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CONTENT Supplement issue on ONSITE CONSTRUCTION n. 7 – October 2020
4 News
by Mirko Brusamolino
COVER STORY
22 Robbins
“Main Beam” carves out a win in Louisville
by Pietro Gabrielli
34 Bauer
The central link of the Mediterranean Corridor
by Ettore Zanatta
Standing the test by Ettore Zanatta
DRILLING
Two B200XP-2 in an Italian biogas plant
Customer satisfaction by design
by Ettore Zanatta
by Mirko Brusamolino
Reliability, efficiency, innovation in drilling equipment
by Stefano Vitali
43 Kelley Engineered Equipment
26 Trevi
Express route to Atlanta
by Mirko Brusamolino
TECHNOLOGIES
The “FOUR Frankfurt” project
by Ettore Zanatta
44 DAT instruments
28 Soilmec
The Soilmec flagship
Certificated soil mixing operations
by Ettore Zanatta
by Stefano Vitali
A new remote controlled mobile drilling unit
by Mirko Brusamolino
32 Vermeer
TUNNELLING
Technology in Cortina d’Ampezzo
by Pietro Gabrielli
SYSTEMS
24 Casagrande
14 Marini Quarries Group
TOOLS
40 Adriatech
12 Epiroc
by Ettore Zanatta
37 SIP&T
INNOVATION
Flood defense in the USA
6 The Lyon-Turin line
16 Sandvik
46 Brigade Elettronica
ZoneSafe: the new RFID Tag Detection System
by Pietro Gabrielli
COMPONENTS
Underground productivity
by Stefano Vitali and Giovanni De Mattia
47 Tsurumi
20 Herrenknecht
Mighty breakthrough for Europe’s biggest boring machine
by Pietro Gabrielli
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Print MDM - Forlì
Editor in chief Ettore Zanatta - ettore.zanatta@capoversoeditrice.it
Frequency Extra Issue
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Contributors: Mirko Brusamolino, Giovanni De Mattia, Pietro Gabrielli, Stefano Vitali Administration Roberta Fabbri - r.fabbri@capoversoeditrice.it tel. 0545 967722 Subscriptions tel. 0545 967722 e-mail: info@capoversoeditrice.it Subscriptions price Italia: euro 48,00 Other countries: euro 60,00
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C apoverso editrice
Deep down into acidity
by Mirko Brusamolino
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NEWS LIEBHERR
On the Way from Paris to Prague by Mirko Brusamolino The new drilling rig LB 45 from Liebherr is the successor of the proven LB 36 model. For the rebuilding of the Neckartal Bridge at Heilbronn the company Hochtief Infrastructure GmbH installed successfully the foundation piles. It crosses through southern Germany stretching between the French and the Czech borders. As part of the European Route 50 it is an important link between Paris and Prague: the A6 motorway. The upgrading of the motorway includes the rebuilding of the Neckartal Bridge at Heilbronn between the junctions Untereisesheim and Neckarsulm. Hochtief Infrastructure GmbH installed the foundation piles using the new drilling rig type LB 45 from Liebherr. The name of the new machine comes from its nominal torque of 450 kNm. That is an increase of approximately 10 % in comparison to the already high performance of the LB 36 with 410 kNm.
Challenge Foundation piles were also required on the “Neckar Island” which lies about 100 m from the riverbank. The drilling rig was transported there by pontoon. Following transportation Hochtief built a pontoon bridge from the pontoon
elements so that site traffic could cross. However, the drilling rig was too heavy for the pontoon bridge. After completion of this construction phase, the bridge had to be rebuilt back to a pontoon so that the LB 45 could return across the Neckar. The simple handling of the machine proved to be a huge advantage both when operating it and when facing such logistic challenges. Implementation During the 6-month piling work, Hochtief installed 106 foundation piles using the Kelly drilling method with auger and rock drilling bucket. The company handled 170 t of steel reinforcements and 2,000 m³ of concrete in the process. On average, the piles are 11.5 m deep and have a diameter of 1.5 m. Depending on the density of the rock and the drilling depth, Hochtief required about 2 hours for each pile. Including concreting, 2.5 piles could be installed per day. Hochtief is particularly impressed with the handling and the power of the LB 45. The bridge is expected to be open for traffic mid 2022.
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ONSITEUNDERGROUND - october 2020
COVER STORY The Lyon-Turin line The Lyon-Turin line is a freight and passenger new railway line that covers 270 km, 70% of which in France and 30% in Italy by Ettore Zanatta (Sorce: TELT)
The central link of the Mediterranean Corridor
I
t is the central link of the Mediterranean Corridor, one of the 9 axes of the European TEN-T transport network, which extends for 3,000 km, connecting 7 EU corridors from East to West. The line is divided into three sections: the common cross-border stretch between Italy and France, from Susa (Piedmont) to SaintJean-de-Maurienne (Savoy), under the responsibility of the Italian-French public promoter TELT, whose main project is the Moncenisio base tunnel measuring 57.5 km, currently under construction;
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ONSITEUNDERGROUND - october 2020
the Italian part, from Turin to Bussoleno (Susa Valley), under the responsibility of RFI; the French part, from Saint-Jean-deMaurienne to Lyon, under the responsibility of the SNCF. The realisation of the Lyon-Turin line is established by four international agreements between Italy and France (1996, 2001, 2012 and 2015, supplemented by the Additional Protocol of 2016). Between the end of 2016 and the beginning of 2017, the Italian and French parliaments ratified the agreement, allowing the final works to start. With this step, the decision-
making procedure for the work, in Italy and France, was completed. Where the works are located The European Union project foresees 9 TEN-T (Trans-European Transport Network) networks to encourage the movement of people and goods via an environmentally friendly mode of transport: rail. Among these networks, there is the Mediterranean Corridor, from Budapest (Hungary) to Algeciras (southern Spain), which includes the Lyon-Turin line.
The route of new Lyon-Turin line
The Lyon-Turin project: guarantees a connection, south of the Alps, between Western and centraleastern Europe; aims to promote economic exchanges and strengthen the competitiveness of Mediterranean European countries; is a freight and passenger railway network, which also intersects with the most important sea and river ports, major cities and airports. The longterm strategic objective is to create the “European Metro Line”, discouraging the use of road transport, in favour of lower greenhouse gas emissions. Based on this objective, 7 tunnels have been foreseen in Europe to facilitate the crossing of the Alps: Moncenisio (57.5 km), Gotthard
(57 km), Brenner (56 km), Koralm (32 km), Semmering (27 km), Ceneri (15.4), Lötschberg (34.6 km). The cross-border section The cross-border section of the LyonTurin line is the stretch between Susa (in Italy) and Saint-Jean-de-Maurienne (in France); it is 65 km long, 89% of which in tunnels. Most of the systems above ground are located in already populated areas. The public promoter TELT, a binational company, has been entrusted with the mandate by the Italian and French governments for its realization and subsequent management. According to the works schedule the project will become operational in 2030.
THE LEGAL ASPECTS OF LYON-TURIN RAILWAY LINE The new Lyon-Turin railway line
so for contracts worth € 1).
tional White List, a sort of register
represents the first case in Europe
The companies that have everything
of entities who can work on the con-
of application of the anti-mafia
in order are included in a transna-
struction sites.
legislation at a transnational level regardless of the nationality of the construction sites. In 2018, the Prefect of the Auvergne-Rhône Alpes Region and the Prefect of Turin signed the agreement that makes the binational structure operational for anti-mafia checks on Italian and French tenders. The two Prefects work in parallel, sharing information, with the support of the respective police forces that carry out joint checks and inspections in the construction site areas. The checks are carried out not only on the contractors, but also on the entire subcontracting chain (aloctober 2020 - ONSITEUNDERGROUND
7
COVER STORY to the logistics platform in Orbassano; works for adapting the Turin hub. A Débat Public (Public Inquiry) took place in France before the works were approved, coordinated by an independent commission, regarding the feasibility of the realization of the works and the project itself. The route has been planned for all major works and involves all the stakeholders (proponents, committees, citizens, experts and all those who wish to participate). In the case of the Lyon-Turin line, the route gained a favourable opinion. The fundamental element of the new line is the tunnel at the base of Moncenisio, the longest railway tunnel in the world. It is a twin-tube single-track tunnel, of 57.5 km of length (of which 45 km in France and 12.5 km in Italy) connecting the international stations of Saint-Jean-deMaurienne and Susa, where it connects to the existing line. 150 years after the inauguration of the Fréjus railway tunnel (at an altitude of 1300 m), where the current historical line passes, this project a turning point to comply with current transport standards.
The works are organised into 81 calls for tender distributed over 12 operational construction sites: 9 for works on the alpine crossing, subdivided by geographical area (4 in Italy and 5 in France) between the interconnections with the old line in Italy and in France; 2 for the reuse of excavated materials in Italy and France; 1 for the technological plant systems and safety
The current route of the cross-border section is the result of a participatory planning. In Italy, it was managed by the Lyon-Turin Observatory, established by the Italian government in 2006 after the violent protests in Venaus against the first track of this work. After 205 work sessions and 300 auditions of technicians and experts, and 10 route alternatives, a definitive project route was established in 2013 and approved in 2015. Moreover, the work was planned to be carried out in phases; the first phase, the so called “low cost” project, involves the construction of the base tunnel; the upgrading of the historical line capacity between Bussoleno and Avigliana the construction of the mixed freight/passenger tunnel from Avigliana 8
ONSITEUNDERGROUND - october 2020
The Base tunnel The new tunnel transforms the current mountain line into a plain railway, making the rail transport more competitive. Trains that travel on level ground allow energy savings and achieve higher speeds. In the Italian-
COSTS AND FUNDING The cross-border section cost amounts to 8.6 billion EUR, certified by the international Tractebel Engineering – Tuc Rail group. TELT has undertaken to respect the budget, and put in place an internal monitoring system. Within the scope of the CEF-Connecting Europe Facility (EU financial instrument for European networks), in 2015 Italy and France signed the Grant Agreement, which provides for a European contribution of 41.08%, equal to 813.8 million EUR. To date, around € 2.5 billion have been allocated to this work, of which € 1.2 billion have already been spent on studies and designs (50% funded by the European Union, 25% by Italy, and 25% by France). Currently there are contracts for around 1.3 billion EUR.
