Geomechanical evaluation of large excavations at the New Level … · 2020. 3. 25. · Caving 2014, Santiago, Chile 486 Geomechanical evaluation of large excavations at the New Level

Caving 2014, Santiago, Chile

486

Geomechanical evaluation of large excavations at the New Level Mine - El Teniente

E Hormazabal SRK Consulting, ChileJ Pereira Codelco,ChileG Barindelli, Codelco, ChileR Alvarez SRK Consulting, Chile

Abstract

The New Level Mine is a 130.000 tpd panel caving project set to start in 2017 at the El Teniente mine.VP-NNM CODELCO (Vice-President Office of the New Level Mine) is currently finishing a detailed engineering design of the underground mine. The evaluation considers, the design of the crusher cavern Nº1 located in the Braden Pipe, which is a waste rock chimney located in the central part of the ore body. A geo-mechanical study has been carried out to evaluate the stability of the planned infrastructure and to provide recommendations about the design of underground caverns and galleries, including support. As part of this study, empirical methods, two-dimensional and three-dimensional continuum models have been developed and applied to evaluate the influence of the high stresses and different geotechnical units, on the mechanical response of the excavation. This paper introduces general aspects of the New Mine Level underground project and discusses in particular geo-mechanical analyses and design carried out to evaluate stability and support of some of the large excavations involved in the project.

1 Introduction

ElTenientecoppermineislocatedinthecentralpartofChile,CachapoalProvince,VIRegion,about50kmNEfromRancaguaCityandabout70kmS-SEfromSantiagoCity(Figure1).

At the ElTenientemine, the copper andmolybdenummineralization occurs in andesites, diorites andhydrothermalbrecciassurroundingapipeofhydrothermalbrecciascalledBradenPipeandlocatedinthecentralpartoftheorebody.TheBradenPipehastheshapeofaninvertedcone,withadiameterof1,200matsurfaceandaverticalextentofmorethan3000m.TheBradenbrecciasarewasterock.Therefore,thedifferentproductivesectorsofElTenienteminearesurroundstheBradenPipe,andthemaininfrastructureandaccessshaftsarelocatedinsidethepipe(Pereiraetal.2003).

TheNewMineLevelisa130,000tpdpanelcavingprojectsettostartin2017attheElTenientemine.Theminingprojectconsidersusing thepanelcavingmethod tominecopperore.TheVice-PresidentOfficeof theNewLevelMine(VPNNM)hasfinishedadetailedengineeringevaluationof theproject,whichconsiderstheconstructionandoperationofseveralminingunitstobeoperatedindependentlyfromeachother.

Amongthemostimportantelementsofthepermanentmininginfrastructuretobedesignedandconstructedfirstarelargecrushercaverns,designatedasSChNº1,SChNº2andSChNº3caverns.Thesecavernsarerequiredtoreducetheoresizefromtheoperationminingsectorsthatwillguaranteethecontinuedoperationforaperiodof50yearsormore.

The objective of this paper is to present general aspects of the design of one of the crusher chambers(SChNº1cavern),includingtheinterpretationofgeotechnicalsiteinvestigationdataanduseofempirical,analyticalandnumericalmethodstodeterminetheappropriatepermanentsupporttobeconsideredforthiscavern.

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Figure 1 El Teniente mine location in relation to Santiago and Rancagua cities in the central part of Chile

2 Geotechnical characterization

Until the early 90’s the Braden Pipe was considered an almost homogeneous body, composed by aconcrete-likerockcalledBradenbrecciaand,initsperimeter,byabrecciacontainingcoarserrockblocks,calledMarginalBreccia(Pereiraetal.2003).However,thebehaviorobservedatdifferentsectorsoftheBradenPipeindicateddifferencesthatcouldonlybeexplainedbythepresenceofdifferentbrecciatypes.Therefore,acomprehensivegeologicalcharacterizationoftheBradenBrecciawasdevelopedinthepast,whichallowedamuchmoredetailedzonationoftheBradenPipeandthedefinitionofseveralbrecciatypes(Floody2000&Karzulovic2000).Themainbrecciatypesarethefollowing:

a) SericiteBreccia–thisbrecciaconstitutesamajorityofthepipe.

b) ChloriteBreccia–foundprimarilyinthesouthernportionofthepipe.

c) TourmalineBreccia–characterizedbylargeclastsandvein-likeoccurrence.

d) MarginalBreccia–hardbrecciaattheboundaryofthepipe.

