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Abstract
During rock cutter dredging for the trench for the Sydney
Harbour Tunnel, partially cut in rock of the Hawkesbury
Sandstone, tool consumption data were obtained and compared with the wear value F developed by Schimazek, and
with the cutting and abrasive wear rates as determined by the
Newcastle-upon-Tyne cuttability tests. It appears that while
the F-values correlate well with actual tool consumption,
correlations with laboratory cutting and abrasion tests are not
always significant.
The F-value is obtained from a number of easily measured
rock parameters (Brazilian tensile strength, mineralogical
composition and grain size.) Use of the F-value is considered
advantageous compared to laboratory tests which measure the
abrasivity of rock directly because it is difficult to perform
sufficient abrasivity tests to cover the variability inherent in a
rock mass and it is impossible to perform laboratory tests that
are truly representative of the actual cutting and abrasion
mechanisms operating. Site investigations for rock dredging
projects would be improved if systematic determinations of
the F-values were carried out. This would help to improve the
'educated guesses' of tool consumption currently practised
during the tendering stages of a dredging project. Accurate
prediction, however, will always necessitate a trial dredge
excavation to calibrate and to check the appropriateness of
the abrasivity parameters chosen.
Introduction
One of the major problems in rock dredging projects is
the correct prediction of tool consumption. During the
tendering stage, potential tool consumption is a
significant factor in the estimation of contractors'
costs. As rock dredging is a relatively recent development it can profit from the experience gained in
mechanical tunnel excavation.
Large parts of the Sydney area, including the
Harbour, are underlain by the Hawkesbury Sandstone,
a weak to moderately strong quartz-rich rock. The
Hawkesbury Sandstone is of Triassic age and up to
290m thick. Major tunnelling projects have been
carried out in this rock and increasingly use has been
made of mechanical excavation methods. For the two
recent projects carried out in the Sydney region, the
Sydney Harbour Tunnel and the Sydney Ocean
P. N. W.
VERHOEF
SUBURBAN SYDNEY
(J
0
TH HEAD OUTFALL
SYDNEY
HARBOUR
BONDI
OUTFALL
SYDNEY
HARBOUR
TUNNEL
MALABAR OUTFALL
BAY
(J
,......,
5
LUCAS
HEIGHTS
Q..
KM
~
FIG. 1. L o c a t i o n m a p .
Qtz x 0 x BTS
100
(N/mm)
(1)
Fractional
(%)
Standard
deviation
58.4
13.0
3.5
24.2
2.8
7.1
8.4
4.4
2.37
16.1
0.13
3.5
(%)
values measured. The variability of unconfined compressive strength values of the Hawkesbury Sandstone
is about 35%, which is rather high for sandstones (a
value of 20% is common; cf. Roxborough 1987). Pells
gives correlations between axial point load strength
Is axia~ and UCS and also between the Brazilian tensile
strength (BTS) and UCS. Based on data from Ferry
(1983) he concluded the UCS was 20 times the Is axi~
and UCS = 13 BTS (modal values; range: 12 to 15
BTS). From these data the correlation between point
load strength and Brazilian tensile strength (necessary
for this study to estimate F-values from the borehole
records) has been derived as: BTS = 1.5 (1.3 to 1.7)
S axial"
P. N. W. V E R H O E F
TABLE 2. Summary of geotechnical properties of the Hawkesbury Sandstone at the Sydney Harbour Tunnel site
Test
UCS dry (MPa)
UCS sat. (MPa)
BTS dry (MPa)
BTS sat. (MPa)
Ductility number UCS/BTS
Qtz (%)
Qtz eq (%)
SE dry (MJ/m 3)
SE sat. (MJ/m 3)
Cutting wear dry (mg/m)
Cutting wear sat. (mg/m)
Abr. wear dry (mg/m)
Abr. wear sat. (mg/m)
Cerchar Abr. dry (0.1 mm)
Cerchar Abr. sat. (0.1 mm)
F-value sat. (N/mm)
Northern Tunnels
No (n) Mean (Range)
70
55
45
--10
-10
3
4
-9
-19
---
42.9 (16.2-93)
22.8 (4-46)
4.6 (1.5-9.8)
70 (40-82)
10.6 (8.3-13.9)
8.5 (6.8-10.7)
1.70 (1.44-2.11)
1.14 (0.57-1.80)
4.8 (2.8-8.7)
Southern Tunnels
No (n) Mean (Range)
18
14
16
--10
-10
---9
-6
6
--
42.6 (29-67)
21.0 (8-40)
3.6 (1.4-6.0)
76 (66-80)
11.6 (10.4-13.9)
1.13 (1.0-1.2)
4.0 (2.0-5.7)
4.0 (2.0-6.3)
Over-water boreholes
No (n) Mean (Range)
-26
-26
6
13
13
-4
4
-6
--10
22.6 (9.0-34.6)
3.3 (1.4-5.4)
9.2 (7.8-10.2)
60 (19-82)
62 (24-83)
11.3 (10.0-12.3)
4.25 (3.83-4.98)
0.87 (0.11-1.15)
0.61 (0.03-1.07)
Sources: Pells (1990); Coffey & Partners SI reports (1987). F-values calculated from data SI report.