The current construction of this project involves almost 800 people: around 530 work in the construction sites and 250 for services and engineering companies
French section, the historic line does not currently comply with international transport standards: it climbs the mountain with a slope of up to 30‰, so the trains need up to 3 locomotives, with a 40% higher energy cost. The diameter of the old Fréjus tunnel, inaugurated in 1871, is smaller than that required by current international standards and it has a single-tube which does not meet current safety standards. Progress report Progress in numbers: over 18.5% of the 164 km of tunnels planned for the work have already been excavated, a complex system consisting of two parallel tunnels, 4 declines and 204 safety by-passes; the first 9 km of the base tunnel (where the trains will travel) have been completed in the Saint-Martin-La-Porte/La Praz construction site; the construction site of
the temporary Saint-Jean-de-Maurienne station is currently operational, since the existing railway lines will be connected to the new base tunnel; at the beginning of 2019, work began on the cut-and-cover tunnel, an artificial tunnel that will be the entrance to the base tunnel; 68 km of exploratory surveys and core borings have been carried out in Italy and France; in France, the declines required to start the construction sites inside the mountain have been completed: Villarodin-Bourget/ Modane (4,000 m, completed in 2007), La Praz (2,480 m, completed in 2009) and Saint-Martin-la-Porte (1,800 m completed in 2016 and 2,400 m completed in 2010); in Italy, the Chiomonte exploratory tunnel (Val di Susa, 7,020 m) has been completed. Alongside the excavations, preliminary open-air works are also in progress, in French and Italian territory. In order to proceed on the cross-border
section, the new works on the base tunnel will begin from the access points already completed. The 4 declines provide access tunnels for the construction equipment and, during full capacity operations, there will be 15 excavation faces and 7 TBM moving forward simultaneously to complete the tunnel through which the trains will travel. On the Italian side, on 21 March 2018, the Interministerial Committee for Economic Planning (CIPE) approved the Modification project for the construction sites, which involves the realization of the main activities of the work starting from Chiomonte, and not from Susa. Work in progress Since the summer of 2016 until September 2019, the “Federica” TBM has been at work excavating the first 9 km of the tunnel through which the trains will travel. The French 2,400-ton TBM, with the power of eight Formula 1 engines, is progressing at an average pace of 15-20 meters a day. Located in an old sawmill, a segment factory is connected october 2020 - ONSITEUNDERGROUND
9
COVER STORY to the construction site. Segments are concrete rings used to line the tunnel. The construction site in Savoy has witnessed two previous operation phases (2003-2010 and 2015 and 2016) for the construction of two declines, respectively 2,400 m and 1,800 m in length. Pursuant to an agreement with TELT, in January 2019 SNFC Réseau started preparatory works for the construction of a temporary station in Saint-Jean-deMaurienne, in view of the connection of the existing railway lines to the base tunnel. To support travellers and maintain the bus and train stations operational during the works, a transitory multimodal exchange hub was realized and will remain in service until the end of 2021. The structure will then become the new international station. At the beginning of 2019, then, work began on the cut-and-cover tunnel,
THE PUBLIC PROMOTER Tunnel Euralpin Lyon Turin is the Public Promoter in charge of the construction and management of the Lyon-Turin cross-border section. A company established under French law on 23 February 2015 according to international agreements that define the realization of the line itself. The above were signed by the two founding partners: the French government and Ferrovie dello Stato italiane (Italian State Railways). TELT succeeds Lyon Turin Ferroviaire (LTF SAS), former Public Promoter involving SNCF (France) and RFI (Italy), and, since 2001, has been in charge of the studies, investigations and preliminary works for the shared Italian-French part. The corporate set-up is structured as follows: 50% Ferrovie dello Stato SpA (FS) for Italy and 50% French State.
an artificial tunnel that will be the entrance to the base tunnel. It is a cement “box” above ground, located under the raised platforms of the A43 motorway and the RD1006 highway.
ITALIAN ABSTRACT
IL NUOVO “CORRIDOIO MEDITERRANEO” La Torino-Lione è una nuova linea ferroviaria per merci e passeggeri che si estende per 270 km, di cui il 70% in Francia e il 30% in Italia. È l’anello centrale del Corridoio Mediterraneo, uno dei nove assi della rete di trasporto europea TEN-T, che si sviluppa per 3.000 km connettendo, da Est a Ovest, sette corridoi Ue. La linea è suddivisa in tre sezioni: tratta transfrontaliera comune tra Italia e Francia, da Susa (Piemonte) a Saint-Jean-de-Maurienne (Savoia), di competenza del promotore pubblico italo-francese TELT, la cui opera principale è il tunnel di base del Moncenisio di 57,5 km, in corso di realizzazione; parte italiana, dal nodo di Torino a Bussoleno (Val di Susa), di competenza RFI; parte francese, da Saint Jean de Maurienne a Lione, di competenza SNCF. L’Unione europea ha impostato nove reti TEN-T per favorire la circolazione di persone e merci su un mezzo ecologico: il treno. Tra queste reti c’è il Corridoio Mediterraneo, da Budapest (Ungheria) ad Algeciras (sud della Spagna), che include la Torino-Lione. Il progetto Torino-Lione garantisce un collegamento, a sud delle Alpi, tra l’Europa Occidentale e quella centro-orientale; inoltre, mira a favorire gli scambi economici e rafforzare la competitività dei Paesi dell’Europa mediterranea ed è impostato su una rete ferroviaria merci/passeggeri, che incroci anche i maggiori porti marittimi e fluviali, le grandi città e gli aeroporti. L’obiettivo strategico di lungo periodo è realizzare la “metropolitana d’Europa”, incoraggiando il trasporto ferroviario, a favore di minori emissioni di gas serra. Con quest’obiettivo, sono previsti in Europa sette tunnel di base che facilitano l’attraversamento alpino: Moncenisio (57,5 km), Gottardo (57 km), Brennero (56 km), Koralm (32 km), Semmering (27 km), Ceneri (15,4), Loetschberg (34,6 km). La realizzazione della Torino-Lione è sancita da quattro trattati internazionali Italia-Francia (1996, 2001, 2012 e 2015, integrato dal Protocollo addizionale del 2016). Tra fine 2016 e inizio 2017, i Parlamenti italiano e francese hanno ratificato l’accordo che dà il via ai lavori definitivi. Con questo passaggio, l’iter decisionale dell’opera, in Italia e Francia, si è concluso.
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About Chiomonte area, it is the largest Italian construction site of the LyonTurin project; since 2012, it has been a site of national strategic interest, and is the access point to the base tunnel works in Italy. According to the variation to the final project approved by the CIPE in 2018, in fact, the main construction site was located here to ensure minimum ground consumption, less inconvenience to citizens, as well as higher safety levels. An expansion of the construction site and the construction of a motorway junction on the A32, built by SITAF, were foreseen to perform the base tunnel works. In 2017, the exploratory activity aimed at gathering information on the structure of the mountain was completed, respecting the timing and environmental parameters. Site maintenance work is currently in progress along with support to the police forces. In December 2019, the contract for the construction of the interchange niches in Chiomonte was awarded. The 40 million Euro contract includes the realization of 23 niches (3 m deep and 30 to 40 m long) in the existing tunnel to facilitate the passage of construction site vehicles. The Maddalena tunnel, created for survey purposes, will be transformed into a service passage and a ventilation shaft for the base tunnel. The reasons for realizing the project When the Lyon-Turin line will be operational, over 1 million lorries used for international road transport will no longer be present on alpine roads,
thus reducing CO2 emissions by 3 million tons per year. The reduction of polluting emissions in the Alpine region is one of the primary objectives set by COP21, the Climate Conference held in Paris in 2015, during which the need to transfer 30% of freight to railway transport by 2030 and 50% of it by 2050 was reiterated. It is necessary to make the railways competitive for the transport of freights and passengers, and to increase connectivity between Italy and the European railway networks. The existing historical line, climbing over 1,300 meters and with a tunnel dating back to 1871, does not meet the international transport standards and involves an energy cost which is 40% higher than the one of a line without any slope. Moreover, the Mediterranean Corridor, to which the Lyon-Turin section belongs, concerns 18% of the European population in regions representing 17% of the EU GDP. To support the economic development
of these territories, an efficient and green infrastructure is essential. In general, cross-border projects are those that give the greatest benefit to the European economy, with a multiplier 3 times higher than the average of the 9 TEN- T corridors. France and Italy are the second and third economies of the European Union and respectively the second commercial partner of one another. The economic exchange
involves over 44 million tons of goods per year, mainly transported by road (92% travels on lorries), and represents a total of € 81 billion (Source: ISTAT 2017), almost twice the trade of France with China. About advantages for passengers: more trains, less travel time and more connections; about for freight transport: greater interchange, greater capacity, ecology and savings. ■
The Lyon-Turin project was conceived with environmental objectives and refers to several initiatives launched by the European Union over the years
october 2020 - ONSITEUNDERGROUND
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INNOVATION Epiroc
Standing the test
Epiroc and mining company Agnico Eagle have conducted tests on battery-powered machines in the Kittilä mine in Finland. Things are looking good for the future of diesel-free mining by Ettore Zanatta
T
he tests in Kittilä play an important role in the testing of batterypowered equipment in an operational mining facility, contributing to a safer working environment with sustained efficiency. They are a part of the Sustainable Intelligent Mining Systems (SIMS) project, in which Epiroc is serving as coordinator. This, in turn, is part of Horizon 2020, the European Union’s most extensive research and innovation program ever. An Epiroc Boomer E2 Battery drill rig arrived on site in April 2019, and in September it was joined by a MT42 Battery mine truck and a Scooptram ST14 Battery loader. Jan Gustafsson – responsible for delivery of batterypowered mining equipment for the SIMS project (work package leader), as well as overall project manager for the SIMS project – is happy about the opportunity. “The tests have focused on 12 ONSITEUNDERGROUND - october 2020
productivity, operational performance and energy consumption, as customers demand that battery electric vehicles works as well as diesel-fueled”.
Scooptram ST14 Battery
Minetruck MT42 Battery working in Agnico Eagle’s underground Kittilä gold mine in Finland
Minetruck MT42 Battery on its way, silently, to dump a full load
Boomer E2 Battery
More details Tests have measured KPIs related to productivity, operational performance and energy consumption compared to diesel-fueled machinery. They have measured and compared ventilation costs, air quality, tramming distance, ramp haulage and battery changing time compared to diesel fueling. The Kittilä mine was chosen because Agnico Eagle, also a SIMS partner, wants to try out battery electric vehicles. The transformation towards battery-powered equipment is driven by three major factors. One is legislation on reduced diesel emissions as well as NOx gases. Another, equally important, driver is the will of mining companies to be a part of the solution to global environmental issues, not a contributor. In addition, mines are getting deeper and deeper, with increased heat leading to higher ventilation and transportation costs. Thus, there is a big incentive in the industry to shift to battery- powered solutions. Another participant in the test project is battery provider Northvolt, and they have supported the Epiroc team during the field tests. Jan Gustafsson: “From the tests, we have learned that the equipment works as well as expected and we have gained a lot of experience. Dual-battery
charging equipment has worked well, too, and existing electrical installations can support the in-stalled charging stations, as they work with regular charging”. Initial feedback from operators who have participated in the testing is very positive; no one misses the old diesel machinery. In parallel, Epiroc has been conducting tests in Örebro
in order to collect data for KPIs and improve equipment. “So far the tests look promising. We have gained valuable experience during the field trial and we are looking forward to evaluating the final results”, says Gustafsson. “This has really been a team effort in SIMS, where we have worked closely together with product development”. ■
ITALIAN ABSTRACT
PROVA SUPERATA Epiroc e la società mineraria Agnico Eagle hanno condotto alcuni test su una flotta macchine alimentate a batteria nella miniera di Kittilä in Finlandia (la miniera d’oro più grande d’Europa) e i risultati promettono bene per il futuro di un’industria mineraria “diesel-free”. I test in corso a Kittilä rivestono un ruolo importante nel processo di collaudo di macchine alimentate a batteria in una struttura mineraria operativa, contribuendo a un ambiente di lavoro più sicuro, con un’efficienza sostenuta. I test sono svolti nell’ambito del progetto SIMS (Sustainable Intelligent Mining Systems), in cui Epiroc riveste il ruolo di coordinatore. Il progetto SIMS fa parte di Orizzonte 2020, il programma di ricerca e innovazione più esteso mai realizzato dall’Unione Europea. Nell’aprile 2019 il carro di perforazione Epiroc Boomer E2 Battery è arrivato in cantiere e, nel settembre dello stesso anno, è stato affiancato dal dumber da miniera MT42 Battery e dalla pala caricatrice Scootram ST14 battery. I test hanno misurato indici relativi alla produttività, alle prestazioni operative e al consumo di energia rispetto ai macchinari alimentati a diesel. Sono stati misurati e confrontati i costi di ventilazione, la qualità dell’aria, i tempi di traslazione, la presenza di rampe e i tempi di cambio batteria/rifornimento carburante. La miniera di Kittilä è stata scelta come teatro per questi test perché la Agnico Eagle, anch’essa partner del progetto SIMS, desidera testare mezzi alimentati a batteria.
october 2020 - ONSITEUNDERGROUND 13
INNOVATION MARINI QUARRIES GROUP
A new remote controlled mobile drilling unit by Mirko Brusamolino Marini Quarries Group is a worldwide leader in the production of machinery and equipment for drilling and diamond wire cut in marble and granite quarries as well as in civil engineering applications. The know-how acquired in 40 years of professional growth and the wide assistance network make Marini Quarries Group an ideal partner to supply either single machines or the whole quarry plant in any part of the world. Flexible and reliable Marini Quarries Group operates in a modern industrial plant in Valdossola, near the motorway network and close to the Swiss border. Its ideal geographical position has without a doubt contributed to the success of the company, enabling it to test the effectiveness and reliability of its products in the nearby marble, ‘serizzo’ and granite quarries in the Ossola valley in cooperation with the local expert quarry workers. Founded in 1975 by Marini Giuliano, and today owned by Zaninetti Valter and Ferraro Massimo, the Marini Quarries Group company
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is considered an historical partner in the drilling and cutting sector in the field of quarries and Civil Engineering. With 25 different models of machines for the quarry sector and more than 30 subdivided into 5 production lines for civil engineering, we are able to offer our customers many different and effective solutions for the cultivation
of quarries and for specialized ground engineering works. The new drilling unit MR - C 20 is the name of the new remote controlled mobile drilling unit suited to execute vertical, horizontal or inclined holes. This machine is equipped with selfmoving wagon unit with variable width rubber tracks and with a 30/44 HP diesel (Lombardini/ Yanmar) or electric motor hydraulic power pack (22 kW / 30 HP) and is completely removable and easilly transportable by helicopter. The new MR - C 20 can be equipped with a hydraulic rotary head mod. ID 500, a hydraulic rock-drill mod. MA 100 ID or a coring head mod. ID CD SPECIAL (26 daNm of max. torque; max. speed 600 rpm). Like all Marini units, the MR – C 20 can be customized in relation to the different needs. The weight of this machine is 2.700-3.100 kg.
