smartest drill

Mechanized rock excavation with Atlas Copco
conexpo 2008:
No 1 2008
INTRODUCING THE WORLD'S
SMARTEST drill
OPERATOR’S RIG OF CHOICE:
ROC D9RRC
ALASKA’S DEVELOPING WILDERNESS
MINING &
CONSTRUCTION USA
Where to find us
Atlas Copco Construction
Mining Technique USA LLC
has combined company stores
and a distributor network to provide
support for Atlas Copco customers across the
USA. Below, Atlas Copco company locations.
State
City
Phone
CO
Denver
800-732-6762
NV
Elko
775-777-2204
MA
Ludlow
413-589-7439
MD
Baltimore
877-797-0987
NH
Henniker
603-428-6500
TN
Knoxville
888-339-0344
WI
Milwaukee
866-254-8511
TN
Nashville
615-641-3000
PA
Clark's Summit
800-950-1049
CA
San Diego
866-374-5757
GA
Atlanta
888-762-3745
CA
Sacramento
916-655-3005
AZ
Tucson
520-834-0400
IL
Channahon
815-467-8166
UT Salt Lake
801-974-5544
OR
Portland
503-459-4145
to find a distributor near you
simply contact your nearest
atlas copco store.
In addition to the locations listed above, Atlas
Copco has Customer Centers providing a range
of other products. These are:
Atlas Copco
Compressors LLC
Air Compressors
Gen Sets
Phone: 803-817-7438 Atlas Copco
Construction Tools LLC
The Near Future Looks Promising for
Atlas Copco Mining & Construction
W
e’ve had dramatic growth in the US in the last five years and the business is almost five times bigger today than it was five years ago. Today
the US is the largest market for Atlas Copco’s Construction and Mining business. And with better utilization of the US distribution network and the
expansion of certain product lines, such as exploration and ground engineering,
we expect it will get even bigger. I am pleased with Atlas Copco’s progress in the
United States.
As we look forward for the US, we are relatively optimistic for 2008, expecting
business to remain on a similar level to 2007. There are, of course, segments that
are negatively affected by the housing market but there are also segments where we
expect growth. What we can see globally is that there are many exciting projects
in relation to mining, but also infrastructure projects, especially in the emerging
markets. Overall, we are looking quite positively at the coming years.
Mining exploration has been booming quite a lot, and this year, 2008, it’s already clear this will be another record year. There are many exploration projects
around the world looking for minerals, and development and production is certain
to follow.
Atlas Copco is always looking for new ways to satisfy its customers and help
them succeed in their business. In addition we want to support our customers in
effective ways through our distribution networks. Looking at growth and market
synergies, there are segments in the mining and construction industries we can
develop further, such as heavy and light construction.
Looking to that opportunity, Atlas Copco acquired Dynapac’s road construction
equipment business recently and has put a large investment in its development. For
the US market, we have a production facility in San Antonio, TX, and will continue
to offer the full range of Dynapac equipment. Atlas Copco will also continue to
use the Dynapac name as it is very strong around the world for its line of light and
heavy compaction equipment.
Through the purchase of Ingersoll Rand’s Drilling Solutions business a few
years ago, it was clear we acquired more than a lot of good products. The people
and distribution have been key to the integration and success of Atlas Copco. The
positives of each company combined to make a much stronger company and better
resource for all our customers. As we look to expand in the construction markets
through paving and compaction, we expect this will be the same with Dynapac.
We are all excited about CONEXPO-CON/AGG in March. It’s a good chance
to meet customers, socialize a little, and show them what Atlas Copco has to offer
them. With both environmental and automation advances, we have many new concepts to discuss this year. I am confident it will be a great show and look forward to
catching up with old friends and meeting new ones.
Heavy Hydraulic Breakers
Demolition Equipment
Hand Held Pneumatic Rock Drills
Phone: 413-746-0020
Björn Rosengren
Senior Executive Vice President Atlas Copco AB
Business Area President, Construction & Mining
Technique Atlas Copco AB
MINING &
CONSTRUCTION USA
MINING & CONSTRUCTION USA
is published by Atlas Copco Construction Mining Technique USA
LLC. The magazine focuses on the
company's products and their uses
in drilling, boring, rock reinforcement and loading and transport of
broken rock.
12
Published by
Atlas Copco Construction
Mining Technique USA LLC
3700 E. 68th Avenue
Commerce City, CO 80022
www.atlascopco.us
24
Telephone
303-287-8822
6
Fax
303-288-8828
I n sid e
Publisher
Joanna Canton
joanna.canton@us.atlascopco.com
No 1 2008
Editor-in-Chief
Scott Ellenbecker
scott@drillstories.com
Page 4-10 CONEXPO-CON/AGG PREVIEW What Atlas Copco is showing off at the
show!
Page 12-14
OPERATOR’S RIG OF CHOICE: ROC D9RRC The rig is assigned to the most
hazardous jobs in Canada
Creative Director
Sarah Karlstad
Page 16-19
Editorial Advisory Board
Joanna Canton, Scott Ellenbecker,
Darwin Hollar, Marlene Moore,
Ulf Linder
SOUTH EAST ALASKA’S DEVELOPING WILDERNESS Unique projects are
happening in this remote area
Page 20-21
ACCURATE DRILLING IN NORWAY WITH HOLE NAVIGATION SYSTEM
A busy roadway needs this improved efficiency of its blasting operations
Page 22-23
THE GRANDDADDY OF SUPPORT FOR EXCAVATION PROJECTS Taking a
street level parking lot and digging down in busy Charlotte, NC
Page 24-25
THE TOOLS OF THE TRADE FOR CSI A job using Atlas Copco’s HardHat 185
compressor
Page 26-27
A NEW YORK STYLE SOLUTION Creative blasting in Manhattan using an
ECM 590
Page 28-30
LATEST ROC SERIES CABS UNVEILED Rig operators benefit from the new
design
Managing Editor
Sue Salzwedel
sue@drillstories.com
507-945-0100
Editorial Production,
Design & Layout
Ellenbecker
Communications, Inc.
30120 State Hwy. 264
Round Lake, MN 56167 USA
To Request Reproduction of Articles
All product names such as Boomer, Boltec,
ROC, Coprod, Scooptram, SmartRig and
Swellex are registered Atlas Copco trademarks. However all materials in this publication including the product names may
be reproduced or referred to free of charge.
For artwork or additional information
please contact Atlas Copco.
Page 31YANKEE STADIUM Supported by Symmetrix
Cover
Operator's
rig of choice
pages 12-14
C7BOO
32 TH
1
Atlas Copco
at ConExpo-Con/Agg
SMART. TOUGH. POWERFUL.
SMART. Atlas Copco’s SmartRigTM is a concept that facilitates all kinds of automation
Highlighted in Atlas Copco’s booth this year are these featured products
from all of our market segments – each sure to make significant changes to
the industry. There is something for everyone, so bring your shopping list to
the show this year…see you in Las Vegas!
in drill rigs. The hardware is designed to
operate in every possible weather condition, and the software can be upgraded onsite. Smart Rigs have built-in logging and
monitoring functions, together with support for diagnostics and faultfinding. Global
Positioning System, GPS, has been chosen
for the highest possible drill rig navigation
accuracy. The Silenced SmartRigTM is for
use especially in urban areas where noise
levels are restricted.
TOUGH. Atlas Copco’s HardHatTM 185 cfm
air compressor features a revolutionary
polyethylene canopy design – possibly the
toughest in the industry. The HardHatTM
resists rusting, denting, corrosion or fading, and performs worry-free in extreme
temperatures. Workers especially like the
49 HP John Deere engine and the rearmounted control panel.
POWERFUL. The title of “the world’s biggest volume-produced hydraulic breaker,”
held for over a decade by the HB 7000,
ROC D9C Silenced SmartRig
will change hands with the launch of Atlas Copco’s HB 10000 hydraulic breaker. A
HB 10000
service weight of 11 tons (10 metric tons)
and 50% more power than the HB 7000,
the power generated in a single impact
between piston and working tool corresponds to a weight force of around 840 ton
(760 metric tons).
