

small diameter raise drill, designed for
applications such as slot raises, backfills
and narrow-vein mining. This multipurpose, lightweight raise drill can be
used for downreaming and upward
boxhole boring, as well as for conventional 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 dimensions, and to allow room for a muckhandling 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 arrangement, which had been fitted on two earlier Robbins 34RH machines commissioned in 1998 and 1999, has been
further developed for efficient muck
collection in the boxhole boring mode.
The remote controlled and hydraulically operated muck collector is fully
integrated into the derrick assembly, and
remains on the machine, even during
transportation.
raiseboring

Boxhole Boring at El Teniente

During pilot hole drilling and reaming, 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 machines 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 slideopening worktable for use in both downreaming and boxhole boring applications. 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 accommodates a 692 mm-diameter reamer
through the worktable, while a wide
frame model of the 34RH accommodates a 1,060 mm-diameter reamer.
The Robbins 34RH worktable is
equipped with semi-mechanized wrenching, which features a hydraulically
powered forkshaped wrench manipulated from the operators control
console.
The rod handler is designed to pick
up all drill string components, including 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 conventional 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 gathering gearbox that transmits torque to the
drive heads.
The Robbins 53RH features a raiseboring and a boxhole float box, which
allows the boring methods to be changed by simply installing drill rods in
either the upper or lower float box. In
addition, this multi-purpose unit is provided with a removable water swivel, to
raiseboring

Robbins 53RH set up underground.

facilitate pilot bit flushing in both raiseboring and boxhole boring modes.
The El Teniente machine has been
substantially upgraded from previous
versions of the Robbins 53RH, to increase its productivity and working
range. The input power has been increased 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 wrenching in the worktable, as well as the
headframe. This features a hydraulically powered forkshaped wrench manipulated 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 collector system designed to suit the machine. 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, hydraulically operated system provides a

360 degree working range for channelling 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 machine 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 before continuing on through the muck
collector, and into the hole.
A new reamer handling system has
been integrated into this machine design to eliminate the handling of the
reamer at each set up. The reamer has
been designed to bolt on top of the headframe during transport and erection.
The hollow centre design of the reamer
still allows prepiloting of the hole if desired, 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 transporter used for this machine is sized to
69

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 features a cordless remote controlled operating 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 Acquisition System was delivered with each
machine. This records operating variables in real time, and stores them on
a memory card. It also features a display 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 graphical plots of the data. The software
also generates data files that can be
inserted into spreadsheets.
70

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 raises. 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, learning progressed steadily, and the operating crew was ready to begin the evaluation 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 second largest contributing factor was
lack of site availability. During the completion of 20 production holes, the average 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 protection of these parts. The boring cycle included pre-piloting of 1 to 2 m, depending 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 cutting the rock. To ensure adequate flushing 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 commissioning. Again, the startup period
was strongly affected by lack of water,
poor ventilation, and availability of
concrete pads in the working area. However, 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
raiseboring

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 evaluation period was 40.3%, with a mechanical availability of 91.3%.
Machine utilization was again negatively affected by non-worked weekends, blasting near the drill site, and
shift changes. The next largest factor
contributing negatively to machine utilizations was site availability due to site
cleaning, waiting for concrete pads, and
the availability of electricity and water.
During the completion of nine production 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 deviation 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 cuttings past the bit sub.

Conclusion
The application environment in the
El Teniente mine placed high demands
on the boxhole boring equipment supplier, both in size constraints, and in
operation of the equipment. The mine
personnel also had aggressive performance expectations, in keeping with
the established high productivity of the
mine.
Atlas Copco chose to offer its proven
34RH and 53RH boxhole machines with
customized features to meet the special
needs of El Teniente. Most of these
raiseboring

Robbins 34RH.

features were focused on accommodating the restrictive work environment

and high performance expectations.
After thoroughly monitoring the capabilities of both machines, the project in

El Teniente has provided important input to future development of boxhole

boring technology.
With production results exceeding
expectations, it has also proved to be
71

Boxhole Boring at El Teniente

a new milestone in the application of

boxhole boring machines.

Acknowledgement
Atlas Copco is grateful to the management and staff at El Teniente for their
help and assistance with this article,
which was originally published in
2001.

Rock Type
Composition Density

[%]
[ton/m3]

Andesite Fw
36
2.75
Andesite Hw
24
2.75
Anhydrite Breccha
20
2.70
Andesite Breccha
12
2.70
Diorite 8
2.75

UCS
[MPa]
[MPa]
100
125
115
100
140

Youngs
Modulus
[---]
55
55
55
50
60

Poissons
Ratio
0.12
0.17
0.17
0.12
0.15

Rock properties at El Teniente.

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 Cameco Corporation, the worlds largest supplier of combined uranium
and conversion services. McArthur
River is the only operation in the
world that relies solely upon raiseboring for production, rather than
methods requiring conventional excavation or utilizing blasting methods. For this extraction technique,
the mine is using five Atlas Copco
Robbins raiseborers. This article
provides an overview of the operation, and outlines recent innovations 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 company producing uranium fuel and
generating clean electricity, but its
core business is the supply of uranium concentrates and associated
nuclear fuel services.
The company owns controlling
interests in the worlds largest
high grade uranium deposits, at
McArthur River and Cigar Lake,
and the largest uranium mills, at
Key Lake and Rabbit Lake, all located in northern Saskatchewan.

Mine access
The McArthur River Operation is jointly owned by Cameco Corporation (70%)
and Cogema Resources Inc (30%). It
entered production in December, 1999
and successfully ramped up production
to become the worlds largest uranium
mine, at over 18 million lbs/year of
U3O8.
The minesite is located approximately 620 km north of Saskatoon. Access
is by both air and all-weather road.
Air travel is used to transport personnel to and from various locations in
Saskatchewan, while road transportation is used for materials.
raiseboring

McArthur River minesite and headframe.