EXPERIENCE
VERONA 3/7 MARZO 2021
TUNNELLING Sandvik
Underground productivity Thanks to the recent launch of the Sandvik DT1132i jumbo, the Swedish manufacturer of machines and equipment for mining has further raised the quality of tunnel drilling by Stefano Vitali and Giovanni De Mattia*
T
he DT1132i jumbo by Sandvik Mining and Rock Technology is one of the latest innovations in underground drilling. It is a highly productive drilling unit suitable for several applications which expands the wide range of drilling rigs of the Swedish manufacturer. Together with the Sandvik RD535 high frequency rock drill and rock tools specifically designed for high speed drilling the DT1132i provides a Heavy Duty tunneling solution.
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Modular design All Sandvik DTi tunneling jumbos have been developed with a special modular design that makes them highly flexible and versatile. Suitable for fast face drilling or mechanized long-hole drilling and bolting, they are proving be highly productive, reliable and effective across the world, using the latest developments in automated drilling solutions such as the iSURE tunnel management software and SICA intelligent control system.The DT1132i, is a three-boom,
electro-hydraulic jumbo that has been purpose-designed for fast and accurate drilling in tunneling and cavern excavation. The on-board computer controls and automates the entire drilling cycle, while allowing full manual drilling when needed.As well as incorporating some of Sandvik’s latest developments in digital solutions, the new rig uses Sandvik’s new high frequency RD535 rock drill, robust booms and advanced drill string guides, making it a complete and new high-speed drilling solution.
Drilling innovations The RD535 rock drill, automated drilling features and new rock tools mean that that the DT1132i delivers the results required, but with 40% less exhaust particles, up to 20% higher penetration rate and with 25% more side coverage. The essential premise behind the development of the new DT1132i is to provide users with increased drilling performance and accuracy, thanks to its fast and adaptive drilling control capabilities, able to account for changing rock conditions. The rig design also maximizing operator safety and ergo-
nomics, with improved fleet standardization (high parts commonality) enabling extended rig usage across different work sites.Amongst the many new features on the new rig is a new 3m telescopic TB160i boom, optimized with a front wrist structure that provides 1 m additional side coverage as standard, and 4 m side coverage with telescopic adjustment. The new boom also uses a new fully proportional boom control for accurate and fast manual boom handling, with intelligent compensation models to give accuracy in all operating conditions.
PRECISION AND SPEED IN DRILLING
The Alpha 360 drilling system is Sandvik latest innovation in the drilling tool area. This system is designed to optimize 48 and 51mm holes.Thanks to a greater quantity of steel on the thread and a shorter and more robust design, Alpha 360 provides optimal drilling precision, a better hole header and an almost double life span compared to standard thread rods. These features ensure straight and parallel holes that significantly increase productivity in tunnels and mines. Thanks to a 10% increase in penetration speed, the new Speedy bit Sandvik is the fastest tip on the market. Drilling faster means reducing all costs related to drilling activity of the machines (operator cost, machine maintenance, etc.).The Sandvik Alpha 360 + Speedy bit systems, therefore, really are a winning combination.
The DT1132i features robust booms and advanced drilling slides which make it a complete and innovative high speed drilling solution
The DT1132i jumbo is an electro-hydraulic three booms machine designed for fast and precise drilling in tunneling and cavern excavation october 2020 - ONSITEUNDERGROUND 17
TUNNELLING
The DTi jumbo series - launched in 2018 in Finland - is the result of 50 years of experience, research and development in drilling of Sandvik Mining and Construction
New cabin for safety and comfort An ergonomic vibration-dampened cabin has been designed for the new DT1132i which provides the operator with excellent all-round visibility, low noise level inside the cab thanks to its acoustic windows, a filtration system to minimize dust inside the cab (according to standard EU6/7) and an open and spacious operator environment. Doorways have been located in the rear of the cab to minimize any disturbance for the operator, whilst safety has been maximized with a FOPS-compliant cabin.To further improve the efficiency of the rig and the operator, comprehensive diagnostics information is integrated into one display in the cabin of the DT1132i. These include drilling diagnostics for boom instrumentation, drill-
COMMANDO DC300RI Another recent “new entry” in the Sandvik product range is the Commando DC300Ri drilling rig, equipped with an external hammer. This model is characterized by its versatility, being able to adapt to the most diverse applications. Completely radio-controlled and equipped with a wheeled carriage, this machine is able to drill holes with a diameter from 38 to 64 mm, is ready for R28, R32 and T35 MF rods. Thanks to the four-wheel drive, the oscillating carriage (± 10 °) and the 43 kNoverall tramming force the DC300Ri guarantees high mobility and stability even on difficult terrain. The particular construction of the new reinforced boom, hydraulic roll-over, which allows the feed to rotate 360 degreesand the HL300 rock drill make it a highly performing solution, which however keeps operating costs low even during demanding operations. A flushing air capacity of 3m3/min allows deeper hole depth with larger hole sizes. The drilling rig is also equipped with the iTorque drilling control system. The wide boom reach, thehydraulic roll-over, the compressor on board, the retainer mounted on the drilling slide to add drilling rods, as well as the possibility of using selfdrillingrods, make the Commando DC300Ri an ideal solution for all construction sites that require rapid and extremely urgent works.
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Automated drilling
The DT1132i is available with some of the latest developments in automation, including a SICA control system for intelligent torque control/feed percussion, with monitoring and fleet The drill rig design maximizes operator safety and ergonomics
ing control system and shank lubrication together with carrier diagnostics for electric motors, pumps (hydraulics and water), transmission system, diesel engines, brake system, jacks and cable reels. The rig also features durable covers to protect components and incorporates a new cover design, in which all sides are covered and all service points are easy to access. Power and efficiency The new RD535 is a high performance and high frequency rock drill. This new rock drill maximizes power transfer capabilities leading to a high drilling speed without compromising hole quality, has an efficient and powerful patented percussion mechanism, as well as a tool-saving, efficient and patented stabilizer structure for increased reliability. These features, together with improved flushing and efficient cooling, provide uninterrupted high-speed drilling.
The DT1132i features a highly powerful transmission system with a Cummins B6.7, 168kW diesel engine (stage 5) which can be operated up to 5,000 m above sea level without any modifications. The new engine provides up to a 90% reduction in NOx emissions (compared to stage 3 engines), with more than 90% mass reduction for DPM. The rig utilizes a new carrier which uses more efficient hydraulic and water systems. These include separate circuits for both drilling and tramming hydraulics. Drilling precision has been improved by using proportional flushing valves to adjust the flushing flow and inlet/outlet pressure monitoring.The rig steers by hydraulic rear wheel steering and its electric current reducer unit provides electric reactive power element (kVar) from an onboard capacitor, reducing electric current draw by up to 20%. The 3 x 90kW IE3 electric motors require 2.5% less energy, with all
ITALIAN ABSTRACT
PRODUTTIVITÀ IN SOTTERRANEO Con il recente lancio del jumbo Sandvik DT1132i lo specialista svedese in macchine e attrezzature per l’industria estrattiva ha elevato ulteriormente il livello di qualità nella realizzazione delle perforazioni di gallerie. Tra le più recenti innovazioni nel settore dello scavo in sotterraneo c’è certamente il jumbo DT1132i prodotto da Sandvik Mining and Rock Technology. Si tratta di una unità di perforazione altamente produttiva, con ampia copertura di applicazioni, che amplia la già vasta gamma di perforatrici del costruttore svedese. Unitamente al martello ad alta frequenza Sandvik RD535 e agli utensili da roccia progettati specificatamente per la perforazione ad alta velocità, il DT1132i offre agli utilizzatori una soluzione Heavy Duty per il tunnelling.
management for My Sandvik. To further improve the excavation process, remote access via WLAN can be chosen which allows web-based data transfer as well as online MWD.As ‘Gold’ standard, the DT1132i comes with torque based semi-automated drilling, manual boom control and rod handling, all enabling drilling to a predefined depth with feed angle measurement and drill bit location measurement. Drill plan visualization and rig navigation are also included. In addition to these standard features, the rig is also available as part of the ‘Platinum’ package with automatic long hole drilling and fully automatic face drilling.
working lights based on LED technology, automatically controlled based on tramming direction and with directional lights available where needed. A new TF535i feed also provides increased feed force for high power drilling, whilst a saving hose reel structure gives longer service life for the hoses which are of an increased size. A hose support structure enables the independent tightening of every single hose, thereby reducing any pressure drop. An integrated accurate linear sensor ensures accurate rock drill positioning, providing a more accurate hole depth measurement. A new slide piece design enables 50% less wear and friction. *Stefano Vitali, OnSite editorialstaff Giovanni De Mattia, Product Line Manager Underground Rock Excavaton, Sandvik ■ october 2020 - ONSITEUNDERGROUND 19
TUNNELLING Herrenknecht
Mighty breakthrough for Europe’s biggest boring machine In Italy, the largest tunnel boring machine ever used in Europe successfully completed its drive in June. The supersize borer made in Schwanau dug 7.5 kilometers of highway tunnel through the Apennines by Pietro Gabrielli
I
n Italy, the largest tunnel boring machine ever used in Europe successfully completed its drive in June. The supersize borer (Earth Pressure Balance Shield, diameter 15.87 meters) made by Herrenknecht in Schwanau, Baden/Southern Germany, dug 7.5 kilometers of highway tunnel through the Apennines. In cooperation with the customer, Herrenknecht designed a new system for the machine, to protect particularly the site crew from the expected methane gas deposits in the ground. Tunnelling mission On June 8, 2020, the largest tunnel boring machine (TBM) built and used in Europe crowned its tunnelling mission with a mighty breakthrough. With this project milestone, the machine from the Schwanau TBM manufacturing plant with an XL diameter of 15.87 meters completed
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On June 8, 2020, the Herrenknecht EPB Shield for the Santa Lucia Tunnel successfully completed its tunnelling mission. The largest tunnel borer in Europe measures 15.87 meters in diameter and bored a large road tunnel for the expansion of the Italian Autostrade A1
7.5 kilometers of particularly complex tunnelling through the Italian Apennines. Following the specifications of customer Pavimental S.p.A., Herrenknecht designed and manufactured an EPB machine (Earth Pressure Balance Shield). Working closely with the contractor, the Herrenknecht engineers tailored the tunnel boring machine to the specific requirements of the project. Among other things, they implemented a comprehensive warning and protection system to reliably protect the site crew against potential dangers from the methane gas deposits predicted underground during the advance. This foresight paid off. The large three-lane “Santa Lucia” tunnel newly excavated by the Herrenknecht EPB Shield is a key project in the expansion of the A1 highway between Bologna and Florence. Thanks to optimized routing on the previously winding highway, the efficient tunnel
ITALIAN ABSTRACT
COMPLETATA LA GALLERIA ‘SANTA LUCIA’ In Italia esisteva già il tunnel ferroviario ‘Santa Lucia’, ferroviario a doppio binario, della lunghezza di 10,265 m, costruito per svincolare il traffico ferroviario a lunga percorrenza dalla difficile tratta di valico tra Salerno e Nocera Inferiore della ferrovia Napoli-Salerno. Era stato aperto nel 1977. Qui invece ci si riferisce alla At the acceptance in 2016, Dr.-Ing. E.h. Martin Herrenknecht presented the XL borer to the contractor and representatives of the client
will reduce the likelihood of accidents as well as travel times and thus the gasoline and diesel consumption of tens of thousands of cars and trucks a day. Following just 12 months of design and assembly, in August 2016 the EPB Shield was punctually ready at Herrenknecht in Schwanau for formal acceptance by the contractor and representatives of the client, Autostrade per l’Italia S.p.A. After the start of tunnelling, in July 2017, the Pavimental miners drove up to 122 meters of tunnel per week through the Apennine mountain range with the 4,800 tonne colossus. During
Galleria ‘Santa Lucia’, che unisce con un tunnel di 8 km i comuni di Calenzano e Barberino del Mugello. Per farlo è stata impiegata una fresa di ultima generazione Herrenknecht, la più grande in Europa, realizzata in Germania e mai usata prima in Italia. Il tunnel “Santa Lucia” entrerà in funzione da metà 2021. Il tunnel a tre corsie è il più lungo mai costruito in Europa e uno dei cinque più grandi al mondo per dimensione complessiva (lunghezza e numero di carreggiate operative).
