2003 Overbreak
2003 Overbreak
2 2003
LINE INFRASTRUCTURE
Line infrastructure and the role of engineering
geology in analysing overbreak, part I
theoretical considerations
ir.Robrecht.M. Schmitz - Géomécanique et Géologie de l’Ingénieur -
Université de Liège, Chemin des Chevreuils 1 - B53/, [email protected]
31
Ingeokring Newsletter
stable rock masses consist often out of large rock blocks applied in order to obtain the minimum excavation size
and have a large discontinuity spacing. Therefore, the in due time (Müller 1978). This type of overbreak is
unavoidable, primary, overbreak can be large. Contrary
rock masses that are less stable have a very small dis- applied at the moment in the Sedrun stretch of the new
continuity spacing, they can be excavated with less Gotthard base tunnel (WT 2003).
harsh methods, even without blasting, with a very small
overbreak (Müller 1978). The confusion is based on the 3 Why should an engineering geologist care?
fact that less stable rock masses have a larger tendency Because:
to produce secondary overbreak and cave-ins. i) of his inquisitive nature, he is interested in all matters
concerning geology and engineering.
- Rock burst ii) overbreak costs money.
Rock bursts are formed by the sudden release of stored The engineering geologist needs to convince the
elastic energy, they are known to occur in deep tunnels tunnel constructor that he is cheaper than the
and mines (Bräuner 1981). Although rock bursts are very overbreak. Therefore he needs to know what type of
important phenomenon having a large death-toll, they overbreak most frequently occurs and how much it will
will not further be discussed in this contribution. cost.
If the final support is rigid then underbreak will not be
- Overbreak related to off set accepted because a minimum excavated size is required.
Another form of overbreak is not related to collapse, Because in addition underbreak is more expensive to
fall or cave in of rock mass but to the restricted working remove than overbreak (Viroux 2003) overbreak is more
space underground. The drills used to drill the contour frequent than underbreak. Tradition has that the client
holes have a non-zero thickness that create an off-set is willing to pay for a defined overbreak, considered as
of 0.2 to 0.4 m as shown in figure 1. the “geological” overbreak. Therefore in general
“gaps” are created and the major expenses of overbreak
are related to the filling this gap with concrete in
tunnelling and waste-rock etc. in mining. The costs
depend on the size of the “gap” to be filled up. What is
the size of overbreak in general?:
Overbreak in % diameter (Wahlstrom 1973, Müller 1978,
Kolymbas 1998):
- 7.5 % Chippis (CH) tunnel
- 10% Simplon (CH) tunnel
- 6 - 38% for tunnels in general
- 10% average drilled and blasted tunnels
- 25% in fractured rock or if blasted incorrectly
Figure 1. Overbreak related to the offset of drills - 22% in biotite schist and gneiss, 16% in shale, 7% in
- Overbreak by intentional over excavation in rock granite, 16% in closely jointed granite, 31% closely
masses with “genuine” plasticity: spaced horizontal joints section of the Orberts tunnel
One has to distinguish between: Colorado
- Genuine plasticity in e.g. mylonites and clays. In rock - 5 - 10cm in compact stable rock mass with few fractures
masses showing real plasticity new rock mass material or in fractured rock with small discontinuity spacing if
will follow in the places where rock mass is extruded support is correctly selected and swiftly installed
into the excavation, the risk of large overbreak is low, - up to 50 cm in compact stable rock mass with large
contrary the underbreak can be significant (Müller scale fractures at large discontinuity spacing
1978). - 15 - 30 cm in fractured, unstable, rock prone to cave
- 1/6 of the diameter of excavation during blasting in
- Pseudoplasticity: in rock masses that are stratified, rock mass with smooth planar discontinuity surfaces
foliated or fractured, pseudoplasticity is very high if
the degree of separation is high or the discontinuity The expenses include the additional concrete, the time
infill is lubricant. In rock masses showing needed to shotcrete all the voids and the time lost that
pseudoplastic behaviour all asymmetric features given could have been used to drill the following blast holes
by the discontinuity matrix will become more and more or to install appropriate support.