XAS 185 HardHatTM
Superior Air
Compressors
The XAS JD(U)7 series of compressor will offer
utility companies or off-shore projects various
options in power in a 1-inch smaller container
than previous models. Come and see the new
XAS 185 JDU7, a 49 HP model, at ConExpo. Different models with the new 80 HP John Deere
motor (4024HF) will provide 185, 250, or 290 cfm
of air, with 100-150 psi of working pressure.
Generate Power!
Atlas Copco generators provide all of the durable design and ruggedness needed
to work in extreme weather conditions.
Atlas Copco’s new QAX 24 generator offers its owners ease of operation. From
the rear-mounted controls to the fronthinging, clamshell canopy, this generator
– rated at 24 kVA – is perfect for general
construction and everyday operation.
Owners and fleet managers alike will appreciate the fact
that the QAX 24 is constructed with a Zincor steel housing and a powder-coated
finish that will give additional protection against corrosion and fading.
The QAS 150
The XAS 375 JD6 and the XATS 375 JD6 portable compressors are workhorses! With actual
free air delivery of 375 cfm and 100-150 psi of
working pressure, they are ideal for demanding
applications including sandblasting and utility
work. The XC 2002 control module with LCD
display puts integrated engine electronics for
performance and diagnostics at your fingertips. These compressors are equipped with the
extremely reliable John Deere engine.
generator can
power many
significant
applications
with its standard 24-hour
fuel
tank,
which allows
for
genuine
versatility. It is mounted on rugged skids for ease of transportation. A standard
sealed spillage-free frame ensures that all fluid can be retained within the frame.
The rugged Zincor steel coated canopy is designed for extreme weather conditions. The rated prime power is 140 kVA, with a John Deere 6068HF285 motor.
Atlas Copco’s QAS 30 (31 kVA) and the QAS
330, with 319 KVA of rated prime power,
both have a comprehensive instrument
panel which enables all key operating
functions to be supervised without open-
The TwinAir™ air compressor has been de-
ing the canopy. Analog gauges provide
veloped to provide the maximum output and
at-a-glance monitoring. Protected by a
airflow for its small 20-foot container footprint.
tough transparent cover, the single panel
Built with the very highest quality parts and
provides easy start up and control of the
standards, everything has been designed to
generator. The panel
withstand heavy-duty use. Two CAT C13 en-
also
gines – 440 HP each – provide pressure options
system monitoring to
that range from 175 psi to 365 psi. The proven
ease operation.
provides
full
optimal cooler configuration, larger air intake
and low airflow restriction are designed to optimize the cooling behavior of the TwinAir™.
The New
CM785
Drill
Smart Drilling
With its high shift capacity, low energy consumption and
innovative modules that improve productivity, we can
safely say that SmartRig™ is a ground-breaking rig. The
options available make it the quietest running rig of its
kind, with greatly reduced setup time and efficient high
precision drilling – under any condition.
What Is Smart About Smartrig
More Power with Less Fuel
The SmartRig delivers exactly the right amount of power
for each phase of the drilling operation from its new Stage
3/Tier III engine. This makes it possible to reduce fuel consumption by up to 30% compared to similar rigs on the
market.
Maximize Your Profitability
The SmartRig is operated by a computerized Rig Control
System (RCS). The RCS software provides integrated control of all of the drill rig systems.
Atlas Copco is excited about the improvements on the new
Easy Maintenance & Environmentally Friendly
CM785 drill rig. CM 785 is built on the straightforward design
With 30% fewer hoses and hose meters there is less need
of the 700 series rigs, combined with well-proven features
for maintenance and less risk of spillage, making the
and components common within the ROC crawler range.
SmartRig environmentally friendly. Service is trouble-free
Improvements have been made with drilling capacity, hole
with easy fault finding and self diagnostics.
quality and overall cost efficiency in mind.
SmartRig modules
CM 785 is equipped with a cylinder-driven aluminum feed
system that provides smooth feed force and contributes to
a high penetration rate and long accessory life. The number
Hole Navigation System
of hoses and valves on the feed system is reduced and the
The precision of the Hole Navigation System (HNS) op-
breakout table is built in one fabricated piece, all to minimize
timizes drilling and blasting results, improves fragmen-
the maintenance requirement. The feed profile itself is sturdy
tation and decreases the amount of explosives needed
and highly resistant to bending. The sliding surfaces are pro-
– substantially lowering your overall production costs. All
tected by easily exchangeable steel caps that virtually elimi-
drilling functions are monitored and controlled to provide
nate the feed profile wear. The aluminum cradle is designed
a record of hole alignment, burden and spacing. By us-
for easy retightening to compensate for the sliding pad wear,
ing the HNS, you will also profit from reduced setup time
thereby ensuring smooth guiding at all times.
and efficient high precision drilling – under any weather
condition.
The drill rig is equipped with variable-speed, cooling fan
controls, load-sense hydraulics and engine auto-throttle for
energy saving and minimized fuel consumption. The well-
ROC Manager & Measure While Drilling
balanced and sturdy super-structure with 17-inch (432mm)
ROC Manager runs on a standard PC and can be used
ground clearance and full length rock guards enables the rig
to consolidate data about multiple rigs at multiple sites.
to drill in rough terrain. The variable air flow switch enables
You can use ROC Manager to design drill patterns, ana-
the operator to adjust the flushing air volume as required from
lyze drilling results, and analyze Measure While Drilling
the cabin and helps to maintain hole quality particularly when
(MWD) results. Using MWD, a number of key parameters
collaring.
are logged at requested intervals while drilling.
with SmartRig
Major
Upgrade
TM
Automatic Feed Alignment & Rod Adding System
for the
SmartRig’s Automatic Feed Alignment reduces set-up
time and cancels out operator error by setting the feed
ROC40
L7
to pre-defined angles at the touch of a button. The Automatic Rod Adding System enables the operator to drill
automatically to a given depth, while carrying out other
duties such as maintenance checks or grinding bits. Operation is easy and setup time is reduced.
Silenced SmartRig
With a noise level approximately 10 dB (A) below that
of other rigs on the market, the Silenced SmartRig is
currently the world’s quietest running rig. A perfect
choice for civil engineering work sites in restricted
urban areas.
Family
Long Feed
The SmartRig ROC D7C and D9C are available as Long
Feed Versions (LF), handling one 20 ft (6.1 m) starter
rod and one 14 ft (4.3 m) rod in the rod adding system.
A perfect choice that saves time by eliminating rod
changes when drilling holes less than 20 ft (6 m).
No matter how you decide to equip your SmartRig, every SmartRig delivered from us at Atlas Copco comes
with highly intelligent standard equipment, and innovative equipment that has been developed with a
focus on improving productivity.
Two of Atlas Copco’s successful crawler rigs, ROC L740
and ROC L740CR, have undergone a major upgrade resulting in numerous advantages for surface drillers.
Both ROC L7 and ROCL7CR have now been equipped
with a larger power pack and a bigger engine enabling
them to utilize 40kW for drilling, compared to the 30kW
offered by the previous models. This gives a 33 percent
potential increase in penetration rate.
The rigs have also been equipped with the unique At-
las Copco cylinder-feed system and aluminum feed beam,
which give accurate and consistent feed force. The aluminum feed beam is not only lighter than its steel counterpart, it is also structurally much stronger and therefore
considerably more resistant to bending.
The operator has excellent visibility from the new,
spacious cabin. For added safety, a camera supervises
the rear end of the rig, which is furnished with high capacity air conditioning and heating systems, a offering
comfortable working environment in any type of weather.
Construction Tools
Taking the Lead
THE COBRA COMBI
The Cobra Combi gas-powered
drill/breaker from Atlas Copco Construction Tools LLC features better
emissions, easier starts, and quieter
and safer operation. Weighing only
LHD 23 M ROCK DRILL
Atlas Copco’s LHD 23 M hydraulic rock
drill is ideal for drilling blast, anchor and
rock-splitting holes. Lightweight and
portable, the drill is used by construction
and utility contractors, public service
55 pounds, the Cobra Combi is easy to
departments and military engineers to
transport. As a breaker, the unit deliv-
provide efficient drilling without the need
ers up to 2,600 blows per minute. With
for large compressors.
the drilling function engaged, the Combi
offers a maximum drill depth of 6.5 feet.