For eachof thesebreccias, there isvariability in the sizeof the fragmentsor clasts and in themineralconstituentsandalterationof thematrixcement. In theBradenSericiteBreccia, thereappears tobeaneffectoftheratioofSericite/Quartzcontentinthecementtothecompressivestrengthofrocksamples.Figure2representsaplanviewcontainingthelocationofcrushercavernNº1andshowingthedifferentgeotechnicalunitsasinterpretedfromtheavailablegeologicalandgeotechnicalinformationfromthesite.Themain geotechnical units are the SericiteBradenBreccia unit (BBS),ChloriteBradenBreccia unit(BBC),TourmalineBradenBrecciaunit(BBT)andtheDaciticPorphyryunit(PDAC).


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Figure 2 Plan view at mine level 1790 of the Crusher Chamber SCh Nº1 location, indicating the main geotechnical units as interpreted from available geotechnical information (taken from SRK, 2014)

Ingeneral,theBBS,BBCandBBTunitsarerockmassesofgoodqualitywithaBieniawski’sRMRvaluelargerthan70;fordetailsabouttheBieniaswki’sclassificationsystemseeBieniaswki(1989).Forexample,Figure3showsaphotographofsomerepresentativecoresofthemaingeotechnicalunitsatthesitelocationofSChNº1;solidandintactcores,fewjoints,lowfracturing,acommoncharacteristicoftheBBS,BBCandBBTunitswhichtranslatesintogoodqualityrockmass,canbeobservedinthephotograph.

Aspartofthegeotechnicalcharacterization,adatabasewithgeotechnicalinformationfromsiteinvestigations(geotechnicalboreholes)atElTenienteMinewasanalyzed;thisdatabasewascreatedandismaintainedbyVP-NNM(VCP2010aandVCP2010b).Inparticular,valuesofgeotechnicalparametersdescribingthequalityoftherockmass,includingFractureFrequency(FF),RockQualityDesignation(RQD),IntactRockStrength(IRS)andBieniawski’sRockMassRating(RMRB).

BasedongeotechnicalwindowmappingofdriftsandgalleriesclosetothesitelocationoftheSChNº1,acharacterizationoftherockmassqualityintermsoftheGeologicalStrengthIndex(GSI)andBarton’sQ-systemvalueswererevised(fordetailsaboutthesesystemssee,Hoek,1994,Hoek&Brown1997,Hoeketal.2002;Bartonetal.1974;GrimstanandBarton1993;Barton,2002).Theresultingrangeof thesevalues,expectedtobeencounteredduringexcavationoftheSChNº1,isshowninTable1.

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a) b)

c) d) Figure 3 Cores of the main geotechnical units at the site location of the SCh Nº1.a) BBS. b) BBC. c) BBT and

d) PDAC

Froma structural geologypoint of view, the sitewhere the crusher cavernwill be emplaced has beenreferredtoas‘BrechaBradenMarginal’(or‘BradenBrecciaMarginalStructuralDomain’).Analysisoftheavailablegeologicalinformationhasrevealedtheexistenceofthreesystemsofminorfaultsandtwojointssets.Table2summarizestheorientationofthesestructuralsystems.

Thein-situstressstateconsideredforthedesignofthecrushercavernSChNº1wasobtainedfromover-coringtestsperformedatXC-01-ASsiteNº5(undercuttinglevel1880).Table3summarizesthein-situstressfieldatcrushercavernlocation.

