RECORD TURKISH HIGHWAY

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1 TUNNELING AND UNDERGROUND CIVIL ENGINEERING EUROPE CENGIZ INSAAT AND MAKYOL Turkey RECORD TURKISH HIGHWAY TUNNEL TO BEAT THE SNOWS Sandvik drill-rigs employed by the CMA contracting joint venture are driving under Mount Ovit in north-eastern Turkey to ensure all-year-round land access to this relatively remote part of the country in Anatolia. Currently the main transport to Trabzon, Rize and surrounding regions from the main centres of Ankara and Istanbul is restricted to air, water via the Black Sea coast, and a long coastal road. More direct road transport to the rest of the nation has been held back by narrow roads and blockage of mountain passes by winter snows. Now, however, there is full momentum to complete a link that has been planned since 1880 in the times of the Ottoman Empire. The current road was constructed in 1930 over Mount Ovit pass at 2,600m (8,500ft) above sea level, and needed employment of 1,500 workers. 196 Sandvik Year 2013 in Action

2 Construction projects around the world 197

3 TUNNELING AND UNDERGROUND CIVIL ENGINEERING The new improved D925 highway project, valued at EUR 150M, will link Ikizdere, in Rize Province, and Ispir, in Erzurum Province, for the first time providing an all-year, all-weather link and boosting the local economies. LONGEST TUNNEL IN TURKEY In addition to various road improvement projects along the route, the Ovit Tunnel is the key element in the new link. It comprises two tubes of and, at 14.7km (48,200ft) long, it will be the longest tunnel in Turkey and, on completion, is expected to be the World s fourth longest road tunnel. reach the optimum portal positions. The two bores are connected by crosscuts at intervals of 250m to enable escape routes and to provide services accommodation. In profile there will be a grade, chiefly to facilitate drainage, of 3.5% for the first 7km from the main northwest portal, and of 1.0% for 5.5km from the other portal. At the high point, 2,500m above sea level there will be a 1,700m long drive, 8m square, to facilitate emergency egress and ventilation. This replaces the original plan for an access shaft as it was decided this would be too deep and difficult to access high up in the mountainous terrain. The tunnel plan is mainly straight with slight curves at each end to CONTRACTORS The contractor CMA (Cengiz Insaat and Makyol), responsible for the whole tunnel and highway construction project, and the client and owner is TCK, the Turkish national General Directorate of Highways. The project management structure is substantially affected by the two construction sites, at each tunnel portal, being remote from each other, especially in winter. Thus the site at the southeast portal has its own tunnelling and mechanical chiefs Ferhat Şahinbaş and Murat Ozan respectively. 198 Sandvik Year 2013 in Action

4 From left: Oğuzhan Öztürk, Burak Özgür and Sedat Şeker The project is led on site by Alper Eryiğit as project manager, supported by chief engineer Kerim Tütüncü. In the management structure under Kerim Tütüncü there is Muharrem Tezcan as tunnelling chief engineer and Sedat Seker as chief mechanical service engineer. Of the joint venture participants, Makyol has 42 years of experience in many heavy construction projects, making it one of the oldest and most experienced contractors in Turkey with many completed highway projects. It has also international experience in Albania, Algeria, Azerbaijan, Iraq, Morocco, and Oman. Tunnelling and mining specialist Cengiz was founded in 1980 and has been involved in many tunnelling, highway, mining and infrastructure projects, including work in Azerbaijan, Bulgaria, Bosnia-Herzegovina and Iraq as well as throughout Turkey. After that, we tested the new Alpha330 rock tools at the site and, with these tools they have minimized the hole deviation problems and consequently minimized the rod and especially shank adapter failures. Oğuzhan Öztürk Sandvik Construction LAYOUT The two tunnels are actually being driven as four drives with two partial faces in each. The full excavation dimensions of each horseshoe-shape drive are 8.4m height x 11.78m width, plus trenches on each side to provide space for future drains. First a top heading is driven to a height of 5.9m followed by a bench of 2.5m height, a contractual distance of 250m behind. A ramp between the two facilitates access for the drill-rig and mucking out. Alper Eryiğit RIGS Most of the tunnelling is carried out by drill-and-blast using four Sandvik DT820 rigs with standard manual controls, one for each of the current main tunnel excavation drives. Construction projects around the world 199