Hydraulic Compactor
Attachments
The HC 409 and HC 920 hydraulic com-
PRECISE DRILLING
APPLICATION
Designed for precise and efficient
diamond core drilling, Atlas Copco’s powerful and low vibration hydraulic-powered
pactors feature FAG bearings, a Permco
core drills are ideal for the most difficult
motor and Lord shock mounts for excep-
and demanding applications. While
tional performance and durability. These
primarily intended for drilling in rock, con-
features make the compactors ideal for
a variety of soil compaction projects.
crete and brickwork, the core drills can
be converted with a drill chuck mounting
for use in wood and steel applications.
Atlas Copco
Post Drivers
The drills can also be used underwater,
making them ideal for challenging wet
diamond core drilling jobs.
Atlas Copco’s hydraulic-powered post
drivers provide stable, powerful, highspeed driving solutions for a variety
of post sizes. Capable of producing
HYDRAULIC CUT-OFF SAWS
Ideal for a variety of demanding applica-
1,500 blows per minute, the post
tions, Atlas Copco’s hydraulic-powered
drivers are suited to applications
cut-off saws cut through a wide range
such as driving road barrier tubes,
profiles, signposts, fences and
anchors.
of materials, including concrete, asphalt,
cement, brick and steel.
The saws’ simple direct-drive design
provides consistent speed and torque
and reduces maintenance requirements,
particularly when compared with beltdriven saws.
POWER PACKS
Offering a power-to-weight ratio higher
than competing pneumatic and electric
systems, Atlas Copco’s hydraulic power
packs efficiently power a wide assortment of hydraulic handheld tools for con
struction, utility and demolition projects.
Major Advancements
in DTH Performance
RC 50 RAISES THE STANDARD
The key criteria our customers want from the new Secoroc
RC 50 reverse circulation drill are simplicity, performance
AQUA 60 eliminates HAMMER
OIL WHEN DRILLING
This is not a new hammer, but one that deserves more attention. The 6-inch class AQUA 60 DTH hammer doesn’t
require lubrication while drilling, saving drillers significant
dollars in operating expenses. Drillers currently using the
AQUA 60 say it outperforms other hammers in the class
and has a life of 70,000 to 80,000 ft in limestone or granite.
Drillers say the only oil this hammer will ever need is the
Friday night “drink” that gives it a coating of protection for
the weekend.
TD 40 HAMMER
FOCUSES ON GEOTHERMAL
With constantly increasing energy prices, geothermal energy wells have become a viable heating alternative for
both domestic and industrial users. Deep wells, 650 ft (200
m) or more, allow more energy recovery from one hole.
The challenge for the driller is to find equipment that can
drill deep quickly without being affected by water backpressure.
The Secoroc TD 40 represents the latest in DTH tech-
nology. Rated at 500 psi working pressure, this new 4”
hammer has the capability to drill quicker and deeper than
any other hammer and still retain maximum performance
and reliability. By incorporating the Quantum Leap® air
cycle into this RC hammer, we’ve created a high frequency
reverse circulation hammer for all rock formations. Plus,
the QL-series hammers are known for their low-maintenance endurance and long-term reliability.
Atlas Copco's RC hammers are specifically designed
for both deep-hole exploration drilling and in-pit grade
control applications. With the RC 50, drillers can expect 15% to 20% higher penetration rates over similar
size hammers. The frequency (blows per minute) of the
Secoroc RC 50 is as much as 34% higher than some competitors.
Exploration
Atlas Copco’s Christensen rigs have become synonymous with surface exploration and core drilling, and the
CS10 is the newest addition to the lineup. It has a foldable
mast with a drilling capacity of 2460 ft (850m) using Nsize in-the-hole tools (ITH). The long mast can split into
three sections for easy transportation over any terrain
and can handle 20 ft (6m) rods. A simple wire line makes
core retrieval quick and easy while the control panel is
user-friendly for smooth operation.
in water-filled holes. All the components are adapted to
keeping water out and compressed air in.
Geotechnical
Advances Overhaul Kits
Atlas Copco offers a broad range of geotechnical products for all aspects of engineering,
Maintenance is critical
stabilizing, and securing of rock and soil for-
for maximum equip-
mations. The innovations in these products all
ment performance.
focus on increasing productivity by reducing
Atlas
time spent on a project.
makes it easy
Copco
and economical
to service your COP
Rock Drills by using
our step-by-step Overhaul Kits. Each kit includes
the overhaul instructions and
spare parts necessary while ensuring that you save money over purchasing the parts individually. Order your kit per a single part number and the complete kit will arrive in a self-contained
wooden box ready for installation.
The UNIGROUT is available in hydraulic, electric or diesel models in various sizes for all projects. These grout plants consisting of mixer,
agitator, pump, control panel and all necessary
ROC Care
Atlas Copco offers ROC CARE as a way for drill owners to pass the responsibility of maintenance to
someone else…Atlas Copco and its authorized dis-
tributors. ROC Care is a multi-step agreement between Atlas Copco and the rig owner that
hoses on a self-contained steel platform are
includes Scheduled Servicing based on hours of operation, Inspection Reports with recom-
ready for immediate use. Their uses include
mended actions, an Extended Warranty that protects owners against unplanned expenses and
stabilizing, sealing or strengthening rock and
Procom™, which is a satellite-based monitoring system that provides remote information trans-
soil formations by pumping grout under pres-
fers of rig performance and operational data. ROC CARE is tailored for each customer based on
sure into the formation. Typical applications
the projected usage.
include dams, tunnels, foundation work and a
variety of construction applications.
SYMMETRIX is a patented drilling system that
advances casing through overburden or unconsolidated formations. Symmetrix can drill
straight holes at any angle (including horizontal) to depths beyond 330 ft (100 m). Working
together as one efficient drill bit, the components are made up of a pilot bit with large
internal flushing holes and external flushing
grooves, a ring bit and a shoe casing. Whether
the application is for surface casing or micropile foundations, the system will save contractors dollars and time.
10
Big Air Performance
Contractors have big air options with proven performance in a solid package through Atlas Copco’s lineup of high pressure
compressors. These high pressure units are winning over customers across the globe both on and off shore.
The XRXS offers 1200 cfm at 435 psi, whereas the XRVS boosts free air delivery to 1256 cfm at 365 psi to give contractors
a range of options. The TwinAir™ combines two compressors in one package to give contractors large annular velocity in one
twenty-foot container. Each compressor in the TwinAir™ can run independently, singularly or together to provide up to 2232 cfm
at 175 psi or 1975 cfm at 365 psi.
Whether you need air for large diameter or deep hole drilling, Atlas Copco has the package to maximize your productivity.
Atlas Copco is committed to your superior productivity.
www.atlascopco.us • 1-803-817-7438
11
MINING &
CONSTRUCTION USA
OPERATOR’S RIG OF
The highways leading to Toronto from Sudbury and North Bay pass through forests, over
rivers and, quite often, cut through rock. The ground in Eastern Canada is much like its
neighboring US states directly south – rock to surface. Castonguay G.P. specializes in contract drilling and blasting services throughout Quebec and Ontario. Atlas Copco’s ROC
D-Series rigs are an important component in Castonguay’s success.
C
astonguay operates around 60
rigs in Ontario and averages 115
throughout the company. Although
t h e y have many brands, the Atlas Copco
D-Series ROC D7 RRC and ROC D9
RRC rigs are the operator’s rig of choice.
President and general manager of Castonguay’s Ontario operations, Bruno Dubé,
says, “We get the jobs no one else will
take.” And the ROC Radio Remote Control (RRC) rigs are a big reason for that.
The safety of using RRC is the rig’s
foremost feature, in Dubé’s opinion. He
points out two important safety benefits.
“The first is obvious, as the rigs have to
work in difficult locations where there is
a risk of turning over and, secondly, be12
cause the operator can move away from
noise and dust.” Because the rig is assigned to the most hazardous jobs, Dubé
orders all D-series rigs with a winch. “A
drill without a winch is not a drill,” comments Dubé.