Values of strength and deformability for all the geotechnical units were computed according to thegeneralizedHoek-Brownfailurecriterion(Hoeketal.2002;Hoek&Diederichs,2006)andfollowingsomespecificrecommendationstotheElTenienteminebyDiederichs(2013).Themechanicalparameterswerederivedfromlaboratoryunconfined,triaxialandtensiletestingofrocksamplesandestimationsofvaluesofGeologicalStrengthIndexfromgeotechnicalwindowmappinginthemainaccesstunnel(TAP),driftsandgalleriesnexttotheSChNº1location.


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Table 1 Classification systems values of the rock mass at the SCh Nº1 location

UGTB RQD (%) RMRB89 Q’ GSI

BBS 70–100(80) 60–92(72) 1.2–250(14) 56–90(69)

BBC 94–100(98) 70–85(77) 40–100(70) 63–82(72)BBT 80–100(90) 72–82(75) 5–71(23) 61–80(73)

PDAC 79–100(89) N/I N/I 65–86(72)

():Meanvalues. RQD:RockQualityDesignation(Deere,1963).Q’:modifiedBarton’sQ-system(Jw/SRF=1). GSI:GeologicalStrengthIndex(Hoek,1994).RMRB89:RockMassClassificationsystem(Bieniawski,1989). N/I:Noavailableinformation.

Table 2 Structures at the site location of the SCh Nº1 (VCP, 2010b)

SETSMinor Faults Joints

Dip/DipDir Nºdata Dip/DipDir Nºdata

S1 84°/125° 12 75°/324° 34S2 83°/035° 7 35°/010° 21

S3 76°/172° 6

Table 3 In situ stress field representative of the site location of the SCh Nº1

Principal Stresses Magnitud (MPa) Bearing (°) Plunge (°)

σ1 50.73 344.0 -7.8σ2 33.11 75.5 -10.7σ3 26.50 218.6 -76.7

Table3summarizesthemechanicalparametersfortherockmass,forthethreegeotechnicalunitsanalyzedwiththeHoek-Brownmethod.[InTable4,miistheHoek-Brownintactrockparameter;σciisunconfinedcompressivestrengthoftheintactrock;γ is thespecificgravityoftheintactrock;Ei is themodulusofdeformationoftheintactrock;GSIistheGeologicalStrengthIndex;mb,sandaareHoek-Brownrockmassparameters;andERMandνarethedeformationmodulusandPoisson’sratiooftherockmass,respectively.

Tocalibrateandvalidatethestressfieldandrockmasspropertiessomeback-analysesweredonetocheckifthebehaviorpredictedusingthesepropertiesagreeswiththeobservedbehavior.Two-dimensionalplane-strainmodelswere constructed fordifferent sectionswithdifferentgeotechnicalunits andorientations,involvingsectionsforwhichoverbreakweremeasured.ThemodelsweredevelopedusingthefiniteelementsoftwarePhase2(Rocscience2009),whichallowsanalysisofexcavationsinplane-strainconditions.

Figure5showstheresultsfromafiniteelementback-analysisofoneofthesectorsconsideredfortheTAPtunnelinChloriteBradenBrecciaunit.Thelightgrayzoneintheroofindicatesfailurebytensionand/oryielding,andtheblackcurveshowsthemeasuredoverbreakeach5malongthetunnelaxisinthisparticularsector.Differenttunnelorientationswithinthesamegeotechnicalunitwereconsideredforthisanalysis.

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TheseresultsindicatethatthegeomechanicalpropertiesofthedifferenttypeofbrecciaspresentedinTable3areagoodestimateoftherockmasspropertiesforthesetypesofmassiverock.

Table 4. Summary of rock mass strength and deformability parameters for the different geotechnical units according to the generalized Hoek-Brown method —see Hoek et al., 2002; Hoek & Diederichs, 2006.