The site is located in a valley between

glacial drumlins. The Pollock Shaft is
the main access for men and materials,
as well as being a source of fresh air
for the underground operations. It is
concrete lined, with a diameter of 5.5 m,
and is approximately 680 m-deep.
Two production levels, at the 530 m
and 640 m elevations, provide access
above and below the ore zones for raisebore mining. These two levels are also
joined by a ramp, which provides access
to a third production level at 560 m
elevation.
The No 2 Shaft, located approximately 300 m south of the Pollock shaft, is
also concrete lined, with a diameter of 6
m and a depth of approximately 530 m.
Its main purpose is mine exhaust ventilation, and as a secondary means of egress
via ladders. Shaft No 3, located approximately 500 m south of No 2 Shaft, is
again concrete lined, with a diameter of
6 m and a depth of approximately 530
m, and is used for fresh air ventilation,
as well as a permanent means of emergency egress, for which it is equipped
with a small mechanical hoist.

Radiation overview
Worker annual exposure limits have been
established in conjunction with the
CNSC, and take into account the cumulative exposure to alpha and gamma radiation and radon gas, along with long-lived
radioactive dust. Radon gas decaying to
its progeny causes alpha radiation. It is
typically derived from radon bearing
groundwater sources that enter mine
workings, and is a critical source of radiation, particularly where inadequate
ventilation allows gas build up.
Gamma radiation is directly proportional to ore grade. Long-lived radioactive dusts are essentially airborne ore
particulate that has been generated by
some aspect of mining or ore handling.
Discreet radon sources need to be
captured in suction ventilation ducting,
and delivered to non-entry return airways. General ventilation is normally
single pass to non-entry return airways
to limit exposure to the decay process.
Time, distance and shielding are the key
design criteria used to limit gamma radiation exposure. Processes are designed to
73

Raiseboring for production at McArthur River

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 ventilation systems where necessary.
A full appreciation of the implications of the radiation exposure potential, 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 extraction and handling carry direct reading
dosimeters (DRDs) that provide realtime numeric readouts of gamma radiation exposure. Personnel working underground are also equipped with personal
alpha dosimeters (PADs) that measure
alpha radiation exposure. Extensive dust
sampling is also conducted. All personnel on-site are provided with thermalluminescence device (TLD) badges that
register gamma radiation exposure over
a specific period of time.

Negative ventilation applied to a raiseborer.

minimize the time personnel need to be

in contact with ore sources. When interaction is necessary, the distance between
personnel and an ore source is maximized. Additionally, the surface area of the
ore source should be minimized where
Inspecting freeze holes on the 530 m level.

74

possible. Finally, shielding, typically

steel, lead, concrete, or even water, is
incorporated into processes as required. At McArthur River, much of the
process piping is Schedule 160, and ore
storage tanks typically have a suitable

Ground freezing
Ground freezing is utilized around the
ore to cut off the groundwater flow path
from the sandstone. It also provides consolidation 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 portion 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 smaller 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

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 freezing. There is also a need to control ventilation circuits extremely well, and low
orebody rock strength eliminated the
use of mining methods requiring explosives.
Initially, three raisebore chambers
were established on the 530 m level inside the freeze-wall. Two rows of raises
are bored from each chamber to respective 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 concrete floor, for ease of setting up the raisebore 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 developed adjacent to these backfilled drifts,
ready for reaming the next two rows of
raises per chamber.
Pilot hole deviation averages just 1%,
due to careful alignment of the raisebore drills, and standardization of pilot
hole drilling parameters.
Raises completed to date have varied
from 50,000 lb to over 1,000,000 lb of
U3O8, with raises averaging 75 m in
length. Due to the generally soft nature
of the ore zone, the production rate,
when reaming in the ore, is constrained
by ore-handling capacity. Reaming in
excess of 50 t/h is theoretically possible, and 20 to 30 t/h has proved to be
sustainable. In a 3.05 m-diameter raise,
this equates to 0.9 m/h to 1.4 m/h.
Special precautions are taken during
both pilot hole drilling and reaming to
ensure the safety of the operators.
Due to radon gas and progeny generation, the raise air has to be contained
during the reaming cycle. This involves
maintaining a good seal at the pilot hole
collar, and introducing compressed air
down the pilot hole during reaming;
utilizing a negative pressure 2.5 cu m/s
wet bath dust scrubber at the bottom of
the raise, as part of the ore collection
chute (OCC) system, that exhausts to
the return air side of raiseboring on the
raiseboring

Robbins raiseborer 53RH-EX, one of four at site.

640 m level; and using proper restrictive barriers to ensure that no personnel
enter on the return air side of raiseboring on the 640 m level.

Loading ore
Ore is collected at the bottom of the
raises by line-of-sight LHD. A simple
chute arrangement is placed below the
raise to direct material to a 1.2 mdiameter chute opening, which dumps
directly into the LHD bucket. Stationary
cameras indicate when the bucket is 75%
full, and the driver contacts the raisebore operator to cease reaming. The
driver, located 20-40 m away on the
fresh air side, then backs the LHD away
from the chute, using line-of-sight remote
control.
He then boards the LHD into a pressurized, air-filtered cab, and drives it to
a scanning station, where the ore grade
is determined by gamma radiation response before delivery to the indicated
location. Ore grading less than 2% U3O8
can be skipped to surface via the Pollock

Shaft. Ore grading greater than 2% U3O8

is delivered to the underground grinding
circuit, with a semi autogenous grinding
mill, and then hoisted hydraulically to
surface. Once at surface, the slurry is
stored in radiation-shielded storage tanks
to await transportation to Key Lake mill,
some 80 km away.
Direct reading dosimeter.

75

Raiseboring for production at McArthur River

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 production of approximately 55,150,000 lb of
U3O8. The following table highlights
the annual production.

Robbins raiseborer 73RM-H at the 530 m level.

If it is necessary for a worker to approach within 10 m of the chute area, a

Radiation Work Permit is required. A
radiation technician conducts an alpha
and gamma radiation survey, to establish both the radiation and work guidelines, and the personal protective equipment 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

Backfilling
Once the reamer has been removed from
the raise, the backfill gantry is placed into
the correct position to act as the formwork for backfilling the raise. This backfill 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 pumped via a feed pipe through the backfill 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 complete raise filling. During this timeframe, the raiseborer is setting up to
drill the next pilot hole. Raises are designed to overlap slightly, in order to
achieve high ore recovery.