Veteran operator, Dwayne Taylor,
likes the fact that he can work at a distance
from the rig. All of the drillers assigned
to the D-series rigs took only a little time
catching on to the remote control. “The
remote is very user friendly,” says Taylor.
He compares its intuitiveness to operating
a vehicle. “It’s like driving a car. After a
while I didn’t even have to look down.
Now I don’t even think about what my
hands are doing, they just do what they’re
supposed to.”
The ability to work on the
edge safely is a benefit for the
D-series, and Taylor also thinks
accuracy is a benefit. Like all
the senior drillers, Taylor has
the benefit of operating the
ROC rigs. He is currently running the ROC D9 RRC. He likes
the straightness of the hole. With other
drills, he explains that you can veer off
center if there’s a deviation in collaring
or if you simply start off too fast. He also
says soft rock or a fracture in the formation can cause a bit to drift. But all these
potential issues are not a problem with the
D9.
Castonguay originally purchased ROC
D7 RRC rigs with the COP2150 rockdrill.
Since the new D9 was introduced last year,
the D7 is no longer available with the 21
kW drill, only the standard 18 kW drill.
Today the standard rock drill with the D9
rig is the COP2160EX rockdrill. This is a
MINING &
CONSTRUCTION USA
CHOICE: ROC D9RRC
Driller Shawn Rancourt is able to stand on solid ground
while maneuvering the ROC D9 over rough terrain.
benefit, as the D9 has extra power and 18
cfm more air to increase speed and performance, and also to clean the hole better.
Although rated for 4½ inch holes,
driller Steve Pellerin says they will go up
to 5 inch. In the right formation, Pellerin
says he gets 800 ft a day with 5 inch and
1,200 ft with 4 inch. If they need to go
to smaller holes because they are in populated areas and need less blasting material,
Pellerin says he will get 1,500 ft with 3
inch and 12 ft T45 steel.
Dubé likes the versatility of hole size
with the ROC D9. He says in some areas
From left to right: Kevin Blackburn, Bruno Dubé, and Dwayne Taylor
they will get as much as 2,000 ft a day
with the D9. With the versatility, the D9
also offers maneuverability. These aspects
also make the rig perfect for handling presheer work. The rig can maneuver to the
working face and work into a position to
get the proper angle on the face. The operators like how the rigs can get into virtually any position, while Dubé adds, with the
ROC D-series rigs, they “will go places
others won’t go.” Pellerin agrees, saying,
“The ROC D9 RRC is super stable, with a
great center of gravity.”
One feature Taylor pointed out to
make the job go smoothly is the preheater.
The preheater is set to 4:30 a.m. When he
gets to work an hour later, the rig is ready
to fire up so he can get right to work. He
also likes the computerized footage counter. The counter tracks right to the decimal
point. He laughingly comments, “I think
I forgot how to write.” Dubé likes the
computerized counter because he knows
footage is accurate and easy to manage.
Along with too many functions to mention, the computerized screen also gives
exact angles of the feed. Taylor says he
has checked it manually when he thought
it looked off, but “the computer was right
on.”
13
MINING &
CONSTRUCTION USA
The unique style of the Atlas Copco knuckle boom allows operators to reach
over obstacles and go where others won’t. With a reach of 18 ft (5.5 m), the
ROC D9 can work a safe distance from a high wall. The boom can angle 30
degrees either way from center and 16 ft (5 m) below grade.
Driller Steve Pellerin hits a vein of water. The pre-cleaner helps keep the dust collector from
clogging up when drilling in water.
While observing Pellerin drill, he hit
a water vein that sent water gushing out
of the hole. He quickly shut off the dust
collector, and commented he really likes
the pre-cleaner, as it keeps water from
clogging up the dust collector system if he
can’t get it shut off fast enough.
All Castonguay drillers agree that the
ROC rigs are their favorite rig to operate,
citing different reasons, but all commented on the lack of problems as the main
reason for calling the Atlas Copco drills
their favorite.
14
Castonguay
Last year Castonguay was acquired
by Dyno Nobel. Although more corporate
structure exists today, the company continues to give its customers and employees
the same dedication it always has. Castonguay works all over Canada, with exceptional success in the six Quebec offices
and three Ontario offices. The company
has over 350 employees, focused totally
on drilling and blasting for construction
and quarry work. Dubé says he has a very
loyal group of people. Many of the drill-
ers and foremen have been with him for
years.
Dubé moved to Ontario in 1992 to
build the business. He says, “We succeed
because we service the customer locally.”
He got his start with the business early,
when he accompanied his driller father to
the site, at just 12 years old. Times have
certainly changed.
Today, the company focuses on developing its people and staying close to the
customer, but also, as Dubé puts it, “doing
whatever job comes up.” He says training
is very important, with safety being an
important piece of their business. Regular communication and safety meetings
are conducted with both employees and
customers. In Ontario alone, Dubé says he
runs 10 service trucks and 15 technicians
to keep the equipment working at top performance.
Castonguay will continue to grow and
has additional regions in sight. Dubé says
building is not difficult, “but to build a
market, it’s necessary to service it right.”
Atlas Copco is committed to helping Bruno Dubé and Castonguay G.P. go where
they need to go – both mechanically and
technically.
M&C 1 08
Your Finance Partner at Work
We know your business, let us finance it too.
At Atlas Copco we know the drilling industry. That’s why Atlas Copco Customer Finance structures leases and loans to fit the
way you do business. Whether you’re searching for longer terms or nontraditional payment schedules, we know having the right
equipment for the job is what matters most. At Atlas Copco Customer Finance we design finance programs that work for you!
Atlas Copco Customer Finance. Your Finance Partner.
www.atlascopco.us • 1-800-732-6762
15
An Extreme Place
SOUTHEAST
An
ExtremeALASKA
Place
Regionally, Southeast Alaska is an area most know little about. It rains a lot (averaging
nearly 100 inches a year), has the highest cost of living in the Pacific Northwest and navi-
this part of the world have “extreme lifestyles to match incredible personalities.”
gation between communities is difficult and infrequent. Economically, it functions as a
shipping thoroughfare between the lower 48 and the nation’s 49th state, tourism is the
highlight industry with 5 to 10 cruise ships passing through daily, and it supports struggling fishing and lumber industries.
I
f you think you can see the “but” coming, you are right. One thing Southeast
Alaska has, better than most anywhere
else, is incomparable beauty. Deep blue
skies and mysterious blue water are separated by majestic mountains and wispy
clouds. What does this have to do with
mining and construction? Well, if you can
handle what makes the area so special –
its remoteness – Southeast Alaska is a hot
place to be for construction workers. And,
for those who live here, they wouldn’t
want it any other way.
Chris Gerondale is the Southeast Alaska region manager for Atlas Copco’s Anchorage-based distributor, Construction
16
Machinery Industrial, LLC (CMI). Gerondale currently supports rental agreements
on dozens of surface drills and a number
of underground operations. Unlike any
other area, CMI’s territory could be described as remote. Service calls for the region cost the company tens of thousands
of dollars monthly as many calls require
an airplane or a helicopter. Gerondale says, “Aside from the cost
of living, the standard of living is extremely high in Southeast.” Nature is so
much a part of what makes that standard
so high. Activities could include fishing,
crabbing, hunting or hiking. Gerondale
thinks the people who choose to live in
Chris Gerondale,
Manager of
Construction Machinery
Industrial, LLC
In these next few pages, we will look
briefly at a few extreme projects that reflect on the beauty of Southeast Alaska.
Near Juneau, Dorothy Lake is being
“tapped” for its hydro-power capability
while a “hiding place” is being quarried
for a major infrastructure bypass. In Ketchikan, there are two major projects underway: a monumental runway extension
that focuses on keeping the fish happy and
a road into the wilderness that will provide
development opportunities for the city. M&C 1 08
MINING &
CONSTRUCTION USA
Juneau
e
Mountain Top Lake
L
ocated 17 miles southeast of Juneau,
Alaska, servicing Lake Dorothy is
no small undertaking. All crew and
equipment working at the project’s “lake
end” has to be brought in by helicopter. When complete, the project will be
the highest head hydro project in North
America. With a lake elevation of 2,440 ft
and a powerhouse located at sea level, the
project will generate 34.4 MW of electrical power to provide for the growing residential, business and industrial needs of
the area.