T h e core c u t t i n g t e s t
In the late 1960s a cutting test was developed by
Roxborough and co-workers at the Mining Engineering Department of the University of Newcastle-uponTyne (UK). This test aimed to assemble information
on the relevant parameters which might describe the
performance of an excavation machine in a rock mass.
The cutting test was developed to determine the four
machine performance parameters on core samples.
The test is standardized to exclude machine design
influences and consists of cutting a groove 12.7mm
wide and 5 mm deep along the surface length of a rock
core sample parallel to its long axis (Fig. 2). The core
is then rotated by 180 to make a similar parallel cut.
If the core has not been broken it may be rotated
ABRASIVITY
OF H A W K E S B U R Y
DYNAMOMETER[~
PICK HOLDER ~ IDIRECTION
CARBIDE INSERTa-~--~ OF CUTTING
....
~ ..........
12.7
...~"
rnm
e"
CORE SAMPLE
Sydney)
cutting speed 105 mm/s
cutting depth 5 mm
cutting width 12.7 mm
insert: tungsten carbide 12.7mm wide, front rake angle 0,
back clearance angle 5
Material properties: grade B23. Composition: Co 9.5%, WC
90.5%. Grain size 6 ~tm, density I4.59 _+ 0.6 Mg/m 3, hardness
HV2o = 1225kgf/mm 2.
rock core: diameter larger than 50 mm, length preferably 200250 mm.
SANDSTONE
(2)
where SE = specific energy; UCS = unconfined compressive strength and C is a constant found by linear
regression and dependent on rock type. This relationship allows cutting tests to be used and advantage
taken of the more numerous data on UCS to make an
analysis of the variability of strength in the rock mass
to be excavated, which can be applied to the
excavation performance prediction. According to Roxborough (1987), equation (2) is basically sound, but
would apply only to machines which have a constant
depth of cut.
Roxborough considers the wear of the carbide
inserts in the cutting test to be attributable to two
sources, namely abrasion and brittle chipping of the
metal. The latter mainly occurs when rock of high
strength is tested. The impact chipping usually takes
place at the cutting edge and corners of the inserts in
the cutting test. Significant chipping relates to the
magnitude of the peak component forces measured
during the test.
10
P. N. W. VERHOEF
LATHE
CHUCK DIRECTION
OF FEED
TOOLHOLDER
CARBIDE
INSERT
Mohs' H.
(--)
Vicker's H.
(kgf/mm 2)
Rosiwal H.
