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Projects Development and Application of a flexible Combined Support

System for Tunnel Rehabilitation
A rehabilitation concept for tunnels consisting of a combination of yielding steel arch
sections and BULLFLEX Roof Support Backfill Hoses was developed and
successfully implemented in the course of the rehabilitation of a conveyor tunnel in
operation at the Rio Tinto Kennecott Utah Copper (RTKC) Bingham Canyon Mine (Utah,
USA).

The focus of the rehabilitation was the approx. 4.5km long C6 conveyor tunnel, which was
originally excavated in 1959 as a 5.5 x 7.5m cross section railroad tunnel, and which is
currently being used as the main conveyor tunnel. At the time, horseshoe shaped steel sets
with a spacing of 1m to 2m were installed as ground support. Furthermore, roof bolts and a
timber lagging (200m per tunnel meter) were installed and subsequently backfilled. In
addition, load distribution structural elements were selectively used as support for the steel
sets in the tunnel invert. Finally, a 25cm to 30cm thick cast in place concrete lining was
installed which has since been repeatedly repaired on a provisional basis in the course of
time using rock bolts, mesh and shotcrete.

At the beginning of 2014, as a result of nearby open pit mining activities, considerable
damage was detected in the C6 conveyor tunnel especially near fault zones. This included
severe damage of the concrete lining as well as a clear increase in displacement of the tunnel
tube. The damage led to a partial closure of the tunnel so that the urgently required inspection
and maintenance work at the main conveyor belt could no longer be carried out. Therefore, a
short-term rehabilitation of the affected sections was required without hindering the operation
of the conveyor belt.

DSI Underground Systems, Inc. (DSI) and their cooperating partner BuM Beton- und Monierbau GmbH (BuM) were asked to provide technical
planning criteria by the engineers Gall Zeidler Consultants LLC (GZ), who had been awarded the contract for developing the rehabilitation
concept. In the shortest possible time, DSI and BuM supplied the required information needed to design an efficient and safe rehabilitation
concept. Important aspects during the dimensioning of the rehabilitation elements included the fact that the installed support measures had to
ensure sufficient clearance, while the impact on the operation of the conveyor belt during the rehabilitation had to be minimized.

Furthermore, a system with immediate loadbearing capacity was needed that ensured a high degree of flexibility in case of increasing
convergence. Within a few days, GZ proposed a rehabilitation concept to the customer RTKC and the rehabilitation project was immediately
commissioned by the client.

Upon the recommendation of GZ, BuM and DSI, the following stabilization concept was chosen:
TH steel sets with yielding locks in areas of overlapping segments, Types TH-25 and TH-29
BULLFLEX Groutable Hoses functioning as a roof support backfill, 3,200mm
The TH system was developed in the 1930s in Germany for application in highly converging ground conditions in coal mining. The single,
interleaved TH sections are connected by lock systems. Depending on number and type, these locks can accommodate a defined load until a
controlled slippage of the segments into each other occurs, thus ensuring the yielding ability of the system. For dimensioning of the yielding
support system for the C6 Rehabilitation project, in-situ measurements carried out in German coal mining were used as references.

The BULLFLEX System, which is filled with grout at a pressure of up to 4 bar, ensures a stable and safe form fit between the steel support
and the rock. Furthermore, point loads are voided and premature relaxation movements are minimized. Thanks to the special filter effect of the
BULLFLEX fabric, any surplus water is immediately drained, thus maintaining the induced pre-load, i.e. the active support.

The main characteristics and advantages of this combined support system can be summarized as follows:
Steel arch support with yielding lock systems
Easy adaptation of the steel support to uneven excavation surfaces
Controlled slippage in converging ground conditions
Immediate, full face load bearing capacity and introduction of an active pre-load thanks to the installation of the BULLFLEX System
The TH steel arch support sections were manufactured at DSIs plant in Louisville including the load distribution profiles and flexible footings
(also known as Dutchmen) in accordance with the design specifications. The steel arch segments and locks were assembled outside of the
tunnel and then transported to the underground jobsite using a support manipulator. The Installation was carried out from an elevated work
deck using a second support manipulator. The BULLFLEX Groutable Hoses were filled on site using a grout mix (portland cement and fly
ash) supplied by mobile mixing units. In addition to this support system, wire mesh and rock bolts were installed.

The described rehabilitation concept including the combined support system was implemented quickly and successfully. Consequently, the C6
conveyor tunnel is now once again fully accessible and can be considered as stable for the medium term. In cooperation with the customer,
Rio Tinto, the mining service provider Cementation and the responsible engineers GZ, DSI and BuM have made an important contribution to
restoring the functionality of a drift that is critical for mine operation.

Sources
German Institute for Standardization, Mine Support, Part 2: Dimensions, Designation and Statical Properties, May 2003.
German Institute for Standardization, Mine Support, Part 3: Requirements, May 2003.
Nitschke, A.G. et al.: Innovative Rehabilitation of Existing Tunnels under Minimum Impact on Operation. 2015 SME Annual Meeting,
Preprint 15-131, February 2015.
Weber, H.: Load- and Deformation Measurements at Supports in differing Mining Locations. Glueckauf, magazine 7/8,
90th volume, February 1954.

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