the long drive over 7.5 kilometers, the EPB machine with its large diameter of 15.87 meters excavated a total of around 1.5 million cubic meters of soil and rock. This corresponds to almost two thirds of the volume of the Cheops pyramid. A pioneer partner Italian contractors and infrastructure projects are known and respected worldwide for very large tunnel
boring profiles and complex tunnel geologies. Herrenknecht is a reliable pioneer partner to them with matching expertise and innovative ability. With the production of the Santa Lucia machine, Herrenknecht beat the existing European record for TBM diameters of 15.55 meters. It had been held since 2010 by the Herrenknecht EPB Shield for the Sparvo tunnel, also for the expansion of the A1 motorway in Italy. ■
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october 2020 - ONSITEUNDERGROUND 21
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TUNNELLING Robbins
“Main Beam” carves out a win in Louisville The 6.5 km (4 mi) long Ohio River tunnel for wastewater storage below Louisville, Kentucky, USA, presented challenging geology for a Robbins TBM and its crew by Pietro Gabrielli completely rebuilt electrical and hydraulic systems. “This was definitely an older machine. I actually operated it on the DART (Dallas Area Rapid Transit) tunnels in Dallas, Texas in the 1990s, but with many of the components being new we were confident in it”, said Oginski.
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6.5 km (4 mi) long tunnel for wastewater storage below Louisville, Kentucky, USA has more to it than meets the eye. “At first glance, this seems like a straightforward project, but it turned out to be much more challenging”, said Shemek Oginski, Project Manager for the contractor, a jointventure of Shea/Traylor. The 6.7 m (22 ft) diameter Robbins Main Beam TBM and conveyor system had to cope with overstress in the crown that resulted in significant rock fallout in seven different areas, as well as methane gas in the tunnel. By the machine’s breakthrough on September
22, 2020, the crew had much to celebrate. The machine was refurbished and consisted of older components as well as a brand new cutterhead supplied by Robbins and
On September 22, 2020 a Robbins Main Beam TBM broke through at the Ohio River Tunnel in Louisville, Kentucky, USA. The 6.7 m (22 ft) diameter Main Beam TBM was refurbished and consisted of brand new components as well as a cutterhead supplied by Robbins
Now and then The original tunnel was expected to be 4 km (2.5 mi) long, but a change order added to the length by 2.1 km (1.3 mi). The extension was ordered by the owner, Louisville Metropolitan Sewer District (MSD), and its Engineer-of-Record Black & Veatch in order to eliminate four surface CSO storage basins. That included one basin originally
ITALIAN ABSTRACT
UN TUNNEL SOTTO L’OHIO Il tunnel lungo 6,5 km sotto il fiume Ohio, progettato per lo stoccaggio delle acque reflue sotto Louisville (Kentucky, USA) ha rappresentato un progetto particolarmente impegnativo a causa del particolare contesto geologico che Robbins e il suo staff tecnico hanno dovuto affrontare con la loro TBM. L’appaltatore (Shea / Traylor JV) ha dovuto superare diverse prove operative a causa del continuo rischio di caduta di roccia e di fughe di gas metano all’interno del tunnel. Infine, la TBM ha raggiunto il suo obiettivo il 22 settembre 2020. La TBM Main Beam da 6,7 m di diametro è stata rinnovata per l’occasione e dotata di una nuova testa fresante fornita da Robbins, nonché di sistemi elettrici e idraulici completamente riadattati. Nonostante le difficoltà la TBM ha raggiunto i 658 m in un mese e 192 m in una settimana.
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located at the site of the TBM breakthrough, explains Oginski: “The original CSO site was located in close proximity to Beargrass Creek and had flooded multiple times. It was decided to extend the tunnel to that site in order to use the tunnel as storage instead, and connect it to the sewer system”. MSD installed a sheeting wall to protect the site from floodwaters while Shea-Traylor installed liner plate in the retrieval shaft, resulting in a site that is in much better shape. It was in the 2.1 km (1.3 mi) extension, essentially a bifurcation of the main tunnel, where the crew encountered much of the crown overstress. “The longest section of overstress was 700 m (2,300 ft) and took two and a half months to get through,” said Oginski. The crew switched up the prescribed rock bolt pattern of four to six bolts at 1.5 m (5.0 ft) centers, and instead installed six bolts at 1 m (3 ft) c enters. “It worked out to two rows per push. When that wasn’t enough, we installed wire mesh in the crown, mine straps, and channels. It definitely took extra time to install steel support, remove loose rock, and deal with the rock coming down so we could install rock support safely”. Overbreak varied from a few inches above the machine to 30 cm (1 ft) or more. “We also had encountered natural methane gas in the tunnel just shortly before holing through”, said Oginski. The methane was discovered while the crew were probing out 150 ft ahead of the machine – something that the crew did continuously throughout the bore, using one, two or four probe holes depending on
the geology. “We were down for about two weeks and were able to contain the methane within the cutterhead, where concentration spiked at 100% LEL. We were able to resume work after systematically ventilating, probing and grouting multiple times”. Despite the challenges, the TBM was able to achieve up to 658 m (2,159 ft) in one month and 192 m (630 ft) in one week. The Robbins
conveyor, including a 68.6 m (225 ft) long vertical belt, made this progress achievable, said Oginski: “The conveyor is definitely the way to go, especially for longer drives. There was quite a difference in performance between the extension tunnel, which we mined with liftboxes, and mining with the conveyor. Our best month in the extension tunnel with the boxes was 221 m (725 ft), so
that is a big difference”. With tunneling now complete, Oginski is “definitely proud that we got to the end, as this is a challenging project”. The contractor is removing the components of the TBM to be stored in their yard in Mt. Pleasant, PA, and sees future applications for the equipment. “If the right project comes up then yes, it’s likely we would use this machine again”. ■
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DRILLING CASAGRANDE
Two B200XP-2 in an Italian biogas plant by Mirko Brusamolino Two Casagrande drilling rigs model B200XP-2 are used for the construction of foundation piles for the expansion of a biogas plant in Vipiteno (BZ), Italy. The morphology of the soil, consisting of layers of clay, compacted gravel and the presence of boulders, has allowed the use of the “soil displacement” technique or lateral compaction pile with some constructive precautions. In fact, compared to classic “soil displacement” tools, the diameter of the tool drag rod is similar to the diameter of the tip to avoid subsidence of the soil during the descent phase. The project involves the construction of about 900 reinforced poles divided into three lots with a diameter of 550 mm and an average depth of 17.5 m. Casagrande model B200XP-2 equipment are multifunctional machines set up for the construction
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site in CFA / Displacement Piles mode capable of reaching a drilling depth of 25.5 m using a 6 m extension. The torque required for the rotation of the tool is guaranteed by the hydraulic rotary H22 which generates a torque of 210 kNm and 34 rpm of rotation speed. Power is
provided by a 242 kW diesel engine compliant with Stage V, which is the latest legislation in terms of emission of pollutants. The tool advancement system offers a thrust of 280 kN and an extraction force of 825 kN by combining the use of the main winch and the pull-down winch mounted on the mast. A feature that makes the Casagrande B200XP-2 drilling rig unique in its class is the transport width kept within the limit of 2500 mm. The Casagrande XP-2 command and control system offers the possibility of remotely monitoring work functions, system diagnostics and customizing the work parameters via the internet. The Casagrande FleetMaster platform and the new CDR system - Casagrande Data Recording - are the ideal tool for monitoring and recording work parameters.
DRILLING Trevi
The “FOUR Frankfurt” project Trevi faced and won the challenge of carrying out all the foundation works in a rather complex context by Ettore Zanatta
“F
OUR Frankfurt” is a unique high-rise building in the heart of Frankfurt city center. Thanks to its purchase in 2015, “Groß und Partner Grundstücksentwicklungsgesellschaft” laid the foundations for the execution of this mega-project. This building development includes 4 new high-rise buildings on a multi-level and multifunctional construction foundation. Thanks to its 228 m high office tower, the building is the highest office space in Germany and, with its slightly shorter 173 m high tower, it also ranks as the highest residential tower in the whole Germany. Parts of the existing buildings will be kept to comply with historical preservation requirements; they will be inte-
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grated into the new construction. Due to the simultaneous execution of the works in all areas and the relevant logistical needs, which add to the enormous pressure set by the compliance with the time limit, one of the main challenges of the construction process concerns its position in the city center.
Due to the strength of the limestone banks, a hydromill is also used in this project, in order to minimize the impact generated by vibrations on the neighbouring structures. Large diameter bored piles ranging from 1500 mm to 2000 mm are used as foundation elements
Under the “cover” The four towers of the Frankfurt “FOUR Project” are supported by a base slab and its perimetral walls. Due to space restrictions, the client decided to build the basements using the “top down construction method”. This means that, at first, the diaphragm wall and the foundation piles are constructed and then the concrete slab is poured to form the first basement floor. Subsequently, excavation
works take place under that “cover” and the other basements floors are all built in the same way, while the construction of the building can already start simultaneously. Since the distance between the opposite walls of the perimeter would span over 100 m, prefabricated columns are positioned into the piles to support the slabs. The structural loads of the above-ground structures and of the slabs are thus directly supported by the construction piles through the columns. The foundation and excavation protection enclosure is carried out using the diaphragm wall method. In this case, two different methods are used. Generally, the excavation of the panels is carried out using a clamshell. However, due to the strength of the limestone banks, a hydromill is also used, in order to minimize the impact generated by vibrations on the neighbouring structures. Large diameter bored piles ranging from 1500 mm to 2000 mm are used as foundation elements. In the upper part, a temporary casing is used. Then, in the lower part, uncased drilling is carried out using stabilizing bentonite mud, to reach a total drilling length of up to 50 m. After reaching the design depth, the reinforcement cage is installed, then, the concrete is poured into the shaft. Since the working level is significantly higher than the foundation one, the reinforcement cage is placed up to 20 m below the working level. Due to the selected topdown construction method, it is neces-
The “FOUR Frankfurt” project render
sary to position the plunged columns in the piles. Since these prefabricated columns are not just temporary supports, but are also used as permanent columns in the basement floors, their installation requires meticulous precision. “FOUR Frankfurt” render Therefore, a maximum vertical tolerance of 2 cm and a maximum horizontal tolerance of 5 cm are allowed. For this reason, an innovative system is adopted for this project. After reaching the design depth of the pile, the reinforcement
cage is installed, and subsequently a collar and a sleeve are positioned around and into the casing. Said sleeve serves to guide the precast column and support its assembly. In the next step, the position of the sleeve is suitably adjusted by using the adjusting screws on the collar in compliance with the given tolerance requirements. After the adjustment of the sleeve, the pile is backfilled with concrete using a tremie pipe, and then the prefabricated column is installed, guided by the sleeve, inserting it for 3 m into the fresh concrete of the pile. ■
ITALIAN ABSTRACT
IL PROGETTO “FOUR FRANKFURT” “FOUR Frankfurt” è un esclusivo complesso edilizio nel cuore del centro storico di Francoforte. Grazie al suo acquisto nel 2015, la società “Groß und Partner Grundstücksentwicklungsgesellschaft” ha gettato le basi per l’esecuzione di questo mega-progetto, il cui sviluppo comprende quattro nuovi edifici ubicati su una fondazione multilivello e multifunzionale. In particolare, essi poggiano su una platea perimetrata. A causa del limitato spazio disponibile, il cliente ha deciso di costruire i piani interrati usando il metodo di costruzione “top down”. Ciò significa che, inizialmente, si costruiscono le pareti del diaframma e i pali di fondazione, quindi si getta il solaio di copertura sul primo livello seminterrato. Successivamente si procede a scavare sotto la “copertura” e in tal modo si realizzano in successione tutti gli altri piani mentre, nel frattempo, si può già iniziare con la costruzione dell’edificio. Si tratta di un altro progetto in cui si è distinta Trevi e, in particolare, una perforatrice idraulica SR-125.