The project includes tunneling under
the 1,138 acre lake to an outlet about 143
feet below the water’s surface. Once the
drift is under the lake, the floor will be
deepened to allow for the final blast material to settle to the bottom. A concrete
plug will act as a cork, allowing a seal for
piping and valves. Drilling within a few
feet of the bottom of the lake, the charge
will be placed for the final blast and the
tap will be complete.
The project will include a 12-ft diameter tunnel under the lake, more than
17,000 ft of 2 ft and 5 ft piping that will
travel from the lake to the powerhouse,
an underground penstock to resist the
very high heads, and a powerhouse and
switchyard bench. To give access to the
glacial mountain lake and for the pipe run,
a ledge is being cut into the mountain ravine that will allow travel from the lake to
the powerhouse.
An Atlas Copco ECM 350 air track
drill was brought to the top of the mountain by helicopter and will work its way
down the mountain. From the bottom,
an Atlas Copco ROC D7 is working its
way up the mountain. Excavators follow
behind leveling the road. When service
needs to be done to the ROC D7, it is
brought to a staging area that allows a helicopter to land near by. A second helipad
at the half-way point allows access to the
ECM 350 and other equipment. M&C 1 08
Hidden Valley
I
n a valley surrounded by mountains, not far from Juneau’s city
limits, is the Hidden Valley Quarry. Rock is being removed for Juneau’s new highway overpass. Over the next couple years, 500,000
yards of rock will be taken from this quarry to fill the needs of the
project.
Brian Thatcher is the man onsite with many skills. Starting off
the 8-month season in March, there were many days Thatcher says
he would shovel snow two-plus hours before he could start drilling.
After the blaster finishes his part of the job, Thatcher returns to Hidden
Quarry in the afternoon to remove the shot material.
In a week, Thatcher drills about 10,000 ft, averaging 60 ft, 3-inch
holes. Through the season, he expects to drill 240,000 ft with the ROC
D3. Thatcher started drilling just last year and really likes operating
the ROC D3.
Thatcher is currently leveling a small plateau within the valley.
An outcrop of trees needs to be removed so he can continue to evenly
bring down the summit. Because Hidden Valley offers such a rugged landscape, Thatcher can take it right to the working edge and feel
comfortable with the rig’s stability. Thatcher says, “The ROC D3 goes
anywhere I want to go…it really sticks to the ground.”
M&C 1 08
17
Ketchikan
Ketchikan
Salmon Runways
T
he federal government has committed dollars for airport runway extensions across the country to meet
current FAA regulations, but there aren’t
many airports that need to move a river to
make that extension possible. Ketchikan’s
airport is located across Tongass Narrows
on Gravina Island, a short five minute ferry ride across the channel from the city. At
the north end of the runway, a river flows
into the channel, and like all rivers in this
part of the world, salmon count on it for
spawning. To expand the runway, the river must first be moved.
To complete the project, 1.7 million
yards of material will be moved in two
phases. The first phase is moving the river
bed. On the 3:1 slope, parallel to the runway, drilling is underway using 12 ft steel
and 3½ inch bits. To move the river, the
natural flow was redirected with a right
turn and then a curve to the left, resulting in the mouth ending up a few hundred
18
yards up the shore line. The project was
a basic borrow and fill, with extensive
coordination and timing, as the rock was
drilled, blasted and then moved, ultimately filling the old stream bed.
The second phase is expanding the
runway 500 ft. To extend the runway, borrowed material is taken parallel to the existing runway. After six months of work,
400,000 yards has been moved from the
stream and 300,000 yards moved as borrow for the extension. The contractor, Secon, Inc., is using
Atlas Copco ROC D7 rigs. Charlie Jewett,
the project manager for Secon, likes the
efficiency of the rig and says his drillers
“really like the D7 because the cab keeps
them out of the weather and the controls
are user friendly.” Drilling is done around
the clock while weather cooperates. The
project began in March, 2007, and is
scheduled for completion in August of
2008.
M&C 1 08
MINING &
CONSTRUCTION USA
Room to Grow
T
he city of Ketchikan (population
14,000) is surrounded by mountains and water. The city has about
40 miles of roads with one 30-mile paved
highway running through town, dead ending at either end. To grow, the town is
looking to Gravina Island, which is relatively flat. Kiewit Pacific, of Anchorage,
has been awarded the contract to build a
3.2-mile road that will continue from the
airport to an area approaching the West
Channel of Tongass Narrows.
Although reasonably flat, the crew has
found the island’s terrain less than welcoming. The project has run into rock,
but less rock than expected – or hoped
for. In the area photographed, engineering reports indicated that there would be
solid rock within 5 ft of the surface. Upon
excavation, muskeg was found as deep as
12 ft. Muskeg is mud and decaying plant
life that is mostly swamp, and doesn’t
come close to a solid foundation. It is reported in Wikipedia on-line that 10% of
Southeast Alaska is covered by muskeg.
This spongy muck exists because of the
region’s cool summers and high rainfall.
For the project to continue, the muskeg
must be relocated to an authorized dumping location.
Although Alaska covers a geographic
area double the size of Texas, with Southeast Alaska equaling the eastern seaboard
of the US, some who live in the region
are fighting to keep it as natural as possible. Going through the process of ob-
taining permits to relocate the muskeg
put the project a month behind schedule.
The project is permitted to stay within a
boundary and leave all other land undisturbed. Plastic fencing barriers have been
placed along the road’s future path to contain any runoff into the pristine muskeg
wilderness.
Kiewit uses ECM 660II rigs for the
drilling work. The operators like the simplicity of their operation and the rigs give
them the hole size and depth needed. Service and support is also a big reason for
using these rigs, which are provided by
Atlas Copco dealer CMI.
“CMI has a unique service & product
support situation with its customers in
Southeast Alaska,” says Ketchikan Sales
& PSSR., Brian Elliot. “As a company
wide entity, we strive to meet those customers’ needs.” Currently, there are about
30 surface drills working in Southeast
Alaska. With 24 rentals in the region,
CMI stays busy servicing its equipment.
Elliot says it’s common to spend 20 hours
a month on a float plane making service
calls, and helicopter parts delivery and
service calls are also frequent. M&C 1 08
19
Norway
Accurate Drilling in
with Hole Navigation
Norwegian contractor, Mesta, is improving the efficiency of its blasting operations at the
Romarheim road improvement project, 31 miles (50 km) northeast of Bergen, Norway. Using Atlas Copco ROC D7C GPS-guided drill rigs, Mesta is achieving a level of speed and
accuracy with drilling and blasting that is resulting in a reduction in the traffic disruption
normally associated with this type of operation. This is proving critical to keeping this
important road open for traffic in the absence of an alternative route.
20
System
T
MINING &
CONSTRUCTION USA
he $27 million (EUR18.5 million)
cause it is now too narrow for the amount
Romarheim road improvement projof traffic it has, and is subject to dangerect represents the first application of
ous rockslides in winter. Blasting takes
the Hole Navigation System (HNS) for
place every day, and safety is paramount.
surface drilling on a construction project.
Each time a blast is scheduled, Mesta
To facilitate the project, a Hole Navigahas to close the road for one hour for the
tion System was retrofitted to a ROC D7C
clean-up operation.
rig, originally supplied to Mesta in 2005.
The HNS can be used on any type of
As the ROC D7C was the forerunner
Atlas Copco SmartRig. It features real
of the current SmartRig range of
rigs, it was already prepared for
upgrading with the new technology. Mesta is typical of Norwegian contractors, who are quick
to adopt innovative drilling technologies.
The Romarheim road development involves construction of
4.5 miles (7.2 km) of new road,
which requires blasting some
300,000 cubic yds (225,000
cubic m) of rock and moving
460,000 cubic yds (350,000 cu.
m) of earth. The overburden has
to be shifted along the existing
narrow road, a logistically difficult task because the contractor’s trucks have to operate at
the same time as normal traffic
is flowing.
The job also includes a 1,000
yd. (950 m) tunnel and four
small bridges. The tunnel will
have two lanes, and will have a
cross-section capable of accomReal time GPS information is downloaded to the SmartRig.
modating large trucks.