asymmetric in time and thereby the overbreak increases. Müller (1973) gives some examples:
- tunnel in general: reduction of overbreak of 10 cm
As long as the rock mass plasticity provokes along the (average dimensions) reduces expenses equal to twice
circumference a gradual and regular decrease of the the cost of the explosives
excavated section, overbreak must deliberately be - shaft: small overbreak, 28% excavation profile and
reduction of 23% concrete could be saved
32
Vol. 10 No. 2 2003
Figure 2. 1 Granite in Alps, excavation by drilling and blasting, the overbreak is clearly visible. 2) The same
formation but excavated with a TBM. Only the traces of the cutter disks are visible in 2b). In 3) an example of
excavation by water in a Devonian limestone show cave. The excavation follows the dip of the strata. Excavation
with a roadheader in clay stone is shown in 4). Even in a close up 4b) only the traces of the cutter head can be seen
but no other substantial overbreak. 5) Mine in carbonate rocks, in Alps, excavation by hammer and chisel 5b) no
overbreak only traces of tools. Of all excavation techniques, drilling and blasting produces most overbreak
Does this mean that there is no overbreak with the - in a bored tunnel the limit of the cross section follows
other excavation techniques? the path of the tools, thereby a circular cross section is
No, according to Müller (1978): during mechanical created as planned.
excavation without blasting, thus non-vibrating - in a tunnel excavated with a roadheader, pick hammer
excavation, cavities that follow a zone of weakness in or tunnel shovel the pathways of the tools create a
the rock or a discontinuity are only a local exception surface less adapted to the planned section.
with a maximal extent in the order of decimetres. Only if - if the degree of separation is large and the rock
very smooth planar discontinuities with an strength high than the excavation with a roadheader
unfavourable orientation with respect to the excavation can loosen rock blocks from the rock mass matrix and
are present then parts of the rock mass can fall from the produce overbreak (Müller 1978).
roof. But in general:
33
Ingeokring Newsletter
Although blasting causes apparently the largest lost this experience and an individual discontinuity
overbreak there is still a tremendous difference in the guided drilling is nearly impossible. An adaptation of
amount of overbreak created by poor and by good the drilling scheme although theoretically possible, is
blasting. not performed in praxis because neither:
- time, nor
What is the effect of poor blasting on overbreak? - stimulus
The effect of poor blasting will cause higher overbreak, is available.
depending on the number of discontinuities, their The hereby caused disadvantages like:
strength, strength of the rock matrix etc.. Some examples - larger overbreak
are shown in figure 3. - more cave-ins
- reduced stability
How does one recognise poor blasting? - increased water inflow caused by loosing up
This is quite simple one should have a look at half- are balanced by:
casts (see figure 4) which are present if the blasting - faster advance => better utilisation of the available
was good. In France reduction of payment follows if a stand-up time
certain percentage of half-cast length cannot be found - more accurate in directionality => better pre-splitting
in the tunnel walls after blasting (Bouvard et al 1988). without substantially increasing drill time
The disadvantages of drilling with a jumbo increase if
the geology becomes more complicated, unpredictable
and variable (Müller 1978).
34
Vol. 10 No. 2 2003
< 25MPa, then the rock will break more easily along
Figure 6. If the bedding planes strike at an angle material bridges in the rock => less overbreak,
between >0 <90° with respect to tunnel axis then especially if the degree of separation is low. However,
the rock will break more easily on the left side, if the rock strength is low the overbreak is low and the
thus here less charge is needed. risk of cave-ins or secondary-overbreak rises.
Overbreak and primary stress > 25MPa, then a lot of explosives are needed to break
The height of the in situ stress has little influence on the rock along material bridges but this will only
the overbreak but the relation between major and minor increase the
stress and the stress condition with respect to the rock degree of separation and cause more overbreak, the
strength does. If the stresses are anisotropic (s3/s1>2), more if the degree of loosing up and the initial degree
a condition that prevails usually in shallow tunnels, the of separation are high (Müller 1978). These effects are
tendency towards: shown in figure 11.
- larger overbreak
- larger secondary overbreak Overbreak and water
- asymmetric excavations Water affects especially secondary overbreak. Water:
increases with respect to isotropic stress (s3/s1<2) of- - reduces the strength of the infill material of the
ten found at greater depths. In the latter case the discontinuities
stresses work from all sides on the tunnel and the rock - generates seepage forces
blocks can form an irregular arch, leading to less - exerts hydrostatic stress
overbreak (Müller 1978). By these processes the fall of friable and small rock
fragments into the excavation accelerates to such an
extent that even with swift working and suitable support
unavoidable overbreak is produced. In loosened up
rock masses with small a discontinuity spacing, high
degree of separation of the rock blocks and a
lubricating discontinuity infill, the overbreak can reach
a value surpassing the overbreak that would have
occurred under dry conditions several times (Müller
1978).
35
Ingeokring Newsletter
36
Vol. 10 No. 2 2003
Figure 11. In this figure a summary is given of the coupling between: the number of discontinuity families,
thickness of the rock blocks, apparent dip and strength of the rock matrix. With the aid of this overview different
qualitative observations can be made:
- If the apparent dip rotates from near horizontal to vertical the amount and position of the overbreak changes.