october 2020 - ONSITEUNDERGROUND 27
DRILLING Soilmec
The Soilmec flagship A Soilmec SR-145 HIT drilling rig was used in the foundation works forthe improvement project of the cruise ship dock in the Savona harbor, which hosted on 21 Decemberthe maiden voyage of the Costa Smeralda, the new flagship of Costa Crociere “Excellence” class by Ettore Zanatta
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avona is one of the major Italian harbors both for cruise sector and merchant marine traffic. Since 1996, when the collaboration with Costa Crociere began, the cruise sector traffic of the Savona harbor increased, requiring over the years
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several investments relating to port infrastructures for cruise traffic. The main goal was to adapt the cruise terminals to the needsof the cruise market, which is oriented towards more and more larger ships. In 2019 the Port System Authority of the Western Ligurian Sea started the
works in the Savona cruise terminal to meet the needs of new generation ships and be able to host the “Costa Smeralda, a 180,000 tons megaship powered by LNG liquefied natural gas. The project included works to deepen from 9 to 11 meters the seabed in front of the main quay of the cruise terminal
in areas 8-9-10 of the Savona basin and the reinforcement of the structure. The 17 million euroscontract was entrusted to RCM Costruzioni and Fincosit. The foundation works included the construction of a frame made of reinforced casings and sheet piles which was used to enlarge the existing quay. The foundation piles of the project, drilled up to a depth of 32 m from the seabed, have a diameter from 1,100 mm and 1,700 mm. The geological composition of the subsoil included a first layer of fill material followed by alternated layers of medium-fine sands and gravels in a sandy and silty matrix up to a depth of about 20 from the ground level and a stone substrate consisting of fractured schists. The piles were drilled using the bored pile technology with telescopic kelly rod and bucket type excavation tool. Furthermore, having to work at sea, the drilling takes place inside casing previously anchored to the seabed using a crane equipped with a vibrator. The machine used for drilling operations was a Soilmec SR-145 HIT, the Soilmec flagship designed to achieve maximum performance for high depth bored piles. Boasting an operating weight of about 145 tons, the SR-145 HIT is able to support 24.5 m kelly rods for a maximum depth of over 120 m extendable to 138 m with a special kit. The fixed double-jack mechanism ensures a more rigid and stable mast – frame connection, providing an optimal solution for rock drilling. The rotary table has been designed with a particularly compact and light case with advantages in terms of weight and dimensions for an increased pull force under the rotary and features the Soilmec automatic torque control system, which calibrates the torque according to excavation conditions and ground resistance in order to maximize the excavation speed and therefore transfer all the available power to the tool. The CAT C18 diesel engine delivers up to 470 kW to maximize excavation performance even in the case of simultane-
Port of Savona, December, 21, 2019: departure of the first cruise of the Costa Smeralda
Soilmec SR-145 HIT drilling rig, the Soilmec flagship designed to achieve maximum performance for high depth bored piles october 2020 - ONSITEUNDERGROUND 29
DRILLING
The foundation piles of the project, drilled up to a depth of 32 m from the seabed, have a diameter from 1,100 mm and 1,700 mm
ous power requests; the Soilmec “low idle” system automatically adjusts the rpm to the minimum speed when the main circuits are not in use, providing significant advantages in terms of power efficiency and operating costs and therefore reducing pollution.
The engine is mounted in line with the longitudinal axis of the machine to improve accessibility during maintenance and is protected by fiberglass canopies featuring sound-absorbing and damping materials that make the SR-145 HITthe quietest drilling rig in its mar-
ket segment at 109 dBA LwA and suitable for works in metropolitan and residential areas. Soilmec uncompromising comfort and safety characteristics are fully met by the SR-145 HIT: full protected walkways on both sides of the machine, radio control allowing the operator to load/unload the machine on the transport trolley, 5-cameras system complete with a dedicated 7 multiscreen LCD screen, for permanent 360° view of the construction site are just some of the features installed on the machine. The cabin provides the highest comfort level featuring sliding door, air conditioning, adjustable automotive seat and touch-screen DMS monitor (providing full control over machine performance and on-site production), more ergonomic controls and joysticks. The works were carried out with no hassle and within the set times also thanks to the performance of the Soilmec equipment. On November 14, 2019 the new quay was officially inaugurated with the ribbon cutting ceremony. ■
ITALIAN ABSTRACT
L’AMMIRAGLIA DI SOILMEC Una perforatrice Soilmec SR-145 HIT è stata impiegata per i lavori di fondazione del progetto di adeguamento dell’accosto crocieristico nel bacino portuale di Savona che il 21 dicembre ha ospitato la partenza della crociera inaugurale della Costa Smeralda, la nuova ammiraglia di classe “Excellence” di Costa Crociere. L’appalto, con un importo base di 17 milioni di euro, è stato affidato all’ATI composto da RCM Costruzioni srl e Fincosit srl. I lavori di fondazione prevedevano la costruzione di una paratia costituita da casing armati alternati a delle palancole che è stata utilizzata per ampliare la banchina esistente. I pali di fondazioni del progetto erano di diametro variabile tra 1100 mm e 1700 mm, trivellati sino ad una profondità di 32 m dal fondo marino. La composizione geologica del sottosuolo, dopo un primo strato materiale di riporto, vede un alternanza di strati di sabbie medio-fini e ghiaie in matrice sabbiosa e limosa fino ad una profondità di circa 20 da piano campagna (p.c.), seguito da un substrato roccioso, costituito da scisti fratturati. Per l’esecuzione dei pali è stato scelto di utilizzare la tecnologia del palo trivellato con asta kelly telescopica e utensile di scavo di tipo bucket. Inoltre dovendo lavorare in mare la perforazione avviene all’interno di casing precedentemente infissi sul fondale utilizzando una gru equipaggiata con vibratore. La macchina utilizzata per la perforazione è stata una Soilmec SR-145 HIT, la “grande ammiraglia” di casa Soilmec sviluppata nell’ottica di ottenere le massime prestazioni per pali trivellati ad altissime profondità.
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The Soilmec SR-145 HIT is able to support 24.5 m kelly rods for a maximum depth of over 120 m extendable to 138 m with a special kit
DRILLING Vermeer
Key projects in Cortina d’Ampezzo
Vermeer Technologies reach Cortina to support the city in some of its key projects: “Smart Road”, underground installation of electrical and phone lines, optic fiber laying for broad and ultrabroadband connections by Pietro Gabrielli
I
t is easy to talk about smart solutions that are useful to improve everyday life, but what does this really mean? How can we fully understand the importance of a strong underground network able to improve our lifestyle? One of the ways could be to explain this through significant examples of companies and municipalities that bring on the desire to improve services and connections for citizens. This is happening in Cortina D’Ampezzo, the exclusive location known worldwide for its beauty. This location, queen of the Dolomites, is famous worldwide for its astonishing surroundings: there are about 120 km of ski tracks for winter holidays and more than 400 km of paths where tourists can enjoy breath-taking strolls in nature. For these reasons the city keeps a close eye on social, economical and technological development of the underground connections. We must underline that Cortina has been chosen, together with Milan, to host the 2021 Alpine World Ski Championship and the 2026 Olympic games. This is both an honor and a commitment and, in order
32 ONSITEUNDERGROUND - october 2020
to be ready for these two big events, Cortina is managing many structural projects studied to combine beauty and technology. Cortina has already hosted the Olympic games in 1956 and indeed it has learned a lot. But 70 years later, structures needs be refurbished and increased in order to host such important matches.
In Cortina, Vermeer is using two main systems to support the city in some of its key projects: rockwheel trenchers and horizontal directional drilling technology
What happened? So, what is happening in and around Cortina? Vermeer Technologies reach Cortina to support the city in some of its key projects: “Smart Road”, underground installation of electrical and phone lines, optic fiber laying for broad and ultrabroadband connections. Vermeer equipment is working both in Cortina and in the surrounding valleys on the main road connections. Here, highly-specialized operators are using two main systems: rockwheel trenchers and horizontal directional drilling technology. The choice between these two systems depends on general and environmental circumstances and also on the kind of soil you have to work in, but, overall, the advantages of both techniques are clear: there is no need for traditional surface excavation and therefore there are no limitations for the circulation of road vehicles, a very important aspect, especially at the mountain (traditional excavation system would cause serious limitations of traffic); jobsite equipment is highly reduced (there is no need for handling high quantities of excavated material and the
jobsite are is reduced); environmental impact is notably reduced; restoration costs are lowered; it is possible to install networks in city centers and on surfaces with high architectural value without damages; thanks to HDD it is possible to install underground networks in complex contexts, too: road and railroad crossings, hydric reservoirs, slopes. In Cortina projects, where Horizontal Directional Drilling technology has been considered suitable for cables laying, the adoption of this system clearly enhances these advantages. Jobsites are still going on the roads that are going to take us to a future where Cortina and Italy will keep
ITALIAN ABSTRACT
ALTA TECNOLOGIA A CORTINA D’AMPEZZO VermeerTechnologies si sta distinguendo a Cortina d’Ampezzo, dove sta supportando la cittadina nelle Dolomiti in alcuni dei suoi progetti chiave: “Smart Road”, installazione sotterranea di linee elettriche e telefoniche, posa di fibra ottica per connessioni a banda larga e ultra larga. Le attrezzature Vermeer sono attive sia a Cortina che nelle valli circostanti, lungo i principali collegamenti stradali. Qui, operatori altamente specializzati utilizzano due soluzioni principali: la perforatrice orizzontale D80x100 e il trencher RTX1250.
to shine, thanks to the help of technicians and specialized operators that are working as a team. The aim is one: to put all the Italian beauties in a frame of advanced technological
infrastructures. Vermeer has been supporting these projects for more than 25 years with a dedicated team and a network of specialized sales and service assistance. ■
STANDARD AND SPECIAL EQUIPMENT FOR EARTHMOVING MACHINE MINI AND HEAVY DUTY BUCKETS FOR EXCAVATORS, SPECIAL ARM AND QUICK COUPLING
SPECIAL CUSTOM SPARE PARTS
Made in Italy
october 2020 - ONSITEUNDERGROUND TRIMECCANICA S.R.L. - Via Cosmo Mollica Alagona, sn 95121 – Catania (IT) www.trimeccanica.it - info@trimeccanica.it / Tel. +39 095292399 - Fax +39 095292454
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DRILLING Bauer
Flood defense in the USA Flood protection is a concern of high priority in the USA. For this reason, Bauer Foundation Corp. involved in important projects in Florida, East St. Louis, Colorado by Ettore Zanatta
34 ONSITEUNDERGROUND - october 2020
F
lood protection is a concern of high priority in the USA. The U.S Army Corps of Engineers (USACE), a federal agency of the Department of Defense is responsible for the maintenance of dams and canals as well as flood defense.