Year

Production

1999
2000
2001
2002
2003 (to March)

3,410,000
11,670,000
17,170,000
18,520,000
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 raisebore drills after every raise; and design
and fabrication of a reamer catcher
system.
For the quality assurance programme, 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 stempin. Magnaflux testing is also carried
out on the pin and box ends of all stabilizers, 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 reamers, this reamer-on-a-rope system
has a wedge anchor at one end that is installed 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 catches the reamer, which is suspended in
the raise until the OCC can be removed
raiseboring

Raiseboring for production at McArthur River

using a remote LHD. Once the OCC has

been removed, a cushion of muck is placed at the bottom of the raise, and the
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 tricone bits is also being actively pursued.
A two-piece reamer stem has been
introduced, which has a joint near the
platform elevation of the stem. This allows the upper portion of the stem to
be changed, rather than replacing the
entire stem complete with flange.
With some of the pilot holes overlapping, various plastics were tried,
before an aluminium standpipe was
implemen-ted. This lighter material
allows for the drilling out of the standpipe of a previous pilot hole, without
damaging the tricone bit.
Two raises have also had to be reamed 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
safety, as well as limiting worker radiation exposures. The procedure involved
reaming to within 3 m of the sill, drilling backfill holes into the raise below
the reamer from the 530 m level, backfilling the raise while still leaving a
void below the reamer for the cuttings,
reaming up through to the baseplates,
removing the reamer from the raise, and
completing the backfilling to the sill of
the 530 m elevation.

Innovative backfilling
In order to reduce radiation exposure during the installation of the backfill gantry
(BFG), a plastic plug has been introduced
to seal the bottom of the raise. This is
utilized if ground conditions around the
collar of the raise will not allow sealing
with Styrofoam.
A canvas bag with attached fibreglass
rebars, that is inflated with concrete, was
designed and tested. It was installed
on top of the BFG, and the BFG placed
under the open raise remotely. Then, the
canvas bag was inflated with concrete,
sealing the bottom of the raise and placing the rebars vertically. This initial test
raiseboring

530 m

Raiseborer machine

Pilot hole
Ore zone

Reaming head

Exhaust ventilation

640 m

Exhaust air scrubber

Fresh air
Remote control
scooptram
Operator

Schematic of production system at McArthur River.

proved to be quite successful, and larger

canvas bags are being investigated for
full plug pours, rather than just for sealing purposes.

The future at McArthur

River
One of the most interesting aspects of
this mining programme is the unconventional use of raiseborers. This unique
operation has created opportunities to
reinvent drilling procedures, as well as
design one-of-a-kind equipment.
With the success of conventional raiseboring as the primary mining method,
the future is bright for McArthur River.
This mining method has been proven,
and has matured to such a level that it
is the primary mining method planned
for new mining zones. However, upcoming challenges in regard to the required

development for access above and below

future mining zones indicates that alternate mining methods should be investigated, such as boxhole boring and jetboring. A test programme is also being
conducted to try mining without the
OCC under the raise, which could lead
to more conventional mining methods
in the future.
The McArthur River Operation has
been granted ISO 14001 Certification,
underlining its commitment to protect
the environment.

Acknowledgements
Atlas Copco is grateful to Cameco
Corporation for permission to publish
this article, and in particular to chief
mine engineer V Clay Wittchen, who
wrote and presented the papers on which
it is based.
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 replacement for the 1940s hydropower
station serving the rdal aluminium smelter, located near Sogndal
in western Norway.
Overall cost of the project will
be approximately 180 million,
with the Selmer Skanska contract accounting for 60 million.
The new power station has been
excavated in rock, together with
nearly 21 km of associated tunnels 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 current 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 rockdrills. Secoroc supplied its Magnum SR35 rock tools for the drill
rigs, and Atlas Copco refurbished
a Robbins 97RLC raiseborer for
the surge shaft excavation. There
was even an Atlas Copco ST1000
Scooptram at site!
The compact dimensions of the
Robbins 97RL C raise drill enabled
the surge shaft to be drilled safely
from the surge chamber, for which
access was limited and difficult.
Tyin is a testament to the ability of a single company to supply
and support all the equipment
necessary for a major tunnelling
project, while complying with the
environmental strictures placed
on working in sensitive areas of
the world.

78

Robbins 97RL C in operation.

Tunnel system
The tunnel system runs from a laketap
intake in Lake Tyin to the existing storage lake at Torolmen, and then on to the
powerstation penstocks and turbines,
finally discharging through a tailrace
at rdalsvatnet.
Five surface creek intakes have also
been constructed. These have been coupled to the existing power tunnel, which
will then work as a top feed to the new
tunnel, connected by a shaft located

approximately halfway along its alignment. Selmer Skanska subsidiary E-Service drilled the 1 m-diameter x 25-50 mlong holes to connect the creeks to the
existing headrace.
An access tunnel 1.54 km-long with
50sq m cross section was driven downgrade at 1:10 to reach the power station
site in June, 2002. The rock cover of
1.5 km is resulting in heavy pressure
on tunnel face and crown.
It involved some 75,000 cu m of
excavation using an Atlas Copco Rocket
raiseboring

Replacing Norways Tyin Hydropower Plant

First worksite for the upgraded

Robbins 97 RL C raiseborer

Tyin
1073-1083 m.o.h.

Torholmen
Tya

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 explosive and Nonel detonation provided
good fragmentation, and spoil removal
was undertaken by a subcontractor.

Power station
The power station excavation was completed 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 designed to replace output from the existing 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 anchored 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 truckmounted 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

created by over 1,000 m of head between

Lake Tyin and the powerhouse. Massive
crane rails have been installed to cope
with the turbine components and the
240 t transformers.

Tailrace
The tailrace tunnel is 2.7 km-long, and
9.5m-high x 5.5 m-wide, with 46 sq m
section. This was driven by an Atlas
Copco Rocket Boomer WL3C drill rig
with three booms and a basket, delivered new in February, 2002. The WL3C
was equipped with the latest 1838 HF
rockdrills, which drilled at 1.5 m/min
in the granite gneiss. It drilled 90 holes/
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 loaders, which discharged into road tippers.
Rock from the tailrace tunnel was carried by bottom dump barges to an area

of the fjord that has been reclaimed as a

nature reserve. The access and tailrace
tunnel entrances are 3 km apart along a
tarmac all-weather public highway.
Large 1.8 m-diameter fans and 2 m
ducts provided 35 cu m/min of fresh air
to the faces.