The largest overbreak can be found in steeply inclined layers.
- If the strength of the rock mass increases and the apparent dip is near horizontal there will be no overbreak in
tunnels with a rectangular form
- If the strength of the rock matrix decreases to zero, in all cases cave-in will result.
- If the number of discontinuity families increases and the strength of the rock matrix is not too weak the overbreak
is generally small.
- etc.
37
Ingeokring Newsletter
To quantify this difference in overbreak shown in figure i) at a very large spacing between two parallel
12 one needs three parameters: discontinuities of 1 family the overbreak = 0 because
the spacing is larger than the diameter of the tunnel
i) discontinuity frequency of a discontinuity family ii) at a very close discontinuity spacing the overbreak
(figure 13). is near zero because now one deals more with a soil
than with a rock, in which as discussed before the
overbreak is negligible, the cave-in risk, however is
increased.
38
Vol. 10 No. 2 2003
39
Ingeokring Newsletter
7 Abbreviations
MBR modified basic RMR
RMR rock mass rating
1/4ldr average length of one discontinuity outcrop
to the other end in the excavated space (in
2D) divided by 4
x = xrα = Volumetric share of discontinuity planes
of discontinuity family α (m²/m³) or short: the
degree of separation of rock blocks from the
Figure 17. Same discontinuity orientation, other
rock mass matrix
tunnel orientation, much more overbreak deter-
mined using a simple spreadsheet TunnelDip.
8 Literature
6 Conclusion AFTES 2003. Recommandations relatives à la
- It is a mistake to believe that if the RMR increases the caractérisation des massifs rocheux utile à l’étude et à
overbreak decreases at all times or vice versa la réalisation des ouvrages souterrains. Tunnels et
- Rock masses with a low RMR are prone to cave-in, ouvrages souterrains. N° 177. Mai/Juin 2003.
not to overbreak BIENIAWSKI, Z.T. (1984) Rock mechanics design in
- Not all the distance between the circumference of the mining and tunnelling. A.A. Balkema. Rotterdam.
excavation and the planned excavation profile is BOUVARD-LECOANET, A., COLOMBET, G.,
overbreak. It can be either an instantaneous “genuine” ESTEULLE, F. (1988) Ouvrages Souterrains. Presse de
overbreak, secondary overbreak or cave-in or rock burst l’école nationale des Ponts et Chaussées. Paris.
- Of all excavation techniques blasting produces most BRÄUNER, G. (1981) Gebirgsdruck und Gebirgsschläge.
overbreak. 2. Auflage. Verlag Glückauf.
- Overbreak is influenced by the presence of water, in GOODMAN, R.E., SHI, G-H. (1985) Block theory and
situ stress, rock strength, layer thickness, number of its application to rock engineering. Prentice-Hall.
discontinuity families, persistency of the JOHANSEN, J., MATHIESEN, C.F. (2000) Modern
discontinuities, orientation of the discontinuities with trends in Tunnelling and Blast Design. Balkema.
respect to the tunnel, infill etc. Most of these elements Rotterdam.
are coupled. These effects are summarised in figure 11. KOLYMBAS, D. (1998) Geotechnik - Tunnelbau und
- Overbreak is a 3D phenomenon and the orientations Tunnelmechanik. Springer.
of the discontinuities should be analysed in relation to MÜLLER L. (1958) Geomechanische Auswertung
the orientation of the tunnel. gefügekundlicher Details. Geologie und Bauwesen.
Jahrgang 24. H. 1. S.4.
Rules of thumb: MÜLLER L. (1959) Der Mehrausbruch in Tunneln und
- Average overbreak in rock masses with loose (x=1) Stollen. Sonderabdruck aus Jahrgang 24, Heft 3-4, 1955,
rock blocks with cubic form, high strength rock matrix, Geologie und Bauwesen.
is approximately equal to the average discontinuity MÜLLER L. (1978) Der Felsbau. Dritter Band. Enke
spacing Verlag. Stuttgart.
- Average overbreak in rock masses with loose (x=1) PACHER, F (1959) Kenziffern des Flächengefüges.
rock blocks with cubic form, low strength rock matrix, Geologie und Bauwesen. Vol. 24. Nr 3/4.
is approximately equal to half the average discontinuity PRINZ (1997) Abriss der Ingenieurgeologie. Enke Verlag
spacing Stuttgart.
40
Vol. 10 No. 2 2003
41