UGTBγ GSI σci

miσt Em

vc φ

(KN/m3) Mean value (MPa) (MPa) (GPa) (kPa) (°)

BBS 25.9 70 81.1 11.00,768

29.31 0,207,336 34

0,384* 5,180* 33*

BBC 26.6 72 77.4 12.00,782

25.60 0,207,578 35

0,391* 5,350* 34*

BBT 25.4 70 100.0 8.01,302

23.01 0,207,448 33

0,651* 5,260 32*

PDAC 25.8 73 144.5 28.50,662

34.55 0,2012,078 48

0,331* 8,500 43*

(*)UbiquitouspropertiesconsidersJennings(1970)criterionwithak=0.3.

3 Support requirements for the crusher cavern according to empirical methods

Figure6showsanisometricviewforthecrushercavernthatconsidersmainlythedumpingchamber,apronfeeder,crusherchamber,mainsilo,mainfeederandlift.

BasedonthelargeexperienceofexcavationoftunnelsandcavernsindifferentrockunitsatElTenientemine,usingthetraditionalmethodoffullfaceblastinganappropriate(temporary)supportconsistinginrockbolts,steelwiremeshandshotcretewereproposedfor thecavern(SGM-I-011/2006,VCP,2010c,amongothers).

Apreliminaryestimationofthequantityofpermanentsupporttouseduringexcavationwasdoneusingempiricalmethods.ThemethodsconsideredwerethosedescribedbyBarton(1974),Palmström&Nilsen(2000),Unal(1983),Hoek(2007)andHönish(1985),amongothers.Thesemethodsgiveguidelinesforpermanentsupportrequirementbasedonseveralofthegeotechnicalindexesdiscussedearlieron,suchasvaluesofRQD,QandRMR.Table5summarizesthecharacteristicsoftherecommendedsupportforSChNº1accordingtotheabovementionedmethods.

Duetotheintrinsiclimitationsoftheempiricalmethods(particularlyinregardtotheassumptionofisotropyofstressesandrockmasscontinuity),thesemethodswereusedasafirststepinselectingasupporttypefor theSCHNº1; the actual verificationof theproposed supportwas carriedout using tri-dimensionalnumericalmodelsasdescribedinthenextsections,whichamongothers,allowedincorporationofseveralgeotechnicalunitsexistingintherockmassandinsitustressfieldshowedinTable3.

Theacceptabilitycriterionforpermanentsupportwasestablishedbasedonfactorsofsafetywithrespecttofailure(incompression)ofthesupport.Basedontypesofsupportsusedandsuggestedlengthspansfromempiricalmethods,factorofsafetyof2.0forpermanentsupport(forstaticloadinganddryground)werejudgedappropriate.Inthisregard,aliteraturesurveydidnotrevealtheexistenceofestablishedrulesforfactorsofsafetytoconsiderforcavernoflargedimensions(asthecaseoftheSChNº1).Forexample,Hoek


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(2007),suggestanacceptabledesignisachievedwhennumericalmodelsindicatethattheextentoffailurehasbeencontrolledbyinstalledsupport,thatthesupportisnotoverstressedandthatthedisplacementsintherockmassstabilize.Pariseau(2007)suggeststhattheloadactingonthesupportforlargeexcavationshouldnotexceedhalfthevalueofthestrengthofthesupportmaterialof(shotcreteorconcrete)—i.e.,thiswouldmeanconsideringafactorofsafetyofatleast2.Forwedgeandblocksfailuresinalargecaverndesignafactorofsafetyof1.5to2.0iscommonlyusedasacceptabilitycriteria(Hoek,2007).

Figure 4 Results from a finite element back-analysis of one of the sectors considered for the TAP tunnel in BBT unit. The light gray zone surrounding the tunnel section indicates failure by tension and/or shear, and the

blue curves show the measured overbreak each 5 m along the tunnel axis in this particular sector

Figure 5 Infrastructure considered for the geomechanical analysis in relation with the main geotechnical units

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Table 5. Summary of preliminary permanent support recommended for the SCh Nº1 as derived from application of empirical methods.