Headrace
The pressure tunnel was advanced at
27 sq m section on a 0.5% gradient from
the power station position towards
Lake Tyin. Meantime, development of
Atlas Copco ROC 642 HP used for bulk excavation
of power station cavern.

79

Replacing Norways Tyin Hydropower Plant

At the controls of the Rocket Boomer WL3 C.

the 350 m-long Biskopsvatn adit was

commenced in October, 2001, at a point
approximately halfway along the 7
km alignment between the power station 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, operated 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 underground at the junction of the Biskopsvatn
adit and the pressure tunnel drives. Towards the right downgrade side, the
drive was in granite, and towards the

One of the Atlas Copco Rocket Boomer 353 C drill rigs.

80

raiseboring

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 because 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 diameter range of 2.4 m-5.0 m. The conversion 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 technology, 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 reduction 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
raiseboring

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 transportation 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 transportation. 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 started 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 shotcrete were installed.

Selmer Skanska and its subcontractors had a total of 160 employees on

site, of which 50 lived at the intermediate 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 Torolmen 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 carried 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 powerstation 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.
81

ROBBINS raise drill specification

34RH
Main specifications

Standard 34RH
with optional
ground loading
pipeloader

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 raiseboring, 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
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
to clear the pilot hole.
A choice of different types of worktables is available.
The slide open worktable facilitates downreaming or
boxhole applications while the horseshoe fork
worktable wrench, as well as the worktable wrench,
are available for conventional raiseboring only.

Frame

Low

Standard

Raise diameter
Nominal

Wide

1.2 m
(4 ft)

1.2 m
1.2 m
(4 ft) (4 ft)

Range*

0.6-1.5 m
(2-5 ft)

0.6-1.5 m
(2-5 ft)

0.6-1.5 m
(2-5 ft)

Raise length
Nominal

340 m
(1,115 ft)

340 m
(1,115 ft)

340 m
(1,115 ft)

Maximum*

610 m
(2,000 ft)

610 m
(2,000 ft)

610 m
(2,000 ft)

Drillpipe
Diameter

203 mm
(8 in)

203 mm
(8 in)

254 mm
(10 in)

Optional diam.

254 mm
(10 in)

254 mm
(10 in)

203 mm
(8 in)

Length, s/s**

750 mm
(2.5 ft)

1,219 mm
(4 ft)

1,219 mm
(4 ft)

Pilot hole
Diameter

229 mm
(9 in)

229 mm
(9 in)

279 mm
(11 in)

Optional diam.

279 mm
(11 in)

279 mm
(11 in)

229 mm
(9 in)

Torque and force

Reaming torque 64 kNm
64 kNm

(47,500 lbf ft) (47,500 lbf ft)

64 kNm
(47,500 lbf ft)

Reaming thrust

1,285 kN
1,285 kN
(289,000 lbf) (289,000 lbf)

1,285 kN
(289,000 lbf)

Installed power

110-160 kW
(150-215 hp)

110-160 kW
(150-215 hp)

110-160 kW
(150-215hp)

Main drive

Hydraulic

Hydraulic

Hydraulic

Dimensions
Height extended 2,900 mm

(115 in)

3,250 mm
(128 in)

3,350 mm
(132 in)

Height retracted 2,900 mm

(115 in)

3,250 mm
(128 in)

3,350 mm
(132 in)

Width

1,700 mm
(67 in)

1,700 mm
(67 in)

2,200 mm
(87 in)

Depth

Weight
Derrick

1,650 mm
(65 in)

1,800 mm
(71 in)

2,250 mm
(89 in)

7,200 kg
(15,870 lb)

7,600 kg
(16,755 lb)

11,100 kg
(24,470 lb)

Dip adjustment
from horizontal

90 - 60 (45) 90 - 60 (45) 90 - 60 (45)

* Depending on machine version and rock conditions

** Shoulder to shoulder

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

Visit www.raiseboring.com for more information

raiseboring

ROBBINS raise drill specification

44RH
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
Diameter

203 mm (8 in)

Optional diam.

254 mm (10 in)

Length, s/s**

Pilot hole
Diameter

1,219 mm (4 ft)

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)

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.

Depth

1,600 mm (63 in)

Weight
Derrick

8,000 kg (17,636 lb)

Dip adjustment
from horizontal

90 - 60 (45)

Features and benefits

* Depending on machine version and rock conditions

** Shoulder to shoulder

The single power pack hydraulic drive features variable

speed and good torque limiting control. The well
proven RCS system adds reliability and user
friendliness.

229 mm (9 in)

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.

Visit www.raiseboring.com for more information

raiseboring

83

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)

Drill pipe
Diameter

286 mm (11-1/4 in) 286 mm (11-1/4 in)

Length, s/s

750 mm (2.5 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
(115,000 lbf ft)

156 kNm
(115,000 lbf ft)

Reaming thrust

3,350 kN
(754,000 lbf)

3,350 kN
(754,000 lbf)

Installed power

255 kW
(340 hp)

255 kW
(340 hp)

Main drive

Hydraulic

Hydraulic

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)

2,150 mm (85 in)

1524 mm (5 ft)

The Robbins 53RH is a unique multi-purpose raise drill,

able to perform upwards boxhole boring as well as conventional 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.

Depth

2,150 mm (85 in)

Weight
Derrick

14,000 kg (30,865 lb) 14,000 kg (30,865 lb)

Features and benefits

Dip adjustment
from horizontal

90 - 60 (45)

The hydraulic drive features variable speed and good

torque limiting control. The well proven RCS system
adds reliability and user friendliness.

* Depending on machine version and rock conditions

** Shoulder to shoulder

90 - 60 (45)

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

ROBBINS raise drill specification

73R
Main specifications

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.

Models

73RAC

73RH

73RVF

Raise diameter
Nominal

2.1 m
(7 ft)

2.1 m
(7 ft)

2.1 m
(7 ft)

Range*

1.5-2.4 m
(5-8 ft)

1.5-3.1 m
(5-10 ft)

1.5-3.1 m
(5-10 ft)

Raise length
Nominal

550 m
(1,800 ft)

550 m
(1,800 ft)

550 m
(1,800 ft)

Maximum*

700 m
(2,300 ft)

700 m
(2,300 ft)

700 m
(2,300 ft)

Drill pipe
Diameter

254 mm
(10 in)

286 mm
(11-1/4 in)

286 mm
(11-1/4 in)

Optional diam.