5 TUNNELING AND UNDERGROUND CIVIL ENGINEERING However the rigs also carry out any necessary rock bolting and excavation of crosscuts between the two bores. The decision to go for Sandvik is attributed to both a strong relationship between Sandvik Construction Turkey and the Cengiz Group, but the delivery times for the ordered rigs were also very important. In addition to the four tunnelling and one surface drill-rig (see below) used on the Mount Ovit site, Sandvik has also sold another three tunnelling rigs and a surface rig to Cengiz for a tunnelling project in Bosnia-Herzegovina. The Sandvik Construction Turkey tunnelling team, consisting of Erdinç Çetin, Oğuz Arslan and Burak Özgür, most closely associated with the Mount Ovit project, mentioned that the 1700-m new access drive to the centre of the main tunnel drives will enable CMA to test the newer DT921i tunnelling drill-rig. This will be equipped with Sandvik s advanced isure control software for fully automatic operation requiring minimal human intervention. Then, CMA will transfer the DT921i rig to granite faces in the southeast end of the planned tunnel. In addition to the four DT820 tunnelling drill-rigs a Sandvik DX700 top-hammer surface-drilling rig has been employed to excavate rock from the portals and associated cuttings. There is a long tradition of drill-and-blast tunnelling in Turkey and for such an important project CMA needed the best. We were looking first for well qualified operators, said Alper Eryiğit, but sometime training is necessary for which Sandvik is supporting us. HARD GOING Most of the rock to be excavated is expected to be granitic, both standard granite and porphyritic, or basalt, generally making good ground for drill-and-blast tunnelling. However there are some fracture zones between the main rock masses (see section summary version being scanned). CMA employs Sandvik ballistic bits of 45mm diameter for blast holes, and 51mm in diameter for rock-bolt holes. Using 4.9m-long drill rods, each round is drilled to a depth of up to 4.5m. This achieves an advance of 7 8m per day on all four current faces. At the time of the reporting some 6.2km of advance had been achieved, in totalling all four faces. Blasting is scheduled twice a day, usually meaning that there is a blast every 12-h working shift. The joint venture s Mechanical Maintenance Chief, Sedat Şeker, reports that the hard and abrasive rock has taken some toll of drill consumables. Even so, on average each blast hole bit lasts m without grinding. Earlier there had been shank breakage problems while drilling in the very hard rock, but since the adoption of the new design (Sandvik Alpha330) of rock tools, there have been no more problems. Sandvik Construction Turkey s Rock Tools Sales Engineer, Oğuzhan Öztürk explains, While they were using R38-R32 standard rock tools they had really big shank adaptor and rod failure problems due to very hard rock conditions the very hard granite. Most of the rod failures were because of the bending of the rods in the deviated holes. That was also the reason of the shank adapter failures. After that, we tested the new Alpha330 rock tools at the site and, with these tools they have minimized the hole deviation problems and consequently minimized the rod and especially shank adapter failures. 200 Sandvik Year 2013 in Action

6 SANDVIK ISURE OFFERS MANY MORE POSSIBILITIES TO CHECK HOLE LENGTH AND DRILLING PERFORMANCE. IT GIVES FAR BETTER CONTROL OF THE WHOLE DRILLING AND BLASTING PROCESS AND THEREFORE GIVES GOOD OPPORTUNITIES FOR PROCESS PERFORMANCE IMPROVEMENT. Erdinç Çetin Sandvik Construction Construction projects around the world 201