For much of its length, the gradient
time (RTK) GPS, offering accuracy rangwill be 4%, with a stretch of 6% gradiing from +/-4 in. (100 mm) to +/-2 in. (50
ent before entering the portal where there
mm), depending on the number of satelwill be an additional lane for heavy, slowlites that are in view. The customer supmoving vehicles.
plies the external GPS equipment such as
the receivers, antennas and modems.
Safety Paramount
Around 2½ miles (4 km) of the new road
runs along the line of the existing road, although the new stretch will be raised on
a bed of rock blasted from the cuttings.
The remaining 2 miles (3 km) of road, as
well as the tunnel, will be completely new.
The existing road is used by an average of
1,500 vehicles a day.
The busy road is being upgraded be-
Anmask Software
On the Romarheim project, the system is
using Anmask mapping software, a commonly-used tool in Norway's construction
sector, as it has data on the geology of
the entire country. This software requires
some additional hardware, and there is an
extra PC in the cab. All drilling data is
taken straight from the Anmask package,
so drill plans are not necessary.
The display screen in the rig’s cabin
shows standard codes that the operator
can follow and by logging the position coordinates provided by the HNS, there is
no need for road boundaries to be marked
out prior to drilling the blast holes.
The cab display shows exactly where
each hole has to be drilled, and the software takes into account the
variations in the surface height
of the rig. Every time the operator repositions the drill rig for
the next hole, Anmask tells the
operator how deep to drill and at
what angle.
Level Bottom
A major benefit of using HNS
is that it guarantees that the
bottoms of the holes are level,
leaving a flat floor after blasting. Meanwhile, ensuring that
the blast holes lie in the same
orientation maximizes blasting
efficiency and reduces the need
for costly and time-consuming
secondary breaking of oversized
material. Parallel holes and flat
benches translate into reduced
use of explosives.
The system also allows the operator to optimize
positioning, so that the greatest
number of holes can be drilled
from one set-up without moving the entire
rig, maximizing productivity.
The combination of these advantages
reduces clean-up time and cuts wear and
tear on loading and hauling equipment by
controlling the fragmentation of the blasted rock. In addition, floors are smoother
which reduces wear on tires and transmissions.
As the holes are more parallel, the
risk of flyrock is also reduced, providing
added safety. Documentation is improved,
too, as all the data is logged and can be
stored for analysis.
When accuracy is important, the
SmartRig Hole Navigation System will
give you the detailed pattern for the job.
M&C 1 08
21
MINING &
CONSTRUCTION USA
The Granddaddy of Support for
Excavation Projects
Taking a street-level parking lot down vertically 65 feet in busy downtown Charlotte, NC, is a job for the professionals. Because of the variation in
the formation and existing structures that need to be worked around, the process has required many types of ground engineering including: retaining
walls, mini piles and soil anchors for securing the walls during excavation.
T
he former parking lot is in the process of becoming an 18-story Ritz
Carlton hotel and a 33-story office
building with a multi-level parking deck
below the two structures. At one time,
Hayward Baker – a Keller Company – had
as many as five drilling rigs in the site.
Today, there are two Atlas Copco ECM
780 rigs working at the location. “It’s a
sweet rig,” says Reggie Goodchild about
the ECM 780. On this project the crew
has run into every kind of rock that North
Carolina has to offer. Goodchild likes how
the drills can handle it all.
Goodchild has been with Hayward
Baker since 1984 and has operated every
type of equipment they have, especially
drills. For the last 19 years he has been a
superintendent with the company.
The future structures to be built are on
the end of the block with an existing parking deck on the one side, which needs to
be tied, below street level, into the parking
ramp yet to be built. During construction,
mini piles were installed along the existing parking deck’s columns to keep the
parking deck stable while excavating for
the new buildings.
Hayward Baker’s part of the job includes earth retention during excavation
of the pit. After the material is removed,
Hayward’s crew shores up the exposed
wall. The grade is being taken down in
five-foot lifts, using hydraulic breakers
and excavators to break and shovel the
rock.
For the street sides of the pit, Hayward Baker installed soil nails 15 to 50
ft deep at 15 degree angles, then lagged
on a wood retaining wall – 3 to 4 strand
tiebacks each. The nails were tested to 28
22
KIPS after three days.
Under the existing parking garage, 25 to 60 ft
soil nails were
installed at 20
degree
angles.
These bars are
tested to 80 KIPS. To
seal up the wall, wire
mesh is wired to the rebar and shotcrete is sprayed on to finalize the process.
To drill the holes, Goodchild likes
the performance of the ECM 780 using a
QL40 hammer. “We have had no problems
drilling,” says Goodchild. In total, 800 to
1000 4½-inch holes will be drilled on the
project.
The job was engineered to utilize #8,
#11, #14 and #18 threadbar anchors at various locations on the site. The spacing of
the anchors is dependent on the formation.
For example, on the east wall, anchors are
installed on 5 ft centers and on 8 ft centers
At the far end of the site one ECM 780 is
drilling at the sublevel of the future Ritz
Carlton. In the far corner shotcrete is being
applied to the wall below the parking garage.
At the far left the ECM is tramming down
the bank after finishing a line of holes.
on the west wall. When asked about Atlas
Copco drills, Goodchild uses the word,
“finessable.” He says, “They’re very nice
and easy to run. They’re good in rough
terrain and they have a very wide range
of uses.” With his experience, Goodchild
should know. In all, he says, “I’ve installed
everything on this job, shear anchors, rock
anchors, tie backs, soil nails…I’ve got it
all down here.”
M&C 1 08
Drill operator Jeff Riner
examines his work and shows how
mesh and shotcrete will finish the
surface. The 4 1/2 inch hole was
drilled beside the mini pile.
Lazaro Melo is spraying shotcrete on the wall.
The CM-780-D drills with its tracks
parallel to the excavated wall and the
mast perpendicular while drilling at
20% off horizontal. 23
The Tools
of the Trade
for
CSI
When Communication Services, Inc. (CSI) of
Marshville, NC, needs to set fiber optic line underground for telephone service to new housing developments, they rely on the Atlas Copco
185 series air compressor to provide air for all
their tools.
Safety Director Wayne Maddox communicates with the other end of th
Dorartes and Juventino Viveras work together to send the mule tape thr
T
he job at hand is to run over 3,000
feet of underground fiber optic cable
through the underground conduit
system that has already been installed.
Most of the new subdivisions are being
designed underground. “They’re running
fiber all the way to the houses now,” according to Travis Brown, a hardworking
foreman for CSI.
Today, CSI is using an Atlas Copco
HardHat XAS 185 JD7 portable compressor. Its unique polyethylene shell provides
durability and the John Deere diesel engine provides reliable air for all of the
tools. CSI has multiple 185 steel compressors that they use daily. Brown likes the
185 and says the “John Deere is a good
engine.” Tim Collie, Regional Sales Manager for Atlas Copco Construction Tools,
LLC, commented that the 185 compressor
is the most common one on the market because it runs such a diversified range of
tools.
24
MINING &
CONSTRUCTION USA
Orlando Dorartes, Travis Brown, and Juventino Viveras pose in front of the HardHat 185 compressor.
he conduit while Foreman Travis Brown, and Workers Orlando
rough.
The first tool that CSI is using is the
“blow gun.” The amount of air needed
for the blow gun depends on the length
of pipe, the diameter of the pipe and the
number of turns or resistance. Brown says
he uses the 185 compressor because it’s
available onsite. Brown points out a 185
cfm will work up to a certain distance
then, if necessary, they may need to join
up another 185 cfm unit. If the conduit is a
mile long, it takes two 185s or a 350 compressor. CSI crews all have 185 cfm units.
“The 185 is a good all around machine,”
says Brown.
The blow gun will blow mule tape or
“string” to the other end of the conduit, in
order for the fiber optic cable to be brought
back through the conduit. The mule tape
rope being used for this project is 2,500 lb
test weight per square inch. Brown likes
to use the mule tape only once, saying,
“because it may fray” and it’s more dependable to use new.