286 mm
(11-1/4 in)

254 mm
(10 in)

254 mm
(10 in)

Length, s/s**

1,524 mm
(5 ft)

1,524 mm
(5 ft)

1,524 mm
(5 ft)

Pilot hole
Diameter

279 mm
(11 in)

311 mm
(12-1/4 in)

311 mm
(12-1/4 in)

Optional diam.

311 mm
(12-1/4 in)

279 mm
(11 in)

349 mm
(13-3/4 in)

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
(935,000 lbf) (935,000 lbf)

4,159 kN
(935,000 lbf)

Installed power

215 kW
(290 hp)

305 kW
(400 hp)

305 kW
(400 hp)

Main drive

Electric (AC)

Hydraulic

Electric (VF)

Dimensions
Height extended 5,550 mm

(219 in)

5,250 mm
(207 in)

5,900 mm
(232 in)

Height retracted 3,800 mm

(150 in)

3,600 mm
(142 in)

3,850 mm
(152 in)

Width

1,600 mm
(63 in)

1,600 mm
(63 in)

1,600 mm
(63 in)

A patented, two piece swivel float box prevents

transfer of bending moments to the gearbox, and a
replaceable threaded insert lowers maintenance costs.

Depth

Weight
Derrick

1,900 mm
(75 in)

1,900 mm
(75 in)

1,900 mm
(75 in)

12,000 kg
(26,455 lb)

11,500 kg
(25,350 lb)

13,000 kg
(28,660 lb)

Rigid crosshead guide columns provide efficient torque

reaction extending the service life of the thrust cylinders.

Dip adjustment
from horizontal

A simple in-line drive system provides balanced thrust

loads to improve cutting action.

* Depending on machine version and rock conditions

** Shoulder to shoulder

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.

90 - 60 (45) 90 - 60 (45) 90 - 60 (45)

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.
Visit www.raiseboring.com for more information
raiseboring

85

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
Diameter

327 mm (12-7/8 in)

Length, s/s**

Pilot hole
Diameter

The ruggedly built, large diameter and high torque

Robbins 83RH, is one of the toughest raise drills going
for the widest applications throughout the mining
industry. The 83RH is recommended for reaming shafts
and raises from 2.4 m up to 4.5 m (8-15 ft) in diameter.

Features and benefits

1,524 mm (5 ft)
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)

Width

1,650 mm (65 in)

Depth

2,150 mm (85 in)

Weight
Derrick

20,000 kg (44,100 lb)

Dip adjustment
from horizontal

90 - 60 (45)

* Depending on machine version and rock conditions

** Shoulder to shoulder

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
www.raiseboring.com for
Visit
formore
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)

Drill pipe
Diameter

327 mm (12-7/8 in)

Length, s/s**

Pilot hole
Diameter

The Robbins 91RH is the latest addition to the Robbins

low profile series that brings the advantage of raiseboring to more underground mine locations. Its modular
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
makes it ideal for large raises up to 5.0 m (17 ft).

1,524 mm (5 ft)
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
Height extended

5,100 mm (201 in)

Height retracted

4,050 mm (160 in)

Width

2,300 mm (91 in)

Depth

2,500 mm (99 in)

Weight
Derrick

24,000 kg (53,000 lb)

Dip adjustment
from horizontal

90 - 60 (45)

* 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 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

The Robbins 97RDC is a high power and low profile raise

drill specially designed for mines with size and weight
restrictions. Despite its low profile, the 97RDC is one of
the largest raise drills ever produced. Recommended
diameter range is 2.4 m up to 5.0 m (8-17 ft).

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)

Length, s/s**

Pilot hole
Diameter

1,524 mm (5 ft)
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)

Width

2,250 mm (89 in)

Depth

3,300 mm (130 in)

Weight
Derrick

24,000 kg (53,000 lb)

Dip adjustment
from horizontal

90 - 60 (45)

* 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

ROBBINS raise drill specification

123R
Main specifications
Models

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.

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)

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
(330,000 lbf ft)

540 kNm
(398,000 lbf ft)

Reaming thrust

8,923 kN
(2,000,000 lbf)

8,923 kN
(2,000,000 lbf)

Installed power

500 kW
(670 hp)

525 kW
(700 hp)

Main drive

Hydraulic

Electric (VF)

Dimensions
Height extended
Height retracted

5,700 mm (224 in) 5,800 mm (228 in)

4,050 (160 in)
4,050 (160 in)

1,524 mm (5 ft)

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

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

89

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
Diameter

375 mm (14-3/4 in)

Length, s/s**

Pilot hole
Diameter

D
W

Designed for large diameter and long hole raiseboring

applications, the Robbins 191RH is the most powerful
raise drill in the Atlas Copco Raiseboring series. The
191RH is designed to meet the requirements for very
long, large raises, ranging from 4.5 m to 6.0 m (15-20 ft)
to a depth of 1,400 m (4,500 ft)

1,524 mm (5 ft)
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)

Width

2,300 mm (91 in)

Depth

2,700 mm (106 in)

Weight
Derrick

45,000 kg (99,200 lb)

Dip adjustment
from horizontal

90 - 60 (45)

* 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 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

At your service wherever you are

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.

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

Before starting on a raise project, collect as much information about the site as possible. Find out about the
typical formations, their compressive strengths and
abrasive qualities.
Then pick your bit. The right one is the one that ultimately
yields the lowest cost per metre drilled. As youll
discover, with Secoroc you cant go wrong.

BMHT

Smith

Sandvik

Security

Secoroc MH

BI-V

M84F

Secoroc H

BI-X

Q7JS

SCM

M87F

Secoroc VH

BI-XX

Q9JS

SCH

H100F

A guide to our pilot bits and the equivalent products from other manufacturers.

Selection guide

Soft/Medium hard rock

Hard rock

Very hard rock

Secoroc MH

Secoroc H

Secoroc VH

10,000 psi
70 MPa

92

30,000 psi

50,000 psi

210 MPa

350 MPa

70,000 psi
480 MPa

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"

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"

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"

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"

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
within recommended tolerances.
2 If the pilot bit is used, check that the carbide buttons
are in good condition and the cones are free to turn
without excessive play. Furthermore, make sure that
all flushing passages are clear.
3 Make sure that the design of the pilot bit complies
with the geological formation youre drilling in as
well as the flushing fluid used.