7 TUNNELING AND UNDERGROUND CIVIL ENGINEERING Now, they are using only Alpha330 tools for their underground drill rigs. This system has decreased their consumption, especially for rods and shank adapters, accelerated the drilling process, increased the hole quality which, in turn, is increasing the blasting efficiency and at the end decreasing the whole tunnelling process costs. Alpha330 rock tools are designed especially for 45mmdiameter drilling with high-power (20kW+) drills. Sandvik s particular expertise in steel metallurgy together with stateof-the-art CAD/CAM procedures has resulted in optimized geometry resulting in higher stiffness and longer service life than the earlier R32 design, also a Sandvik innovation. Project Manager Alper Eryiğit of CMA confirmed that although the rock is generally massive and hard, it can be variable. There are about 70m of soft ground at the portals, requiring special support measures. The rock was very abrasive between 300 and 350m in from the northwest portal. It took about four hours to drill a round until 250m, but on hitting the granite from 250m it took 3.5h. I would prefer moderate rock conditions for optimum progress, with time taken of 2.5h to drill a round rather than the h in granite. But the rock is changing and we are quite ok now. Overall we expect 75% of the drives to be in granite and 25 45% in basalt. CMA Tunnelling Chief Muharrem Tezcan reported that the normal drill patterns included blast holes in the top-heading wedge cut, and parallel holes in the bench. He explained that the blasting itself employs micro gel-style explosive in 38mm-diameter capsules as these produce lower air pollution, allowing the face to be approached earlier for support work and mucking out. Around 200kg is used in each top-heading blast. Initiation uses one electronic detonator attached to a non-electric circuit. INSTABILITY At the southeast portal there is up to 350m of overburden superficial and a large fracture zone, making tunnelling more problematical. We have suffered from water penetration and collapses, reports Eryiğit. The ground has changed to basalt with an alteration and fracture zone, but we are still continuing with drill-and-blast. Basalt actually occurs at both ends. To a considerable extent, the CMA tunnelling team has to be ready to tackle whatever it encounters. Eryiğit explained, There has been limited site investigation due to the great overburden, of up to 900m, meaning that there would be long investigation hole lengths with difficult access. This is partially why we are keen to check the performance of intelligent jumbos in the emergency access drive. Çetin added, Sandvik isure offers many more possibilities to check hole length and drilling performance. It gives far better control of the whole drilling and blasting process and therefore gives good opportunities for process performance improvement. SEQUENCE A typical tunnelling cycle starts with drilling the top heading first followed by blasting and loading out. The newly blasted surfaces are scaled with an excavatormounted hydraulic breaker. Then a primary lining of sprayed concrete, reinforced with polypropylene fibres, is applied up to the face for safety. Next the bench face undergoes the same sequence. SUPPORT Meanwhile systematic rock bolting, using the Sandvik DT820 drill-rigs, is carried out up to 15m behind the face, together with welded steel-mesh sheet installation and fibrereinforced sprayed concrete according to the determined 202 Sandvik Year 2013 in Action

8 rock type. Split-set-type rock bolts are normally installed. Although the more difficult rock types necessitate increasing measures such as higher rock bolt density and thicker sprayed concrete, the most unstable zones require different approaches. In soft rock and zones with high overburden self-drilling anchors (SDAs) are used to avoid having the drill hole stand open before installing the bolt. Using SDAs the drill-bit employed is sacrificial and the rebar drill steel is grouted in place immediately to secure early support. In addition, within the overburden area umbrella support is installed with lengths of rebar over the next stretches to be excavated. In all cases the versatile Sandvik DT820 drill rigs carry out all drilling and bolt installation. SERVICE CMA has its own workshops and maintenance crew on site, but supported in the case of drilling equipment by Sandvik. Frequently used consumables and service parts such as drill requirements and machine filters are stocked in the sites at both ends of the tunnel route but larger or less frequently needed parts are supplied by Sandvik from its depot in Trabzon. CMA uses original parts for all drillrig requirements. Commented CMA Chief of Mechanical Maintenance, Sedat Şeker, We are quite happy with Sandvik s performance in service and that of the equipment. There is usually sameday service response from the Trabzon depot. Two spare drills are available on site to permit overhauls in the workshops every 500 hours of operation. If view of the remote location of the sites, all workers usually remain in site accommodation, working 13 days out of 14 on 12-h shifts. FINAL STRUCTURE The support elements described earlier provide the required support during construction and as a base for the final structure. CMA will install cast-in-place concrete to a depth of 460mm using travelling formwork made in Turkey. First, however, a plastic waterproofing membrane is installed over a smooth layer of sprayed concrete. This provides a drainage passage to the main drains to be installed at the foot of each tunnel wall alongside service ducts. SCHEDULE CMA mobilized on its two construction sites and camps in 2012 with a groundbreaking ceremony on 12 May attended by national and local dignitaries. The tunnel is scheduled to be open for traffic in November/December 2015, in time for the winter snows, necessitating tunnelling to be complete by the mid-summer of that year. Sandvik Construction would like to thank all Mount Ovit project site management for their great co-operation in arranging the site visits and with the compilation of this report. FACTS SANDVIK DT820 Coverage m 2 Hole diameter mm Hole length 3,440 6,180 mm/10 16 ft Boom 2 x TB 90 Feed Rock drill Control and operation system Length (with default) feed) Width (drilling) Weight Weight with Utility boom 2 x TF Cylinder feeds 2 x HLX5 14,900 mm 4,660 mm 3,000 mm 26,500 kg 28,900 kg Construction projects around the world 203

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