Excavation B × H (m) Sector

Barton (1974) Palmstrom & Nilsen

(2000)

Hoek (2007)

Unal (1983) Hönisch (1985)

PatternLc (m)

Lc (m) Shotcrete Thickness (mm)

BBS BBC Lb (m) Lb / Lc (m) BBS BBC BBS BBC

DumpingChamber 24,3×8,8

Roof 1,3x1,3to1,7x1,7m;Shotcrete

120-150mm

1,7x1,7to2,1x2,1m;Shotcrete

50-120mm

7.5–8.1 5.8 5.6/9.74.1–14.2 6.3–11.2

100-150 100a150

Walls 2.4–2.6 4.4 N/A 50(min) 50(min)

StorageHooper 14,3×21,2 Walls


120-150mm

1,7x1,7to2,1x2,1m;Shotcrete50-90mm

5.7–6.2 4.0 5.2/7.4 3.8–12.5 6.0–9.8 50-150 50-100

ApronFeeder 9,2×10,8


90-120mm


2.8–3.1 3.2 N/A2.1–6.2 2.8–5.0

50(min) 50(min)

Walls 2.9–3.2 3.0 3.6/3.8 50-100 50(min)

CrusherChamber 16,8×43,6


150-250mm


90-120mm

5.2–5.6 4.4 4.5/6.7N/A N/A

50-150 50-100

Walls 11.7–12.7 5.3 8.5/15.3 150-200 150-200

LoadingHooper 17,0 Walls


90-150mm


5.2–5.7 4.6 4.6/6.8 3.1–10.0 4.5–7.9 50-150 50-100

B: SectionLength. H: SectionHeight. Lb: BoltLength. Lc: CableLength.

4 Three-dimensional numerical analysis of the crusher cavern excavation

Three-dimensional models implemented in the finite difference software FLAC3D (Itasca 2007) wereconstructed for the main infrastructure of the SCh Nº1 (see Figure 6). The three-dimensional modelsincorporated only the permanent support (with characteristics described in the next section) and theproposedexcavationadvance,coincidingwiththeminingdesignexcavation.

Thepurposeofthismodelwastoaccountfortheactualthree-dimensionalnatureoftheexcavationproblem;themodelallowedwalldisplacementsonthelargeexcavation,extentoftheplastic-failurezonearoundthewallsofthelargeexcavations,andtheperformanceofthepermanentsupporttobequantified—i.e.,theverificationoftheacceptabilitycriteriaintermsoffactorofsafetydescribedinSection3.Ingeneral,majorprincipalstress(s1)reaches60to80MPaintheupperpartofcrusherchamberandapronfeeder(seeFigure7a).Unconfinedstress(s3<4.0MPa)areobservedbelowofthefloorofthedumpingchamber(seeFigure7b).Also,amaximumdisplacementof4cmisobservedinthefloordumpingchamberaftertheexcavationofthecrusherchamber(seeFigure7c).Maximumdisplacementsof5cmareobservedintheintersectionof thecrusherchamberwallsandapronfeederandintersectionof loadinghooperandmainfeeder(seeFigure7d).


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Figure 6 Three-dimensional numerical model of the crusher cavern. The figure shows the 93 advance intervals considered for the excavation in different colors. The model, which incorporates only permanent support, was

constructed using the finite difference code FLAC3D —see Itasca (2007)

Analysis of results from these three-dimensional models allowed to conclude that the support (withcharacteristicsdescribedinthenextsection)satisfiestheacceptabilitycriterion—i.e.,afactorofsafetyof2.0forpermanentsupport.Figure8aand8bshowntheresultsforthedoublecablesinstalledintheroofofthecrusherchamberandthefinalexcavationofthemodel.