8 Do not over torque the pilot bit during makeup.

Recommended torques given by API manufacturers
should be followed. Slow rotation speed during
makeup is advised.
9 During bit breakout, raise the pilot bit and drill string
component high enough to allow the bit to drop into
the bit breaker box.
10 Do not drop the pilot bit with the drill string weight
attached.
11 After removing the pilot bit and bit reamer stabilizer
from the drill string after breakthrough, lubricate the
cones of the bit with light oil prior to storage.

4 If flushing with compressed air, check that nozzles

are installed and of the correct size.
5 If flushing with water, check that nozzles have been
removed from flushing passages.
6 Clean up and inspect the threads and mating
shoulders of the pilot bit and drill string component.
Liberally coat with lubricant approved by the bit
manufacturer.

12 Any time the pilot hole is open, make sure you dont
drop anything in it. But if you do, be sure to remove
the object before you resume drilling.

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
(in)

Design

Makeup
torque range

Weight-on-bit

Bit
weight

Rotary
speed (rev/min)

7 7/8
Secoroc H

16,270-21,015 nm
12,000-15,500 lbf ft

10,630-21,260 kg
23,625-47,250 lb

30 kg
67 lb

50-90

9
Secoroc H

16,270-21,015 nm
12,000-15,500 lbf ft

12,150-24,300 kg
27,000-54,000 lb

35 kg
76 lb

50-90

9 7/8
Secoroc H

37,963-43,386 nm
28,000-32,000 lbf ft

13,330-26,660 kg
29,625-59,250 lb

64 kg
140 lb

50-90

9 7/8
Secoroc VH

37,963-43,386 nm
28,000-32,000 lbf ft

13,330-26,660 kg
29,625-59,250 lb

64 kg
140 lb

40-80

11
Secoroc MH

37,963-43,386 nm
28,000-32,000 lbf ft

14,850-29,700 kg
33,000-66,000 lb

77 kg
170 lb

50-120

11
Secoroc VH

37,963-43,386 nm
28,000-32,000 lbf ft

14,850-29,700 kg
33,000-66,000 lb

77 kg
170 lb

40-80

12 1/4
Secoroc H

37,963-43,386 nm
28,000-32,000 lbf ft

16,540-33,075 kg
36,750-73,500 lb

101 kg
224 lb

50-90

12 1/4
Secoroc VH

37,963-43,386 nm
28,000-32,000 lbf ft

16,540-33,075 kg
36,750-73,500 lb

101 kg
224 lb

40-80

13 3/4
Secoroc MH

37,963-43,386 nm
28,000-32,000 lbf ft

18,560-37,125 kg
41,250-82,500 lb

130 kg
285 lb

50-120

13 3/4
Secoroc VH

37,963-43,386 nm
28,000-32,000 lbf ft

18,560-37,125 kg
41,250-82,500 lb

130 kg
285 lb

40-80

15
Secoroc H

35,000-45,000 lbf ft
48,400-62,200 nm

20,250-40,500 kg
45,000-90,000 lb

168 kg
370 lb

50-90

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

OD*
in

OD*
mm

S/S*
in

S/S*
mm

Box
connection
DI22

Pin
connection
DI22

Wrench
flat (in)

Wrench
flat (mm)

Weight
lb

Weight
kg

Raise drill rod, integral

8.000

203.2

48

1,220

6.750

6.750

175

385

Raise drill starter sub (short)

8.500

215.9

12

305

6.750

6.750

175

170

77

Raise drill starter (short)

8.500

215.9

21

533

6.750

6.750

175

297

135

175

513

234

175

480

218

175

480

218

175

620

280

175

44

20

175

58

26

Raise drill starter (long)

8.500

215.9

48

1,220

6.750

6.750

Raise drill stabilizer,

6 rib, T.C.I.

9.000

228.6

48

1,220

6.750

6.750

Raise drill stabilizer, 6 rib, hardface

9.000

228.6

48

1,220

6.750

6.750

Raise drill stabilizer, model 60, DI22

pin x reg box

9.000

228.6

48

1,220

6.750

4.500

Lifting bail, 6" DI22 box, 20,000 lb

capacity

8.000

203.2

Lifting bail, 6" DI22 pin, 20,000 lb

capacity

8.000

203.2

6.750
6.750

Saver sub

8.000

203.2

20

508

6.750

6.750

175

161

73

Drill pipe, standard strength

8.000

203.2

29.5

749

6.750

6.750

175

390

178

Stabilizer, 6 ribs

9.000

228.6

29.5

749

6.750

6.750

175

390

178

Stabilizer, bit reamer

9.000

228.6

29.5

749

6.750

4.500

175

400

180

Starter pipe, long

8.500

215.9

29.5

749

6.750

6.750

175

305

139

Starter bit sub

8.500

215.9

29.5

749

6.750

4.500

175

395

180

OD*
in

OD*
mm

S/S*
in

S/S*
mm

Box
connection
DI22

Pin
connection
DI22

Wrench
flat (in)

Wrench
flat (mm)

Weight
lb

Weight
kg

Raise drill rod, integral, 8" OD pin

x box

8.000

203.2

48

1,220

6.750

6.750

175

385

175

Raise drill starter sub (short), 8"

OD box

8.500

215.9

12

305

6.750

6.750

175

170

78

Raise drill starter (short), 8" OD

8.500

215.9

21

533

6.750

6.750

175

206

94

8 pipe using 978 pilot hole size

Raise drill string description

Raise drill starter (long), 8" OD

8.500

215.9

48

1,219

6.750

6.750

175

470

214

Raise drill stabilizer, model 60, DI22

pin x reg box

9.875

250.8

37

940

6.750

6.625

175

510

230

Raise drill stabilizer, 6 rib, hardface,

9.875H.S x box

9.875

250.8

48

1,220

6.750

6.750

175

475

215

Lifting bail, 6" DI22 box, 20,000 lb

capacity

8.000

203.2

44

20

Lifting bail, 6" DI22 pin, 20,000 lb

capacity

8.000

203.2

58

26

6.750
6.750

*OD = outer diameter

*S/S = shoulder to shoulder

96

raiseboring

DRILL STRING COMPONENTS

10 pipe using 11 pilot hole size

Raise drill string description

Raise drill starter (short)