Bauer is constructing a 350 feet long cut-off wall to seal the Teller Dam
Currently USACE is implementing several measures in a number of US states, and Bauer Foundation Corp., the American subsidiary of Bauer Spezialtiefbau GmbH based in Odessa, Florida, is involved in a total of five major projects with a total contract value of approx. 200 million US dollars (184 million euros). Four of the construction projects – Herbert Hoover Dike Task Order 1, Task Order 3, Task Order 5 and the East St. Louis Cut-off Wall Project – are being executed by Bauer Foundation as a direct contractor of USACE. Bauer is involved as a subcontractor in the Teller Dam Project in Colorado.
rehabilitation of the approx. 140 miles long dike around Lake Okeechobee. In 2007, Bauer Foundation Corp. was initially tasked with the execution of cutter-soil mixing walls (CSM) along the southeastern part of the dike. Based on previous successful cooperation, Bauer was awarded further partial contracts for the years between 2011 and 2021, among them works on various culverts. The current work phase includes the execution of a cut-off wall over a total length of 28 miles along the southwestern section of the dike. Divided into five sections, also referred to as task orders, Bauer Foundation managed to win three of the five contracts: Task Order 1, Task Order 3 and Task Order 5. For the first two sections, a total of approx. 3,325,000
square feet of cut-off wall will be created to a maximum depth of approx. 66 feet. Predrilling is required to remove organic deposits and loosen the occasional dense layers of sand and underlying weak limestone. Subsequently, the actual soil mixing will begin with an RTG RG 27 drilling rig, using the CSM method which combines the features of a trench cutter while mixing the soils in-situ. In addition, the jet grouting method is used to connect the newly constructed cut-off wall with the existing culverts. “Bauer, as the main contractor, was also tasked with the installation and subsequent removal of the necessary work platforms and is responsible for the access roads to the site. Following the works on the cut-off wall, we are
THE NEW MEMBER OF THE BAUER GROUP
MÜHLHÄUSER-OBERMANN GMBH HAS BECOME OBERMANN MAT GMBH The former Mühlhäuser-Obermann GmbH based in Michelstadt has been part of the Bauer Group since November 1, 2019. In the future, the company will be operating under the new name Obermann MAT GmbH. The company which was founded in 1974 in Odenwald has nearly 50 years of experience in specialist foundation engineering. The Obermann portfolio includes injection pumps, mixers and jet grouting pumps. “This makes it an ideal addition to our range of products”, explained Timo Seidenfuss, head of sales of Bauer MAT Slurry Handling Systems. “This enables us to serve the existing market even better and also open up new markets”. Obermann products will now exclusively be sold via Bauer MAT Slurry Handling Systems.
Remediation of the Herbert Hoover Dike Covering a total area of 730 square miles, Lake Okeechobee is the largest freshwater lake in the U.S. state of Florida. Even though it extends over a length of about 35 miles and a width of about 30 miles, the lake is very shallow with an average depth of only 10 feet and lacks a larger natural outflow. To protect against storm surges and flooding due to unusually high water levels, the existing dike already received its first upgrade in the 1920s. In the 1960s, additional canals, floodgates, and dams were added. Since the early 2000s, the U.S Army Corps of Engineers has been responsible for coordinating the october 2020 - ONSITEUNDERGROUND 35
DRILLING cutoff wall. In total, with the three construction phases, Bauer Foundation was commissioned with the execution of 17.7 miles out of the total of 28.6 miles of the south-western part of the Herbert Hoover Dike.
Construction of a cut-off wall at the Herbert Hoover Dike: Bauer was able to win three of the five task orders awarded to date. In order to restore the existing dike on the east bank of the Mississippi, Bauer Foundation uses a grab and a cutter in combination to create a single-phase cut-off wall
also responsible for the revegetation and asphalting of the finished dike and the quality control tests and installation of monitoring instruments”, explains Andrew Ebendick, Project Manager with Bauer Foundation Corp and in charge of Task Order 1. “The work on the first two projects has already begun. Successful completion of the work on Task Order 3 is expected in the spring
of 2022 and Task Order 1 in the fall of 2022”, according to David Millar, Project Manager for Task Order 3. At the beginning of May 2020, Bauer Foundation was awarded Task Order 5 with a total value of approx. 42 million US dollars. This is the last construction phase comprising a total length of almost 4.1 miles and the construction of approx. 750,000 square feet of
ITALIAN ABSTRACT
PROTEZIONE DALLE INONDAZIONI La protezione dalle inondazioni è una delle preoccupazioni prioritarie negli Stati Uniti. L’US Army Corps of Engineers (USACE) è un’agenzia federale del Dipartimento della Difesa ed è responsabile della manutenzione di dighe e canali, nonché proprio della difesa dalle inondazioni. Attualmente, a tal proposito, l’USACE sta implementando diverse misure di sicurezza in diversi Stati degli Stati Uniti e Bauer Foundation Corp., la filiale americana di Bauer Spezialtiefbau GmbH con sede a Odessa, in Florida, è coinvolta in un totale di cinque grandi progetti con un valore contrattuale totale di circa 200 milioni di dollari USA (184 milioni di euro). Quattro dei progetti di costruzione - Herbert Hoover Dike Task Order 1, Task Order 3, Task Order 5 e East St. Louis Cut-off Wall Project - vengono eseguiti dalla Fondazione Bauer in qualità appaltatore diretto dell’USACE. Bauer è coinvolto come subappaltatore nel progettoTeller Dam in Colorado. Nel frattempo, dal primo novembre 2019 l’ex società Mühlhäuser-Obermann Gmbh – con quasi 50 anni di esperienza nello sviluppo e nella produzione di gruppi d’iniezione, pompe ad alta pressione, iniettori e sistemi di misurazione - è entrata a far parte del gruppo Bauer, svolgendo le proprie attività sotto il nome di Obermann MAT GmbH.
36 ONSITEUNDERGROUND - october 2020
Cut-off wall project in East St. Louis In East St. Louis, in the U.S. state of Illinois, another existing levee system on the east bank of the Mississippi is receiving an upgrade. The existing levee structure is built on sandy ground that extends to the limestone bedrock at a depth of approx. 135 feet. These sandy soils allow the water to undermine the levee contributing to erosion of the system, and neighboring developments are under threat from frequent and severe flooding. To create a cut-off wall which will restore the existing dike, Bauer Foundation uses a grab and a cutter in combination to create a single-phase cut-off wall with a selfhardening slurry. “For this work, we use a DHG diaphragm walling grab and a BC 40 cutter, each attached to an MC 96 duty-cycle crane”, explains Matteo Bertoni, Project Manager at Bauer Foundation Corp. A total of approx. 570,000 square feet of cut-off wall will be created over a length of 4,600 feet and to a maximum depth of approx. 143 feet. Bauer, as the main contractor, was also commissioned with the provision of the necessary work platform, the installation and dismantling of the guide wall for the cut-off wall works, and with the final quality and lab testing. The location of the project poses a particular challenge: several important utilities cross the work front on the existing dike on the banks of the Mississippi River. As a result, Bauer can only carry out the works within certain timeframes and at specific locations, all of which requires close cooperation with all participants. Mobilization of the construction site went underway in March and completion of the overall project is scheduled for January 2022. ■
TOOLS SIP&T
Customer satisfaction by design Customer satisfaction represents the primary purpose of the Italian company, that is becoming more and more customer oriented with efforts aimed at developing a continuous, stable and lasting relationship with customers, through the fulfilling of their needs, desires and expectations by Ettore Zanatta
T
he starting point is the creation of value for customers, i.e. the satisfaction of their needs and requirements in an effective and efficient way. The market in which SIP&T operates is very turbulent and competitive. For this reason, part of the company strategy is based on an increasingly service-oriented business model in which the customer is placed in the center. The company is adopting a more customer-centric and innovative approach, placing a greater attention also to services in order to provide customers the products that best suit their specific needs. The company orientation is to align the design, development and distribution of products and services with the current and future needs of customers including safety, in order to establish a relationship of trust that remains solid over time and maximizes company performance over the long term. The principles that guide
SIP&T start from product design to the way of collecting and use information; from the language used with customers, from the attitude towards them and the efforts made to fully understand their needs and habits, up to the definition of performance indicators that emphasize Customer Satisfaction and are oriented to the customer’s life cycle. Product development is structured as a response to customer needs. The kelly bars, for example, are designed starting from the compatibility with the piling rigs made by the major players in the sector and according to their maximum torques but at the same time they have a series of customizable functional and technical features ranging from the number of elements and therefore the maximum overall dimensions, to the upper and lower shock-absorbing system, to the soundproofing solution, to the geometry of the locks to transmit the torque and thrust, to the terminal attachment for connection with the excavation tool.
The single and double wall casings are supplied with connection joints having the same dimensions as those of the end user, in order to allow the continuity of the column. SIP & T offers two product categories, distinguished by the use of different steel types with different values of yield strength and break point, according to the required diameter and the constraints of the drilling machine and the ground conditions. Furthermore, in the casings segment, thanks to its focus on safety, SIP&T has designed and patented the fully mechanical casing drive adapter which is having enormous success in the market. Rotary tools represent the most customized product range because the only fixed points are the diameter and the connection to the Kelly bar. Here SIP&T shows all of its thirty years of experience which translates into a myriad of technical solutions, difficult to spot even in the eyes of an expert observer. Structurally, the tool is october 2020 - ONSITEUNDERGROUND 37
TOOLS
Automatic Casing Drive Adaptor OD 880/800 mm
designed to respond to all mechanical stresses. The target is always to ensure the customer maximum penetration and the highest productivity. The type of tool, the inclination of the equipment based on the resistance of the ground, the wear protections to increase the useful life of the product, the resistance of the material in case of drilling in the aquifers are just a few examples of the vocation to client that SIP & T shares with its competitors. But the added value is much more and consists in a much wider support to the customer to whom a documented solution is submitted with delivery time, technical drawings, customizations, materials used, estimate of the penetration rate, torque values i n relation to compressive rock strength, recommended spare parts, operation and maintenance manuals, benchmarks, all illustrated in a commercial offer that may include the possibility of testing, renting or selling. All the things described till now apply to all other product lines such as CFA (Continuous Flight Augers) manufactured with hexagonal, octagonal and toothed connections and concrete passage as per customer specifications, soil mixing tips and smooth extensions, FDP tools (Full Displacement Pile) which have a profile chosen not by chance and never standard but always in relation to the rig and the stratigraphy of the soil in which 38 ONSITEUNDERGROUND - october 2020
they will drill. The range is completed by tremie pipes with threaded or wire cable joints of several diameters, hydraulic and mechanical clamps to support the casings during the extraction operations, stop ends manufactured with different profiles. The user requirements Good user requirements are one of the key factors leading to successful design. User requirements capture the stakeholders’ needs, wishes and
expectations for a product and are the basis for the development of technical specifications, the statements on which a project will be verified. Engineering specifications are used as a collection of criteria that the project must meet in order to satisfy the user requirements that have been solicited by interested parties. SIP&T places a strong focus on this topic and articulates many activities such as the methodical collection of information on the market, close communication with customers using their language, an always ethical attitude, a measurement of certain performance indices such as customer satisfaction and related corrective actions, investments in time, energy and money to fully understand customer needs, practices and habits. The habit of helping drilling companies is a well-known feature of SIP&T, as well-known is its propensity to visit the customer for analyzing the characteristics, criticalities and constraints of the project combined with the rigs to be used so as to have a scenario clear and get the best performance. Requests and results achieved on site are systematically shared with the technical office which prioritizes user requirements and translates them into engineering specifications. The new concept of equipment developed by the designers is initially tested, with
Interlock Kelly bar 4 sections, 26 meters long, 96 m depth
Progressive Rock Auger OD 2800 mm
subsequent modifications, and then moves on the production, marketing and market introduction phase. The enormous advantage is to have a clear responsibility between the parties, limited risk management, better coordination & planning combined with adequate compliance and more fluid communication. All of these issues, allows the SIP & T team to handle the various companies needs with best practices, i.e. a set of activities, procedures, behaviors, habits organized in a systematic way and taken as a reference and which, when reproduced, favor the achievement of the best results desired by the customer. On the wear parts front, SIP & T has always been very attentive to the most specific supplies but always in accordance with the wishes of the customer who very often prefers one brand over another. SIP & T has linked its name to Betek becoming its official distributor for the Italian market. Betek is a very high-end German brand that offers a complete range of teeth, casing accessories, wear parts such as the Tungstuds regularly applied on SIP & T tools. However, on specific indication of the customer, it is also possible to use other brands but always high-end. From tests on the jobsite, we have verified the excellent combination of SIP & T-Betek made up of continuous exchange of information and product development aimed at increasing the penetration rate. This means that the performance level is equal if not higher than the top players and is 90% higher than players who use low quality wear parts. It is easy to understand that using SIP & T products on which Betek equipment is assembled is reasonably more expensive but with a very high level of pay back that it is far more convenient.
