Good Practices in Tunnelling

The Experience of Norway

Introduction
Underground excavation is often a key factor in the cost and time for opening production in a mining projects. Mining in Chile is in general world class. Nevertheless, tunnelling performance is still very poor. Norway has a long tradition in tunnelling and excavation rates commonly reach 70 m/week though working less hours (100 vs. 168 h/week) and with less people. This study aims to summarize the good practices of tunnelling in Norway, trying to identify some of the reasons behind the differences in the tunnelling rates and costs between Chile and Norway.

The Norwegian Experience

Tunneling in Norway started with Mining in the 15th century, but has been developed mainly through construction of a big amount of railroad tunnels, hydropower tunnels and road tunnels.
lenght [km] 950 125 200 3600 250 5125 Longest [km] 24,5 7,9 14,6

Road tunnels Sub sea road tunnels Railroad tunnels Hydropower tunnels Other tunnels Caverns Total tunnel projects

nos 975 35 > 700 >500 >200 250 2910

1980ies Ulla Frre, 120 km

1891 - Eidfjordvatn

2000 Lrdalstunnelen, 24,5 km

m/week vs. Year

Source: NTNU

Normalized excavation cost vs. Year

Source: NTNU

The Norwegian Experience: Geology

The conditions for tunnelling in Norway are mostly considered favourable. However, tunnelling projects in Norway may face significant adverse ground conditions: Heavy rainfall tunnels usually well below phreatic level and huge wateringresses are commen (if not handled properly) Complex tectonic history many weakness zones with crushed rock and swelling clays High in situ stresses spalling and rock burst potential

Risk Sharing Contract Type

Why the risk should be shared?

risk-sharing inthe tunnel contracts is The Themain groundprinciple condition is of always uncertain when contract is sign. toIf the contractor has to assume all the risk he will ask a each very high price in give to the parties a tool for converting unit order to be safe. work into time-equivalents and cost-equivalents Courtactivity proceedings regarding change ground conditions may be very costly and time consuming, the only winners are the lawyers.
Such How the allows risk can be shared? tool to meet any contingency arising from
All types and activities possibly needed during tunneling are estimated in discussions over regulation of the construction time the BoQ. where A unit price is offered by the costs contractor for each unit activity. needed, or over incurred. An equivalent time is offered by the contractor for each unit activity. For rock support elements, different time is defined for primary support and support behind the face. Thus, the contractor is paid by unit of work done and the contractual construction time is adjusted to the actual ground conditions by mean of the equivalent time system.

changed ground conditions, eliminating any future

Rock Support
The support is decided at face based on the observed conditions, without predefined classes, this requires to have: Flexible Contract. Contractor compensated by unit (not by rock class!). Flexible Support Elements. Main elements are shotcrete with fiber and bolts. Expertise. Experienced geologist in the tunnel for defining the support. Support is installed in two stages:

Initial support. Installed at face to ensure safe working conditions during construction. Permanent support. Installed behind face to ensure project requirements during operation. Initial elements are recommended to be part of permanent support system. i.e. all elements have to reach long term standards.

Rock Support
The main support elements in Norway are rock bolts and shotcrete (with and without fiber). Most typical rock bolt types are rock bolts end-anchored by resin capsules and CT-Bolts. Fully grouted rebar bolts is considered to be optimal for hard rock applications. Combi-coat corrosion protection and hot-dip galvanized steel have shown to be very effective for harsh environments. Shotcrete is normally improved by the use of fiber and accelerators. The use of Reinforced Ribs of Shotcrete (RRS or Norwegian arches) can usually replace the more expensive and time-consuming cast in place concrete lining. CT-Bolts: Expansion Shell for instant support plus arrangement for grouting injection for permanent support. Spilling Bolts: XXX RRS is Double a very flexible method in which the thickness and spacing of the ribs corrosion protection. can vary as required. When required, support may be installed ahead the face.

The Contractor
Rather small and self sufficient teams
State of the art equipment and methodology Managers with hands on experience (former tunnel workers and supervisors etc) Flat structure in the organization (mutual respect and thrust) Knowledge, responsibility and decision making power at the face Culture of responsibility at all levels (internally and towards the client and side contractors) Strong focus on logistics and optimization of processes Dynamic payment based on production and KPI (bono system) Problem solving focus rather than focus on short term gains

Decision Making and Tunnel Crew

Quick decision making, mostly at the face itself, is key in unstable rock conditions and water problems. Avoid bureaucracy! Tunneling teams are well-trained, self confident and motivated. Decision making is encouraged at all levels in the project hierarchy. Basic crew in normal size tunnel consist in three persons covering all production activities: mark up, drilling, charging, blasting, scaling, temporary support. For single face sites the same crew is involved, fully or partially, in mucking and transport. For alternating faces, permanent support, mucking and transport is solved by a different crew. Commonly, there are two shifts (7.5-10 hours) per day, 5.5 days per week.

HEALTH AND SAFETY

Procedure driven Process driven

-Top down approach -Only following instructions -Little communication -Low knowledge transfer -Static system -Punishment

-Bottom up approach -Procedures only basis -Safe Job Analysis -Running communication -Positive focus on registered unwanted events -Dynamic system - Bono systems

Typical Problems Observed in South America

To many people at site (creates chaos and risks) Non recommendable type of contract Management groups with unclear roles and often internal conflicts Lack of trust between different levels Beaurocratic decision making with low level of hands on knowledge Placing of blame rather than focus on solutions Lack of knowledge on and hostility towards changes on supervisor level Lack of motivation at workers level To little focus on logistics Short term focus

Case example The Sauda Hydropower Project

Dalvatnet

Snn HPP

Raundalen Kraftstasjon

GRANITIC GNEIS

VULCANITES
Sagelva

Maldal

Tengesdalselva

10 km

VULCANITES
Lingvangselva

GRANITIC GNEIS

Adit Raundalen

Snn Powerstation area

Design as you go in cooperation

Good solutions through cooperation

Adjustment based on in situ observations!

Design as you go!

Final Comments Dynamic rock support incl. Inital (at face) and permanent support (additional behind face) High competence at face De-sentraliced decition making Benefit sharing with tunnel workers
(KPI dependant salary = Production, HSE, Teamwork) (ventilation, water control, road surface, light)

Maintain optimal working conditions at all times Good logistics is essential Running maintainance and supply of critical spare parts

Thank you for the attention!