(--)
Talc
Gypsum
Calcite
Fluorite
Apatite
Window glass
Orthoclase
Quartz
Topaz
Corundum
1
2
3
4
5
5.5
6
7
8
9
20
50
125
130
550
600
750
1000
1850
2300
0.25
1.0
3.8
4.2
5.4
15
31
100
146
833
Feldspars
Clay & micas
Carbonates
----
----
3l
4
3
ABRASIVITY
OF H A W K E S B U R Y
11
SANDSTONE
TABLE 5. Results of cutting and abrasion tests and F-value determination on aged samples from the over-water
boreholes of Sydney Harbour and from a block sample taken at Lucas Heights disposal site
Specific Cutting Abrasive
BTS
Cutting force
Normal force
energy
wear
wear
F-value
(MPa) Mean (kN) Peak (kN) Mean (kN) Peak (kN) (MJ/m 3) (mg/m) (mg/m) (N/mm)
Core
Number Description
3001
3002
3201
3211
3212
3213
3233
3241
3252
3261
3262
3281
sl.w. SST
fine gr. SST
med.gr. SST
med.gr. SST
sl.w. med.gr. SST
med.gr. SST
med.gr. SST
SST
SST
sl.w. SST
SST
Siltstone
0.4
2.7
2.3
0.5
0.4
2.0
3.0
0.9
2.3
0.3
1.3
1.9
0.27
0.36
0.29
0.27
0.29
0.50
0.68
0.25
0.58
0.20
0.37
0.55
0.40
0.79
0.65
0.43
0.38
0.79
1.39
0.37
1.05
0.27
0.56
0.77
0.12
0.31
0.40
0.07
0.11
0.27
0.57
0.13
0.54
0.07
0.13
0.06
0.18
0.55
0.57
0.10
0.12
0.43
0.89
0.16
0.75
0.10
0.20
0.16
2.28
4.39
-2.55
3.13
8.53
10.09
3.52
9.23
2.79
4.65
--
1.61
2.52
2.53
1.35
0.32
1.46
1.80
1.00
-0.41
0.69
0.83
0.59
0.32
0.88
0.40
-0.36
-0.49
1.00
0.51
0.63
--
0.12
0.09
0.67
0.12
0.08
0.61
1.03
0.17
0.52
0.07
0.28
0.08
1.0
0.3
29
14
0.26
0.06
21
14
0.36
0.08
22
14
0.13
0.04
34
14
0.15
0.05
30
14
3.00
0.72
24
12
2.84
1.23
43
14
0.43
--2
0.19
0.09
48
13
4.:t
Ec~ 3.51
Cutting wear
v
3
2.5-
1.5
o
Abrasive wear
0.5 ~
0
0.2
0.4
0.6
0.8
Estimated F-value (N/mm)
12
P.N.W.
VERHOEF
TABLE 6. Estimate of average strength, quartz content and grain size for the length of borehole actually excavated
2.5E
E
Length
(m)
Is
(MPa)
BTS(est)
(MPa)
7.2
5.2
1.6
13.0
1.8
4.0
0.5
5.0
2.7
2.9
4.0
0.6
0.3
0.3
0.2
0.3
0.3
0.9
0.4
0.4
0.3
0.5
0.5
1.0
0.8
1.4
0.7
1.5
1.2
2.1
1.1
gg
"~ 1.5-
1t
o'.1
0'.2
o'.8
0'.9
Quartz
vot. %
Size
(ram)
F-mass
N/mm)
65
0. I0
60
0.10
60
0.10
70
0.35
68
0.35
80
0.50
extremely weathered rock
77
0.60
67
0.60
60
0.40
71
0.50
0.06
0.02
0.02
0.07
0.12
0.18
0.69
0.48
0.50
0.37
Q.
o.1
0.2
0.3
0.4
ols
//~
329
a0,
13
]Note that the cuttability test has also been carried out on
these samples in Newcastle-upon-Tyne (England). Only
cutting wear rate was determined.
\~
1~
r" ~
""
"
"
"
%X
-5
"
,,
EZ~]
N
329
~'~ ='~e
'"5'"
.,
o',,qu'wai~N'~
.
or~ d a y ~
eoce,'=~ zo~
30rn
14
P. N.
W.