“Fire in the hole!” Brown laughingly
shouts to start the string moving through
the conduit, making sure to communicate
with the other side. Three men are needed to keep the string moving at the right
speed and tension. One man holds the
spool of mule tape through a rake handle.
The next man makes sure that the tension
is slack on the string in order for the third
worker to feed the string through the line.
The worker stringing the mule tape must
make sure the tension is just right or the
string may bunch up. This is a hard and
tedious job, since the string is heavy and
the air is powerful. The Hard Hat 185 is
handling the job perfectly.
When the missile is at the end of the
conduit, it’s time to pull it out and attach the fiber optics cable and then start
the process of winching the string back
through the conduit. Once the string has
pulled the fiber back through the conduit,
the fiber is ready to continue being strung
above ground to the intended central station, or “node.”
Safety is extremely important for CSI. All workers of course wear a
hard hat, gloves, safety
glasses, safety vests and
ear plugs. Pre-inspection
of all equipment is a must
for CSI. There is a form that
is filled out every day and
signed by all who are on the
site. For inspecting the 185 com-
pressor, Brown checks the oil, water, and
fuel levels, as well as inspecting for leaks.
Other pre-inspection safety assessments
include: looking for hazards on the job
such as traffic or power lines, looking at
the conditions of the weather and ground,
making sure that traffic signs and cones
are posted as necessary. Wayne Maddox,
Safety Director at CSI, states, “We’re all
on the same team.”
Working together as a team is what
CSI did to finish the job of bringing fiber
optic cable the 3000 plus feet through the
underground conduit system. Interestingly, Brown retired from a power company
in California after 30 years on the job and
“retired” to North Carolina. Brown decided to go back to work because “you can
only fish so much.” Maddox commented
that Brown knows his stuff and gets the
job done, using the right tools and the
right compressor – Atlas Copco’s 185 JD7
M&C 1 08
Hardhat.
25
New
York
Style Solution
The word “Manhattan” translates from the Lenape language as
“island of many hills.” The island of Manhattan in New York City
doesn’t have many hills any longer. Over the centuries, massive
amounts of rock have been removed and excavated to create one
of the largest commercial, financial and cultural centers in the
world. John S. Civetta of Civetta & Sons, Inc., specialists in excavation and foundations from the Bronx, N.Y., is following
in the tradition of removing rock
from Manhattan, only he is
doing it a bit differently.
26
W
hen an old eight-story building on the corner of Madison
Avenue and 53rd Street was
demolished to make way for a 30-story
building with 350,000 square feet of office space, Civetta was called on to remove rock 20 to 35 feet below the city
surface. Since 2001, blasting in Manhattan has become a cumbersome process,
and since the rock Civetta had to move
was near a subway tunnel, he had to be
creative. To crack the rock he turned to a
chemical product called Da-mite.
“Everybody is still blasting, but we are
experimenting with this,” Civetta said.
To drill all the holes necessary for excavation, Civetta turned to an ECM-590
drill from Atlas Copco. The ECM-590
was a much-needed upgrade for Civetta. He had been using a first-generation hydraulic drill. To pull off the job on Madison Ave., Civetta needed a versatile, yet
powerful drill. Not only would he be
drilling hundreds of 2½-inch holes – 15
feet deep – to hold the chemical mixture
that would break up the bulk of the rock,
he needed a drill that could line drill 4inch holes eight inches apart around the
perimeter of the foundation. A sizeable
MINING &
CONSTRUCTION USA
undertaking for any drill, but the ECM590 handled it without a problem.
“This drill is great. It is so much better than the old one we had, and we keep
it running all the time. We drill holes for
the chemical and while that is heating up,
because it has to sit a while, then we line
drill around the foundation,” Civetta said.
Drilling in the rock of Manhattan is a
challenge. The pegmatite and Manhattan
schist that support large concentrations of
skyscrapers is extremely hard.
“That rock over there, you can stand
on that with a hammer all day and you’re
not going to get anywhere,” Civetta said. “The rock, it doesn’t get much harder than
it is, and that’s what we’ve got.”
The Daigh Company of Georgia distributes Da-mite, a highly expansive,
rock-splitting mortar. When it is mixed
and poured into a hole, it creates 18,00020,000 psi of pressure after 24 hours. If it
sits for several days, 40,000-50,000 psi of
breaking force can be generated.
Civetta required every psi the chemical could muster. Holes for the chemical
were generally drilled 2½ feet apart for
most of the project. Civetta said in softer
rock the spacing can be opened up to cre-
ate a larger pattern, but there isn’t much
soft rock in Manhattan. After the chemical
is in the hole, a large steel slug is placed
in the hole and blasting mats are placed
over the area. After the rock cracks, it is
hit with a 12,000-pound hammer to break
it into pieces.
The ECM-590 was part of a rental
purchase agreement in which some of
the rental payment is used as equity for a
down payment. The financial arrangement
is just one of several flexible financial solutions offered by Atlas Copco Customer
Finance.
As the ECM-590 revved its engine
at the site on Madison Ave., Civetta was
standing at the edge of the foundation his
crew was creating in Midtown Manhattan
when asked how he liked working in the
city.
“It’s crazy. You know, to get the equipment down here, and even to get in and
out of the city each day, it’s crazy,” Civetta said. Then as he looked at the glass,
steel and stone buildings, knowing he is a
part of the construction tradition towering
around him, he added, “How can you not
love it?”
M&C 1 08
The ECM-590 drill is hard at work here.
27
MINING &
CONSTRUCTION USA
Latest ROC
Series Cabins
Unveiled
Atlas Copco’s ROC series of surface drill rigs will benefit from this new cabin design, which
features increased operator space, improved comfort and even higher levels of safety.
W
hen Atlas Copco designed the
new cabins for the ROC series
of surface drill rigs, the operator was in the forefront of its mind. Despite a great many other considerations,
the design team had no doubt that “the
next generation” workplace could only be
achieved by talking with and listening to
the professionals who would ultimately
occupy it. The design challenge behind
the new cabins was to achieve increased
operator space and the overall in-cab environment while simultaneously improving
ergonomics. The resulting design achieves
all of these objectives, further increasing
the effectiveness of the well-proven ROC
series drill rigs.
Better View
The design changes led to improved visibility, which in turn contributes to safety.
The large windows give good, all-around
visibility and the front windscreen is
slanted inwards, which helps to keep off
the rain and dust. This design, together
with the new skylight in the roof and repositioned instrument panel, enables the
operator to see the whole drilling process,
from surface collaring to the top of the
feed.
The forward-angled front window
of the cabin also reduces the amount of
dust that can accumulate on the surface. A
number of glazing options are available,
including clear or tinted laminated panes,
as well as approximately an inch-wide
(24 mm) pane that provides
extra protection against
stone throws.
Better Ergonomics
Free space around the
operator has been significantly increased, while
a range of smart storage
solutions have been built
into the cabin’s interior.
This includes a document holder, bottle and
cup holders, room for a hotplate and a cooler, larger storage
and durable trays.
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Easier access to the cabin has been
achieved by moving the door to the front
of the cabin. This greatly improves access
and also makes it easier to step across to
the front service platform from where the
operator can clean the windshield and roof
glass or change the wiper blades. The design team took notice to the observation
that the previous cab models were difficult to keep clean and fit the new cab
with single-molded rubber mats, designed so that dust and debris can
be easily swept out the door.
The operator’s seat is fully
adjustable and ergonomic placement of joystick controls for
drill-and rod-handling operations
are designed to minimize fatigue
and maximize comfort. To the
operator’s right, a side-mounted
rail is included for the easy adjustment of monitors for rig control systems, reverse camera or DVD viewing
as well as an easy-to-reach, touch control panel for supporting functions.
Better Working Environment
As operators often have to remain in their
cabs for lengthy shifts, the designers
have paid close attention to ergonomics
and comfort. The cabins feature an improved ventilation system that includes
a relocated air intake, two-stage filtering
and more efficient heating and air conditioning capable of maintaining a pleasant
working environment, even in the harshest climates.
In addition to highly effective noise
and vibration insulation, the new cabins
offer increased protection, easily exceeding ROPS and FOPS requirements 20 tons
(19 tonnes) for the D-series and 33 tons
(30 tonnes) for the F- and L-series.