Soil mixing Tip OD 3000 mm
Must have: auto CDA The Automatic Casing Drive Adaptor made and patented by the SIP&T represents an interesting locking system for casings that can be used on all piling rigs and can increase the safety and productivity in the execution of cased piles, by avoiding any damages and time loosing caused by the manual locking phase. The system is directly controllable from the rig cabin and all the manual operations carried out so far by the site personnel can become a distant memory, with undisputed advantages both for the safety and for the casing arrangements and the piling rig itself. The connection system represents an innovation in the cased piling construction. It is widely used in job sites all over the world, its feedback is extremely positive and we can state that nowadays it is recognized as a must-have tool. The application can make a significant contribution to improving safety in special deep foundations and, above all, in drilled piles. This particular locking system
Double Wall Casings OD 1300mm
increases productivity as the various elements of the casing column can be assembled and disassembled faster than mechanic standard operations. Furthermore, in presence of very long casings sections, the automatic driver is the main faster solution (the connection of long elements is not possible with the use of a simple ladder, a wheel loader or a harness). Lastly, the cost savings are evident, the personnel that can be used elsewhere on the site. The remote and management control is a great example of technical innovation that increases safety and productivity in special foundations. Manufacturing high quality tools that allow operators to have high safety standards and excellent production performance is the core business of the Italian company. SIP&T offers a very wide range of solutions characterized by specific applications on job site and is recognized as one of the world leaders in the industry. This is how the “best product” is born, from a day-byday direct comparison with end users. ■
ITALIAN ABSTRACT
OBIETTIVO: SODDISFAZIONE DEL CLIENTE Il principale successo del produttore campano sono gli investimenti in ricerca e sviluppo, la personalizzazione delle attrezzature, la loro affidabilità e la continua espansione sui mercati mondiali. Oggi SIP&T è un’eccellenza nel comparto delle attrezzature per perforazioni verticali di grande diametro, con un’ampia gamma di prodotti suddivisa in svariati modelli. La propensione dell’azienda campana è quella di mettere al servizio degli operatori tutta l’esperienza maturata negli anni in diverse aree geografiche, costruendo insieme a loro “best practice” che, organizzate in modo sistematico, possono essere prese a riferimento e riprodotte per facilitare il raggiungimento dei migliori risultati. È in questo contesto che nasce la sfida più importante: progettare e realizzare prodotti personalizzati per ogni tipologia di terreno e per ogni gamma di perforatrici. Questo è il modo per ottenere dai prodotti le migliori prestazioni in termini di velocità di perforazione, resistenza, efficacia e durata, nonché un ideale ritorno sull’investimento.
october 2020 - ONSITEUNDERGROUND 39
TOOLS Adriatech
Reliability, efficiency, innovation in drilling equipment A real drilling specialist, the Abruzzo-based company provides a full range of equipment to meet the needs of those working in this industry by Stefano Vitali
A wide range of TCI amd Tooth Rock Bits of the major brands
A
driatech chose to settle 33 years agoin Pescara, a city in central Italy washed by the Adriatic Sea. Born as a Supply Company for Italian and Mediterranean oil companies, the Abruzzo-based brand has evolved over time to become a real specialist in design, construction and distribution of drilling equipment.
Recognized values Professionalism, know-how, cutting-edge products and equipment, as well as a highly qualified technical-commercial staff, specialized workshops, contracts and exclusive agreements with various historic US companies are the key points of Adriatech activities. The company, in particular, 40 ONSITEUNDERGROUND - october 2020
In the wide range of Adriatech products there are different types of down-the-hole hammers made in USA, as well as DTH Bits and Hole Openers
manufactures and distributes a wide and continuously growing range of equipment for oil companies, for water wells drilling contractors, exploration companies, piling and foundations, HDD, mining, both in Italy, in Europe and worldwide. The current Adriatech product range is definitely wide and varied and includes drilling tools (rock bits, three/ four blades bits, PDC, claw bits, DTH hammers, holeopeners, reamers), drilling unit components (drill pipe, drill collars, stabilizers, subs, Hoisting Plugs-rotating and not-rotating), fishing tools/milling tools, drilling mud control systems (pumps, tanks, mixers, desander/desilter, shale shakers) and handling tools (elevators, slips, tongs, clamps), additives/high pres-
OUR PHILOSOPHY IS QUALITY “About 70% of our products are distributed abroad, in Europe and worldwide. We work in synergy with several drilling rigs manufacturers and what differentiates us from our competitors are our first 20 years’ experience, when we worked in the oil industry. We grew a solid expertise in some Non Rotating Diverter is used to improve drilling conditions for stationary and mobile installations. Suitable for Oil & Gas, Water Wells, Geothermal, Consolidation Works, etc.
sure joints/diverters/float valves, laboratory instruments and measuring and control tools (tripoint calipers, bit gauges). The best sellers Some solutions stand outwithin this wide range and gained Adriatech a strongreputation in the international drilling sector. Since 1987 the company from Pescara is a qualified distributor of rock bits - from the smallest diameter 215/16” up to 36”- of the best US oil brandsas well as the brands Thompson USA, Glinik and Halliburton-Adaero. Adriatech also manufactures hole openers with sealed bearing milled tooth or tungsten carbide insert cutters according to the rock formation to be drilled. Drilling mud circulation is assured through the nozzles located under cutter shoulders. Each hole openeris “custom made”, suitable for drilling in an optimal way depending on the specific work requirement based on customer needs.
ING. SALVATORE PRANO ADRIATECH TECHNICAL MANAGER
equipment and drilling technologies,
which we are however still waiting for,
which we then used in different areas.
including TAV. Being trained as an oil
Our philosophy is quality: if you man-
engineer I like to study the best way
ufacture a hole stabilizer or a drilling
to produce energy and I believe that
bit in the right way, they will obvious-
keep following the path of fossil fuels
ly work better than a ‘cheap’ product.
is a wrong choice. Italy and the whole
This means that you cannot use low
world must switch to more advanced
prices as leverage, therefore suffering
energy production technologies. In
the competition from companies that
my opinion, all road transportation
base their business on this philoso-
should switch to electric (or at least
phy. On some heavy equipment, such
fuel cells) and we need to get back to
as the drilling unit components, some
nuclear power for low-cost, unlimit-
companies offer much lower prices
ed energy. I have great hopes for the
and processing costs than ours and
ITER (International Thermonuclear
therefore they are competitors which
Experimental Reactor) project, which
are hard to beat. Especially in recent
is under development in the south
years we experienced some problems
of France: if we can produce energy
in this regard, also due to a quality
at very low cost and in a non-pollut-
improvement which should be rec-
ing way, thanks to the nuclear fusion
ognized to our competitors. Our gov-
we will start a real revolution. At that
ernment has repeatedly announced
point, we might switch everything to
the launch of various major projects
electric power.”
The flagships Equally important in the Adriatech range are the DTH hammers, the bits and the bit hole openers made in USA: featuring a reversible wear sleeve and spare parts always available, they provide a long life span. DTH hammers
Adriatech boasts a historic partnership with Lamberti, a company specialized in drilling fluids additives and chemicals such as foaming agents, polymers, etc. All these products are always available in the Pescara warehouse
and their accessories, in particular, provide high quality and reliability and are designed to last. Among the equipment distributed by Adriatech we find the elevators for wells, filters and production/pumping tubing. Also worth mentioning are the conical clamps, consisting of a sturdy seat equipped with support brackets and treated steel tongs with lifting handles, used for laying and anchoring welltubings, filters and production tubingsequipped with coupling joints. These solutions are robust and at the same time light, simplify piping operations by eliminating possible slips and avoiding piping conical clamps. Conical clamps are made of a rugged bowl equipped with support hangers and slips in special steel complete with october 2020 - ONSITEUNDERGROUND 41
TOOLS
The wide choice of “casing elevators” proposed by Adriatech ranges from “light weight” (with capacity from 5 to 10 t) to “HeavyDuty” (from 20 to 50 t)
lifting handles. They are used during setting and anchorage of casing pipe, screens and production tubing. Rugged and light-weighted, they are of great help to the tubing operations avoiding possible slipping and ovalization of the
pipes, and reducing waste of time during manoeuvring operations. Innovation and tradition The Non Rotating Mini Diverter is the most recent innovation introduced on
the market by Adriatech: it is a solution used for fixed and mobile systems in order to improve drilling conditions, diverting the exhaust material coming from the well towards tanks placed laterally, thus to ensure cleanliness and easy access to the operation area. Its use is particularly indicated in the Oil & Gas industry, as well as for water wells, geothermal energy, consolidation works and other similar applications. We conclude by highlighting the fact that for over 25 years Adriatech has been the distributor/Stock Point of Lamberti, a manufacturer of special products for drilling (foaming agents, polymers, etc.). This partnership allowed the creation of a historic Stock Point of Lamberti products in Pescara, which are readily available for immediate delivery. ■
ITALIAN ABSTRACT
AFFIDABILITÀ, EFFICIENZA, INNOVAZIONE NELLE ATTREZZATURE DI PERFORAZIONE The Abruzzo based company, on the basis of customer needs, is able to supply Hole Openers, for HDD drilling as well
“Casing clamps” and “slips” are part of the excellence represented by the Adriatech range, also recognized abroad: a share of approximately 70% of its production is in fact exported, directly or indirectly
Quality Rock Bits, of various sizes and types, from size 215/16” thru 36” 42 ONSITEUNDERGROUND - october 2020
Autentica specialista della perforazione, l’azienda abruzzese offre una gamma completa di attrezzature grazie alla quale riesce a soddisfare le molteplici esigenze di chi opera in questo settore. È a Pescara, città dell’Italia centrale bagnata dal Mar Adriatico, che Adriatech ha scelto di insediarsi 33 anni fa. Nata come Supply Company per le società petrolifere italiane e del bacino del Mediterraneo, l’azienda abruzzese si è evoluta nel tempo divenendo un’autentica specialista nella progettazione, realizzazione e distribuzione di attrezzature per la perforazione. Professionalità, know-how, prodotti e attrezzature all’avanguardia, nonché uno staff tecnico-commerciale altamente qualificato, workshop specializzati, contratti e accordi in esclusiva con diverse storiche società statunitensi: sono questi i punti cardine e le attività intorno a cui ruota l’attività di Adriatech. L’azienda, nella fattispecie, produce e distribuisce una vasta gamma di attrezzature in continua crescita e ottimizzazione, sempre al servizio di compagnie petrolifere, contractor di perforazione di pozzi petroliferi e pozzi per la ricerca idrica, società di sondaggi, palificazioni e fondazioni, HDD, miniere. Il tutto, sia in Italia che in Europa e nel mondo. L’attuale gamma produttiva Adriatech è davvero molto ampia e variegata e include: utensili di perforazione (rock bits, trilama/quadrilama, PDC, “claw bits”, martelli fondo foro, “holeopeners”, “reamers”), componenti batteria di perforazione (aste, “drillcollars”, stabilizzatori, riduzioni, teste di sollevamento fisse e girevoli), attrezzi di pescaggio/”millingtools”, attrezzature per il trattamento dei fanghi (pompe, serbatoi, miscelatori, “desander”/“desilter”, shaleshakers) e di manovra (elevatori, cunei, chiavi, clampe), additivi fango/ giunti alta pressione/diverter/”float valves”, strumenti laboratorio fanghi e strumenti di misura e controllo (“tripointcalipers”, “bit gauges”).