OD*
in

OD*
mm

S/S*
in

S/S*
mm

Box
connection
DI22

Pin
connection
DI22

Wrench
flat (in)

Wrench
flat (mm)

Weight
lb

Weight
kg

9.500

241.3

20

508

8.250

8.250

200

220

100

Raise drill bit sub

9.500

241.3

12

305

8.250

6.625

200

200

91

Raise drill starter

9.500

241.3

60

1,525

8.250

8.250

200

550

250

Raise drill rod, standard strength

10.000

254

60

1,525

8.250

8.250

200

550

250

Raise drill rod, high strength

10.000

254

60

1,525

8.250

8.250

200

860

390

11.000

279.4

60

1,525

8.250

8.250

200

1150

522

Raise drill stabilizer, model 60,

DI-22 pin x , reg box

11.000

279.4

60

1,525

8.250

6.625

200

1025

465

Lifting bail, 8" DI-22 box, 30,000 lb

capacity

10.000

254

73

33

Lifting bail, 8" DI22 pin, 30,000 lb

capacity

10.000

254

66

30

Raise drill stabilizer, 6 rib, hardface

8.250
8.250

Bit sub DI-22 pin x reg box

8.250

209.6

9.5

241

6.625

8.250

200

440

200

Saver sub, 6 ribs

11.000

279.4

23

584

8.250

8.250

200

1023

465

Drill pipe, STD

10.000

254

29.5

749

8.250

8.250

200

440

200

Starter pipe, long

9.370

238

29.5

749

8.250

8.250

200

422

192

Bit sub, 6 ribs mod

11.000

279.4

16.75

425

8.250

6.250

200

341

155

Starter sub

9.500

241.3

48

1,220

6.625

8.250

792

360

OD*
in

OD*
mm

S/S*
in

S/S*
mm

Box
connection
DI22

Pin
connection
DI22

Wrench
flat (in)

Wrench
flat (mm)

Weight
lb

Weight
kg

Starter pipe, short

11.000

279.4

30

760

9.250

9.250

230

800

364

Raise drill starter sub

11.000

279.4

36.5

927

9.250

6.625

230

850

386

11 pipe using 12 pilot hole size

Raise drill string description

Starter sub

11.000

279

48

1,219

6.625

9.250

230

1060

482

Raise drill starter (long)

11.000

279.4

60

1,525

9.250

9.250

230

1400

636

Raise drill rod, integral, standard

strength

11.250

285.8

60

1,525

9.250

9.250

230

1060

484

Raise drill rod, integral,

high strength

11.250

285.8

60

1,525

9.250

9.250

230

775

350

Drill pipe, standard strength

11.250

285.8

29.5

749

9.250

9.250

230

775

350

Stabilizer, 6 ribs

12.250

311.2

30

762

9.250

9.250

230

655

297

Stabilizer, 6 ribs

12.250

311.2

36

914

9.250

9.250

230

985

467

Stabilizer, 6 ribs

12.250

311.2

60

1,524

9.250

9.250

230

1500

680

Stabilizer, bit reamer

12.250

311.2

26

660

9.250

6.625

230

728

331

29.5

749

9.250

9.250

230

572

260

93

42

213

97

Starter pipe, short

11.250

285.8

Lifting bail, pin

11.250

285.8

Lifting bail, box

11.000

279.4

raiseboring

9.250
9.250

97

DRILL STRING COMPONENTS

1278 pipe using 13 pilot hole size

Raise drill string description

Raise drill rod

OD*
in

OD*
mm

S/S*
in

S/S*
mm

Box
connection
DI22

Pin
connection
DI22

Wrench
flat (in)

Wrench
flat (mm)

Weight
lb

Weight
kg

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

pin x 6-reg box

13.750

349.3

48

1,220

10.500

6.625

10

250

1500

682

Raise drill stabilizer, 16 rib, hardfaced, Robbins wrench squares

13.750

349.3

60

1,525

10.500

10.500

10

250

1605

730

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

capacity

12.875

327

139

64

Lifting bail, 10" DI22 pin, 70,000 lb

capacity

12.875

327

149

68

10.500
10.500

1278 pipe using 15 pilot hole size

Raise drill string description

OD*
in

OD*
mm

S/S*
in

S/S*
mm

Box
connection
DI22

Pin
connection
DI22

Wrench
flat (in)

Wrench
flat (mm)

Weight
lb

Weight
kg

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

reg Ibox

12.750

323.9

53.75

1,365

10.500

6.625

10

250

1725

784

Raise drill stabilizer, Model 60, DI22

pin x reg box

15.000

381

48

1,220

10.500

7.625

10

250

1200

545

Raise drill stabilizer, 6 rib,

hardfaced

15.000

381

60

1,525

10.500

10.500

10

250

1750

795

Lifting bail, 10" DI22 box, 70,000 lb

capacity

12.875

327

139

64

Lifting bail, 10" DI22 pin, 70,000 lb

capacity

12.875

327

149

68

OD*
in

OD*
mm

S/S*
in

S/S*
mm

Box
connection
DI22

Pin
connection
DI22

Wrench
flat (in)

Wrench
flat (mm)

Weight
lb

Weight
kg

13.880

352

60

1,525

11ST

11ST

11

279

1685

764

10.500
10.500

1378 pipe
Raise drill string description

Raise drill rod

*OD = outer diameter

*S/S = shoulder to shoulder

98

raiseboring

powering the raise drill

Power packs
Main drive pack

Thrust 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.

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.

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

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.
99

powering the raise drill

L
W

Specifications
one for thrust. Each unit is built to withstand the harsh
environment in underground mining and uses standard
Atlas Copco components.