Simpler Maintenance
These cabins have also been built with
ease of maintenance in mind. Design details including an easy-to-change air filter
at ground level, a service platform that allows access to the window for cleaning
and changing wiper blades and also
doubles as a toolbox, and an all-inone molded floor mat for regular
cleaning are just some of the innovations built into the cabins.
Looking to the Future
The new cabs are already available on all ROC D- and ROC
F-series rigs and are expected
to be on the ROC L-series by
the end of this year. There’s no
denying that the new cab is a major all-around improvement on previous models. A great deal of time has
been spent on testing, not only involving
operators but also service personnel, marketing and sales representatives as well as
distributors and importers. Their input has
heavily influenced all aspects of the design process, with the aim of making the
final product as good as it can be.
M&C 1 08
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MINING &
CONSTRUCTION USA
FIRST IMPRESSIONS
M&C tested the initial response to the new
Initial response to the new
cabs has been positive.
Björn Nordahn in his
SmartRig ROC D9C.
cab among some experienced Swedish
rig operators. Here, one of them gives his
view.
B
jörn Nordahn operates an Atlas
Copco SmartRig ROC D9C, fitted
with the new cab, for contractor
Bohus Bergsprängning AB. Here are his
thoughts about the new cab:
This new cab is a big improvement.
The extra space is great. There’s room
for everything, from lunch-box and stove
to sprays and drill bits. Some of my colleagues say it’s now so big that it echoes!
I think the controls are now positioned
much better. It’s really very easy to get to
“The new cab is a
big improvement.”
Björn Nordahn,
operator, Bohus
Bergsprängning AB.
them when you want to change the angle
of the boom or drive the rig to the next
hole. I think the repositioning of the controls is the best improvement.
The placing of the control buttons is
good too, but I prefer small switches as it
can be difficult to feel your way across the
smooth buttons to the find the right one.
This can be a bit tricky when, for example, you are using the rig’s support legs
and you need to have your eyes totally focused on what you are doing.
I have only had this rig over the summer this year, so I can’t say anything yet
about the climate control system, but the
air conditioning has worked well.
It’s also easy to keep this cab clean
– and the vacuum cleaner is a great idea!
We thought it was so good that we have
also installed one in our ROC D7. And
it’s easy to keep the storage compartments
clean because they are large and straight.
In the old cab there was just a little
place at the front where you could put a
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few tools down temporarily. Now there’s
a whole toolbox there, which is great. Allin-all, I think the new cab is good, even
though there are a few small things that
can still be improved.
It’s almost too easy and can make you
a bit lazy. Almost everything is automatic so once you’ve thought about the job,
ground the bits and cleaned up – there’s
not much left to do!
Maite Santamarta, application engineer at Atlas Copco in Spain, confirms
that the new cab is a winner among operators in Spain. “All our customers are
very happy with the new cab because it is
“All of our customers in Spain are very
happy with the new
cab.”
Maite Santamarta
Application Engineer
Atlas Copco Spain.
just so comfortable,” she says. “Another
advantage is the placing of the steps and
grab-rails on the door. They make it very
easy and safe to climb in and out of the
cabin. The air conditioning is good too
and everyone is very happy with the new
positioning of the joysticks.”
M&C 1 08
FROM CABS TO OPEN AIR
NOT ALL OF Atlas Copco’s hydraulic surface drill
rigs have cabs. ROC D3, ROC D7RRC and ROC
D9RRC are all “open air” rigs. These also vary in
the way they are used. RRC rigs, for example, are
operated via radio remote control while on other
versions, the operator stands up on the rig to operate it. Compressed air-driven rigs vary even more
and can require up to three operators.
The ROC D3, one of several rigs in the Atlas Copco range of cabless crawlers. Designed for drilling in urban areas in rough terrain,
the ROC D3 handles 15/8"–31/2" (41–89 mm) holes. The rig was
upgraded this year with a more powerful engine (116 kW Cummins
QSB4.5), rock drill (COP 1640 or 1240) and compressor (8.5 bar).
MINING &
CONSTRUCTION USA
Symmetrix Supports
Yankee Stadium
Those of you out there who love the New York Yankees will have a new home in which
to cheer them on next year. Regardless of whether you’re there to root for the home team
or would like to see the Yankees get pummeled, be assured the foundation of the new
$1 billion ballpark is solid under your feet.
T
o support the foundation of the new
park, Underpinning & Foundation,
Skanska, has installed two different
types of drilled piles on the project to date. For support of excavation (SOE), 12¾
inch piles were used and for foundation
support, 95/8 inch mini piles were needed.
In total, about 235 drilled piles have been
installed.
For the SOE portion of the job, the
process included drilling the soldier piles
30 ft deep, then excavating, and finally
lagging timbers in place. For the foundation piles, a series of piles were grouped
for the future footings. These were up to
120 ft deep with 20 ft rock sockets. The
hammer used was an Atlas Copco DHD
380 with the STD 324 Symmetrix system
for the SOE piles.
Symmetrix was used because of its
ability to drill through the overburden and
leave the pile in place in just one pass.
Time and speed are critical for Underpinning. Doug Maffei, project executive for
Underpinning, really likes using Symmetrix. “It’s a good thing that you can set up
once and bring it home, then go to the next
one. [Symmetrix] goes through almost
any obstruction,” emphasizes Maffei.
Underpinning has been using Symmetrix for a number of years, and projects for
Symmetrix are becoming more frequent.
Maffei says, “I would use it every time in
this application if I could.”
Keystone Drill Services, out of Somerset, Pa., is the distributor for the Atlas
Copco Ground Engineering Products
being sold and serviced to Skanska, Underpinning and Foundation Contractors.
Kevin Goliwas is Keystone’s sales engineer, who designs and sells the Symmetrix systems, which Keystone stocks in the
Northeast. He sees the Symmetrix becoming more popular because of the efficiency
of the systems.
driven in a day to as many as 35 a day
using Symmetrix. On another job, he said
it took 3 days per driven pile and just 20
minutes per Symmetrix! “The ring cost is
nothing compared to the cost of labor,” he
says.
Hislop also helps contractors outfit
their drills to work with Symmetrix. “Most
drills can be outfitted to install Symmetrix. Even cranes are becoming more common,” he says. If a drill is rigged up for
micro piles, it can be made to work.
This winter the parking structure phase
of the Yankee Stadium project is beginning. This is much larger in scale, requiring 285 10¾ inch piles.
Opening game, 2009, will be the beginning of many new memories for Yankee fans, and Atlas Copco and Underpinning & Foundations, Skanska, can say
they’ve been there since the beginning.
There will be many winners and losers in
the future who walk on and off the new
Yankee field, but if you’re into foundation
work, you can be assured that Symmetrix
can certainly make you a winner every
time!
M&C 1 08
Time Is Money
“The project benefited from significant
time savings,” says Maffei. Time has been the big advantage for
most contractors. John Hislop is responsible for technical support in the United
States for the Symmetrix products. He
says that in most instances, time is an issue. One highway job went from 2-4 piles
Doug Maffei is the
project manager for
Underpinning.
Symmetrix mini piles
are used in support of
excavation.
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BO
O
Smart. Tough. Powerful.
With innovations ranging from the intelligent to the durable to the flat-out earth-shattering, Atlas
Copco has job site solutions you’ll want to see at CONEXPO-CON/AGG 2008.
SMART. Automated, silenced and guided by GPS, the SmartRig ROC D9C offers increased
productivity and accuracy, and the facility to drill in sound-sensitive areas.
TOUGH. Built with a double-walled polyethylene shell to withstand the rigors of the job site, the
XAS 185 HardHat compressor provides excellent durability.
POWERFUL. Weighing in at an impressive 10 metric tons, the HB 10000 hydraulic breaker with
ProCare™ brings a whole new definition to power.
Atlas Copco provides not only superior productivity products but also service and parts programs
to maintain superior productivity.
Committed To Your Superior Productivity
For more information contact:
800-732-6762 Atlas Copco Construction Mining Technique
800-232-3234 Atlas Copco Compressors
800-760-4049 Atlas Copco Construction Tools
www.atlascopco.us
TH
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