VERHOEF
TABLE 7. Summary of geotechnical data for the Malabar Decline Tunnel (from Lowe & McQueen 1988)
SSST type
1
2
3
4
5
Nwp.sst
Nwp.siltst
Vol.%
mass
39
*
*
7
1.5
23
74
Grain
size (mm) Qtz %
0.30
0.30
0.50
0.60
0.40
0.13
0.09
UCS
(MPa)
63
78
78
76
57
60
45
32.0
45.0
45.0
55.0
-38.0
60.0
2.5
3.5
3.5
4.2
-2.9
4.6
0.47
0.81
1.35
1.93
-0.23
0.19
1.09
2.19
2.45
1.30
2.35
0.42
0.26
AM75
(pps/m 3)
AM100
(pps/m 3)
0.302
1.189
1.189
-----
0.866
0.950
0.950
--0.535
0.206
2.16
3.13
4.10
3.93
3.07
1.30
0.92
* Type 2 & 3 make up 50% of the rock mass excavated; they could not be distinguished in the tunnel
A
nwp sst
~5-
sstl
sst2
sst3
SSt4
1.2~
nwp siltst
4"
~3-
o8~
Cutting wear
E 0.6~
~ Abrasive wear
o12 0'.4
~2
~3
1-
1.
0'.6 0'.8
i
1'.2 1'.4
Estimated F-value (N/mm)
1'.6
~1
1'.8
nwp sst
nwp siltst
-~ 0.42
o2~
AM 75
FIG. 8. Estimated F-values of the typical Hawkesbury Sandstone types (SST 1-4) and Newport Sandstone and Siltstone
compared with the wear rates determined with the laboratory
cutting and abrasion test. Malabar Outfall Decline (Lowe &
McQueen 1988). See text for discussion.
0.2
014
016
018
1
1.2
Estimated F-value (N/mm)
1.4
1.6
1.8
Discussion
This study has attempted to relate laboratory or
in situ derived rock parameters to actual excavation
performance. Despite the fact that state-of-the art site
15
lrnu
4.
Vl Model test with simple
testbodies
mml
16
P. N. W. VERHOEF
Conclusion
For the first time relatively accurate tool consumption
data of a rock cutter suction dredger could be studied.
In this case the wear factor F derived by Schimazek,
related reasonably well with tool consumption.
Another method commonly applied in rock tunnelling,
the cutting wear and abrasive wear rates derived from
the Newcastle-upon-Tyne cutting and abrasion tests,
did not correlate with the tool consumption of the rock
cutting dredger. Both F-value and the cutting and
abrasion wear rates were related to the tool consumption of the roadheaders used to excavate the Malabar
Outfall Decline in Sydney.
The amount of cutting or abrasion tests which can
be performed on rock cores will always be limited. In
site investigation practice, therefore, use should be
made of rock index tests which relate to cutting
performance and abrasive wear. Such tests include
UCS, BTS, I s, thin section examination (mineralogy,
microscopic structure, grain shape, grain size), Emodulus and so on. The results of this paper indicate
that further study into the use of wear factors
combining index tests, such as the F-value, is warranted. For wear prediction, it is necessary to calibrate
the results of abrasion tests or wear factors against a
trial excavation with a real cutting machine at the site.
ACKNOWLEDGEMENTS. This research is supported by the
Technology Foundation (STW, The Netherlands). Andr6
Veldstra, Kevin Green and John Watson of the Westham
Dredging Company Pry Ltd, Sydney are thanked for the
confidence and enthusiasm with which the experience and
reports on the Sydney Harbour dredging with the Kunara
rock cutter suction dredger were entrusted to me. Likewise,
Coffey Partners International Pty Ltd (Philip Pells, Patrick
List of notations
CV = coefficient of variation = s/x x 100 (%)
s = standard deviation
x = average (weighted mean)
UCS = Unconfined compressive strength (MPa)
BTS = Brazilian tensile strength (MPa)
Is a~ial = axial Point load strength (MPa)
TS = Tensile strength (MPa)
F = Schimazek's wear factor (N/mm; equation (1))
Eq Qtz = Equivalent quartz volume percentage (%);
this is determined by adding the Rosiwal hardness with
respect to quartz ( = 100) of the minerals comprising
the rock, considering the volume percentage taken by
those minerals
, = grain size (mm)
SE = specific energy (N/m2; MJ/m 3)
F c = specific cutting force (N/m)
/7, = specific normal force (N/m)
Rsq = regression coefficient squared
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SANDSTONE