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

Power pack

Length

Height

Width

Weight

metric

imperial

metric

imperial

metric

imperial

metric

imperial

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

Thrust pack

2,200 mm

87 inch

1,450 mm

57 inch

1,300 mm

Drive pack

2,800 mm

111 inch

1,450 mm

57 inch

1,500 mm

Thrust pack

2,200 mm

87 inch

1,450 mm

57 inch

1,300 mm

Drive pack

2,800 mm

111 inch

1,450 mm

57 inch

1,500 mm

Thrust pack

2,200 mm

87 inch

1,450 mm

57 inch

1,300 mm

Drive pack

1,900 mm

75 inch

1,300 mm

52 inch

800 mm

Thrust pack

2,200 mm

87 inch

1,450 mm

57 inch

1,300 mm

34RH Low

53RH-EX
73RH
73RAC
73RVF
83RH

4,250 kg

9,400 lb

2,400 kg

5,300 lb

59 inch

4,250 kg

9,400 lb

52 inch

2,400 kg

5,300 lb

59 inch

4,250 kg

9,400 lb

52 inch

2,400 kg

5,300 lb

32 inch

900 kg

2,000 lb

52 inch

2,400 kg

5,300 lb

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

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

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

123RH
123RVF
191RH

100

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

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

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
powering the erection system. There is also an airdriven 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.

Air crawler

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

Ancillary Tools

Tools

Makeup and breakout tool (MBT)

Starter bushing

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.

The starter bushing is used during pilot hole start up, together with the starter sub and starter pipe to initiate an
accurately aligned pilot hole. The starter bushing is installed 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.

Blooie assembly

Accumulator charging kit

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.

This kit is used to charge the pipeloader clamp accumulator 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.

raiseboring

103

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 readout, 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 assemblies 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

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

raiseboring

upgrades

RCS mounted on a moveable trolley for better

view and position of the operating controls.

RCS is a common platform for all Atlas Copco

mining and construction products.

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.

can also be included and operated via a joystick on the

panel. This improves performance and availability as
well as reducing cost.

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:

The hydraulic power pack provides hydraulic power to

the derrick assembly and auxiliary components. It consists 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.

RCS upgrade
The new Rig Control System (RCS) follows a well-proven
Atlas Copco standard featuring CAN-bus. It is totally enclosed in a waterproofed envelope designed for outdoor
and underground use under severe conditions. All components 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

Power pack upgrade

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.

105

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 machine 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 electricaldrive 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.
106

Hydraulic power unit.

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 handheld 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

Length
mm (millimetre)........................ x 0.001 (10-3).............= m
cm (centimetre)......................... x 0.01........................= m
dm (decimetre).......................... x 0.1..........................= m
km (kilometre)........................... x 1 000 (103).............= m
in (inch)...................................... x 25.4........................= mm
ft (feet)....................................... x 0.305......................= m
yd (yard).................................... x 0.914......................= m
mile............................................ x 1609.......................= m
Power
J/s (joule/second)...................... x 1.............................= W
Nm/s (newton metre/second)... x 1.............................= W
kW (kilowatts)............................ x 1 000.....................= W
hk (metric horse power)........... x 735.5......................= W
hp (horsepower UK, US).......... x 745.7......................= W
ft.lbf/s......................................... x 1.36........................= W
Btu/h........................................... x 0.29........................= W
Volume
l (litre)......................................... x 0.001......................= m3
ml (millilitre).............................. x 0.001......................= l
dm3 (cubic decimetre).............. x 1.0..........................= l
cm3 (cubic decimetre)............... x 1.0..........................= ml
mm3 (cubic millimetre) . .......... x 0.001......................= ml
in3 (cubic inch)........................... x 16.39......................= ml
ft3 (cubic feet)............................ x 28.316....................= l
Imperial gallon.......................... x 4.546......................= l
US gallon................................... x 3.785......................= l
Ounce (Imp. fluid oz)................ x 28.41......................= ml
Ounce (US fluid oz)................... x 29.57......................= ml
Pint (US liquid).......................... x 0.4732....................= l
Quart (US liquid)....................... x 0.9463....................= l
yd3 (cubic yard)......................... x 0.7646....................= m3
Force
kN (kilonewton)......................... x 1 000.....................= N
kp (kilopond)............................. x 9.81........................= N
kgf (kilogramme force)............. x 9.81........................= N
Ibf (pound force)....................... x 4.45........................= N
Torque (moment of force)
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
by unit

108

This unit

Times

Equals

Mass
(commonly but incorrectly called weight)

g
(gramme).
............................... x 0.001.................... = kg

t (tonnes, metric)....................... x 1 000................... = kg
grain.
.......................................... x 0.0648.................. = g

oz
(ounce)..................................
x 28.35.................... = g

ozt
(troy
ounce).........................
x 31.10.................... = g

lb
(pound)..................................
x 0.4536.................. = kg

ton
(long,
US).
.
..........................
x 1 016.................... = kg

ton
(UK).....................................
x 1 016.................... = kg

ton
(short).
.
................................
x 907....................... = kg


Speed
(velocity)

km/h
(kilometre/hour).
.............. x 0.2777.................. = m/s

m/s
(metre/sec).........................
x 3.6........................ = km/h

mile/h.........................................
x 0.45...................... = m/s

mile/h.........................................
x 1.61...................... = km/h

ft/s
(foot/second).......................
x 18.29.................... = m/min

ft/min
(foot/minute)..................
x 0.3048.................. = m/min


Frequency

blow/min.
................................... x 0.017.................... = Hz

kHz
(kiloHertz)...........................
x 1 000................... = Hz

rev/min.
.
.....................................
x 0.01667................ = r/s

degree/second.
.
.........................
x 0.1667.................. = r/min


Pressure

bar..............................................
x 100....................... = kPa

bar..............................................
x 100 000 (105)....... = Pa

2
kp/cm
........................................
x 0.98...................... = bar

atm
(atmosphere).....................
x 1.01...................... = bar

2
psi
(pounds/in
).........................
x
6.895.................... = kPa

psi.
.
.............................................
x
0.06895................ = bar


Area
mm2 (square mm)..................... x 0.000001 (10-6).... = m2
cm2 (square cm)........................ x 0.0001 (10-4)........ = m2
in2 (square inches).................... x 645....................... = mm2
ft2 (square feet).......................... x 0.0929.................. = m2
yd2 (square yard)....................... x 0.8361.................. = m2
Acre . ......................................... x 4 047.................... = m2
Square mile............................... x 2.590.................... = km2
ha (hectare)............................... x 10 000................. = m2

Equals
Divided
This
by unit

raiseboring

Atlas Copco

No surprises

Raiseboring
in Mining and Construction

Committed to your superior productivity.

Printed matter no. 9851 2575 01

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,
machines have to be online to make money.

Atlas Copco Rock Drills AB

2008

www.atlascopco.com

First edition 2008

www.atlascopco.com