SYSTEMS KELLEY ENGINEERED EQUIPMENT
Express route to Atlanta by Mirko Brusamolino On July 1st, 2020, The Atkinson / Technique Joint Venture entered into a contract with Kelley Engineered Equipment (KEE) for the supply of a 90.25” (2.3 m) digger shield. On August 15th, just Six weeks later, the machine was on site and ready to work. Averaging about 5.3’ (1.6 m) per day, the distance needed to install 4 rings of liner plate, the shield finished its drive on October 6th, 2020. The task at hand was tunneling 356’ (109 m) of varying stiff clays, saprolite and mylonite for the City of Atlanta’s Water Supply Project Phase II. This undertaking connects a new 3.4-billion-gallon (12.9 million m³) emergency drinking water reservoir to a new treatment plant. However, the shield’s most important job was to provide the required Cooper E-80 Loading support under 154” (47 m) of the CSX railroad passing intermittently overhead with cover as low as 15’ (4.6 m). In addition to thrust and steering systems, the unit was designed with special features to expedite assembly and disassembly in the heading. After the collapsed shield was
lowered down a 30’ (9.1 m) diameter shaft, it was transported through an existing pre-lined tunnel and assembled at the mining site. The shield was assembled within these liner panels and thrust off smaller ID panels that were erected within the safety of the shield. Fabrication, workshop assembly and factory acceptance testing were performed at KEE’s longtime partner, Wolf Hills Fabricators, LLC in Abingdon, VA. Wolf Hills supplied exceptional quality and were instrumental in achieving the very quick delivery. Atkinson Construction’s Konner Horton was quoted as thanking KEE for “a machine that worked great and getting it done for us so quickly”.
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TECHNOLOGIES DAT instruments
Certificated soil mixing operations All equipment with DAT instruments data loggers can provide documentation about certificated soil mixing operations that prove the correct execution of works by Stefano Vitali for any special foundation work, above all, in this case, for certificated soil mixing operations. In particular, in this field, certificated soil mixing operations were necessary for soil consolidation. In facts, a new warehouse for a very important soft drinks producer is about to be built in this site. DAT instruments data loggers have been installed on an Enteco E300 drilling rig and on two Tecop drilling rigs. The integration of data loggers and drilling rigs carried out soil consolidation in order to execute building foundations of the new warehouse. Using JET 4000 AME / J – MM DAT instruments data loggers for certificated soil mixing operations, the Customer is able to determine different
H
ow can you manage when Building Site Supervisor asks for documentation about your works? It is easy: all equipment with DAT instruments data loggers can provide documentation about certificated soil mixing operations that prove the correct execution of works. This is exactly what happened in Spain. Spanish experience The Building Site Supervisor asked that all works carried out in field (a new warehouse building site) should have a proper documentation in order to check the correct execution
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JET 4000 AME / J – MM DAT instruments data logger. The new DAT TinyLog is a jolly
of the operations. This is why DAT instruments JET 4000 AME / J – MM data loggers have been installed on all Customer’s equipment. This kind of DAT instruments data logger is suitable
parameters. From drilling and injection depth, to pressure and flow, from which it is possible to check if cement output is blocked or not. In addition to that, other parameters are recorded
The integration of data loggers and drilling rigs carried out soil consolidation in order to execute building foundations of the new warehouse
and displayed. Rod translation speed, rod rotation and torque, which lets demonstrate the correct execution of your work. Counting the volume, you can display the total amount of injected litres and the total report of the end of your work, which you can give to your Building Site Supervisor. In addition to that, recording working time is useful for your company to evaluate and improve the productivity of the construction site. Product specifications for this field are: JET 4000 AME / J – MM data logger; JET DEPTH2 depth sensor; sensor for rod torque JET TORQUE; JET ROT sensor for rotation speed; sensor for cement pressure JET PRESS; JET FLOW W24 wireless sensor for the piston pump; USB pendrive data transfer system; Easy DAT software. Other DAT instruments products: The new DAT TinyLog is a champion of versatility. As it is possible to connect any kind of sensor, this new datalogger can be used in any drilling sector such as: drilling, Cement
injection, Geognostic survey, DAC test; jet-grouting; grouting, TAM, GIN; low pressure cement injection, Compensation grouting; deep mixing, Soil mixing, DSM; vibroflotation, Vibrocompaction, Sand Compaction Piles; CFA; diaphragm walls,
Hydromills; water tests, Lugeon test. Data can be downloaded via USB pendrive or uploaded to the Internet: in fact, the DAT TinyLog is equipped with a Ethernet port and Wi-Fi antenna for Internet connection. Moreover, it is also possible to install a 3G-4G modem. During the operating phase data are transferred to every single hole, and they are available in the office in real time. They can be displayed on every kind of device: PC, smart phones or tablets; all files are compatible with Microsoft Excel e OpenOffice Calc. “The new DAT TinyLog - says Amedeo Valoroso, CEO of DAT instruments - is a jolly. It is perfect for the most innovative markets but able to work even in the most common fields. The price of this datalogger is between the top of the range DAT WideLog and the cheaper JET DSP 100, JET SDP and JET 4000 AME”. Born from the top range DAT WideLog, this new instrument, as usual for DAT instruments, is born from the market and from the demands of specific needs of operator. It is a product with high performance and maximum functionality and connectivity together with small dimensions. It is high technology in 35 cm wide, 25 cm height and less than 6 cm thickness. Its monitor is 12”, colour touch screen. ■
ITALIAN ABSTRACT
LAVORAZIONI “SOIL MIXING” CERTIFICATE Come fare quando la direzione lavori richiede la documentazione dei lavori di soil mixing effettuati? Semplice: tutti i macchinari dotati di data logger DAT instruments possono presentare la documentazione delle lavorazioni soil mixing certificate che attestano la corretta esecuzione dei lavori. Questo è quanto accaduto in Spagna, quando la direzione lavori del cliente dell’azienda lombarda ha richiesto che tutte le lavorazioni del cantiere, che prevedeva la costruzione di un nuovo magazzino, fossero accompagnate dalla documentazione appropriata per controllarne la corretta esecuzione. Quindi i datalogger DAT instruments JET 4000 AME / J – MM sono stati in stallati su tutti i macchinari. I datalogger DAT instruments sono stati installati su una perforatrice Enteco E300 e due Tecop. L’integrazione delle perforatrici con i data logger ha reso possibile la realizzazione del consolidamento del terreno propedeutico alla formazione delle fondamenta per il magazzino in oggetto. Grazie a questa tecnologia è possibile visualizzare e registrare diversi parametri, come la velocità di spostamento e rotazione e la coppia dell’asta. La registrazione delle tempistiche di lavoro è utile anche all’azienda, per migliorare la produttività in cantiere.
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TECHNOLOGIES BRIGADE ELETTRONICA
ZoneSafe: the new RFID Tag Detection System by Pietro Gabrielli A new device has joined the wide range of Brigade Elettronica, for over forty years leader in driving safety solutions for commercial vehicles and mobile machinery: this is ZoneSafe, a machineman detection system, with RFID Radio Frequency Identification Technology, able of promptly reporting the presence of people near the machines. ZoneSafe consists of a control unit with an internal memory to store up to 4000 detected events and a WiFi interface for remote monitoring and downloads; one or more (up to six) antennas installed on the vehicle; a Vibratag Driver carried by the driver and other Vibratags worn by pedestrians. Vibratags are robust and hermetically sealed; their high-capacity batteries can be wirelessly charged within two hours and can last up to three months between charges. Each tag has a unique identifier and it is linked to specific individuals.
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An “intelligent” system When a ZoneSafe tag enters a detection zone, the vehicle operator will automatically receive a visual and audible alert via the in-cab control unit which will enable them to take action as necessary. A vibrating tag will also warn a detected worker of an approaching vehicle. A double warning for maximum alert. The detection area of the antenna is programmable, with a variable range from a minimum of 3 meters to a maximum of 10 meters, even through walls and obstacles: the
tags don’t require eye contact and are intercepted regardless of obstacles, blind spots, adverse weather conditions or poor visibility. The ZoneSafe tags, apart from giving a better protection to people working near the machines, are also useful to monitor the access of personnel and to know who is present at any time, for example in yards or handling areas. An additional safety, because, even remotely, it is possible to check that nobody stays in dangerous areas. The system is easy to set up and use, through the specific application and the dashboard, which, via wi-fi, monitors the various tags, as well as generates automatic reports and shares data. ZoneSafe enables fast, reliable and accurate information exchange with no restrictions on the number of tags or antennas. An intelligent system that, in addition to protecting operators “on the ground”, can also be an aid in other areas, such as, in fact, controlling access and, not least, integrating with company automations (activating other alarms, opening shutters or barriers...)
COMPONENTS Connecting Global Competence
TSURUMI
Deep down into acidity Ambitious civil engineering projects and distant raw material deposits: when the job is to go really deep, it is not only sheer pump performance that matters. Often more important is the pH value of the water. This is where the actual selection of the pump model is essential, so that the dewatering does not collapse suddenly. If the value falls well below neutral, there is a risk of serious corrosion damage to the machinery. The pH value provides information as to whether an aqueous solution is acidic or alkaline. A value of about seven is considered neutral (in fresh water without Co2). Many dewatering water pumps can still be operated relatively well in alkaline environments, with high pH values. However, in acidic environments, things become tough. Only a few manufacturers can still supply suitable pumps for pH values down to two. The Japanese supplier Tsurumi, with its European headquarters in Düsseldorf, Germany, goes particularly far in this sector. The range includes not only pumps with all common housing materials. As a special feature they offer a dedicated range of pumps that have been developed explicitly for pumping water in deep mines and chemically acidic environments. Tsurumi is one of a few manufacturers with this range of products. The LH and LH-W series are the nonplus ultra-here, with the LH6110 leading the way: this pump with 110 kW motor power is considered one of the most powerful units in the EU delivery programme. It can pump water up to 177 m vertically upwards and can achieve up to 3.000 l/min. As a submersible motor pump, it is also pressureresistant to an immersion depth of 30 metres. This means that theoretically a single unit is sufficient for dewatering even the deepest pits. If numerous mineral substances are found at the extraction site, for example because pyrite, chalcopyrite and similar sulphides oxidise there, the water quickly takes on an acidic character. For this reason, Tsurumi builds models in the above-mentioned series from austenitic stainless chrome-nickel steel with molybdenum addition and uses the material DIN 1.4401, also known as AISI 316. This gives the manufacturer a higher resistance in the aggressive operating environment compared to other grades. Tsurumi covers different performance configurations in this area. A closer look at the data sheets is worthwhile here: if a conveying depth of about 107 m is sufficient, the sister model LH8110 already achieves a maximum flow rate of 6.500 l/min.
OUR COMPETENCE, YOUR INNOVATION. bauma CHINA, Shanghai, SNIEC, November 24–27, 2020
SHAPE THE INDUSTRY AND BE AN EXHIBITOR Apply now !
www.bauma-china.com
COMPANIES Company
Page
Adriatech
1 Advertiser, 40
Bauer
34
Bauma China 2020 exhibition
47 Advertiser
Bauma Conexpo India 2020 exhibition
31 Advertiser
Blumaq
3 Advertiser
Brigade Elettronica
46
Casagrande
24
DAT instruments
44
Demac
21 Advertiser
Epiroc
12
Fai Filtri
23 Advertiser
Herrenknecht
20
Kelley Engineered Equipment
43
Liebherr Marini Quarries Group
IV COVER-4 14
MP Filtri
5 Advertiser
Robbins
22
SaMoTer exhibition
25
Sandvik
16
SIP&T
II COVER-37
Soilmec
28
Trevi
26
Trimeccanica
33
Tsurumi
47
Vermeer
III COVER-32
48 ONSITEUNDERGROUND - october 2020