Thevaluesof loads resulting inpermanent liners (i.e., thevaluesof thrust,bendingmomentandshearforce) were recorded for each of the large excavations analyzed. The values of support loading wereplottedincapacitydiagramstoverifythatthefactorofsafetyvalueswerebelowadmissiblelimits—foradiscussiononthemethodologyinvolvingverificationofsupportusingcapacitydiagrams,seeHoeketal. (2008);Carranza-Torres&Diederichs (2009).For example,Figure8c represents capacitydiagramsforapermanentsupportofthickness0.3mintheapronfeederroofforthefinalexcavationofthemodel.Inbasicallyallthelargeexcavations,loadingintheproposedsupportanalyzedwiththecapacitydiagramapproachwasfoundtobewithintheadmissiblelimitsoffactorofsafetymentionedearlieron.

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Finally,toverifythesupportrecommended,awedge/blockanalysiswasperformedbasedonthestructuralinformationprovidedinTable2usingkeyblockteory(Goodman&Shi,1985)andthesoftwareUnwegde(Rocscience2009).Figure9showstheapplicationofkeyblocktheorytothedumpingchamberroof.Allthekeyblocksintheroofsandwallsforallthelargeexcavationswereverified.

a) b)

c) d)

Figure 7 Representation of the results in the model sliced by a cross section plane located at the midpoint of the apron feeder. Represented are: a) major principal stresses after crusher chamber excavation, b) minor

principal stresses after crusher chamber excavation. c) displacements after crusher chamber excavation and d) displacements for the final excavation model


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a) b)

c)

Figure 8 Support performance for some of the main large excavations. a) Axial force for cables in the crusher chamber roof at the end of excavation. b) Resulting axial force for cables installed in the crusher chamber at the end of excavation (yielding load, pre-stressing load and factors of safety of 1.5 and 2.0 also are shown). c)

Capacity diagrams for shotcrete liner in apron feeder at the end of excavation

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Figure 9 Dumping chamber section showing maximum removable blocks for each JP superimposed on the stereographic projection of the JPs. To the upper left, the analysis for the roof with Unwedge program to verify

the support recommendations for the JP 1011 block (shaded in red)

5 Proposed crusher cavern support

Basedonexperienceindesignoflargeexcavationssupportandontheapplicationofempirical,analyticalandnumericalmodelsdescribedinprevioussections,forthelargeexcavationscrossingthegoodqualityrockmassunits(BBS,BBCandBBTunits),permanentsupportwith thecharacteristicssummarizedinTable6wereproposed.Thetemporarysupportconsistsmainlyofrockbolts(andwiremesh)withquiteuniformcharacteristicsformostofthelargeexcavations.

Forthelargeexcavations(dumpingchamber,storagehooper,crusherchamberandapronfeeder),inwhichhighstressconfinementintherockmasscouldtranslateintogroundinstability,heavierpermanentsupportproposed.

Table 6 Summary of permanent support proposed for the Crusher Cavern SCh Nº1

Excavation B (m) H (m) SectorCables*

ShotcretePattern Length (m)

DumpingChamber 24,3 8,8

Roof 1,0x1,0 10 H30t=300mmWalls 2,0x2,0 8

StorageHooper 14,3 21,2 Walls 1,5x1,5 14

H30t=150mm

ApronFeeder 9,2 10,8Roof 1,0x1,0 14 H30

t=200mmWalls 1,5x1,5 12

CrusherChamber 16,8 43,6

Roof 1,0x1,0 15 H30t=300mmWalls 1,5x1,5 15

LoadingHooper 17 - Walls 1,5x1,5 12

H30t=200mm

B: SectionLength. H: SectionHeight.(*) Allthecablesaredoublessinglestrandoff=15.6mm,additionallyasteelwiremeshC443wasrecommended.


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6 Conclusions

ThispaperhasdescribedseveralaspectsoftheprocessofdeterminingthepermanentsupportforthelargecrushercavernSChNº1attheNewMineLevelprojectatElTenientemine.Thecrushercavernistobeexcavatedinarockmassofgenerallygoodquality(BBS,BBCandBBTunits),inamediumtohighstressenvironment.

Thesupport recommendedforcrushercavern,asdescribed in thispaper isnotdefinitiveandwillhavetobeoptimizedonceconstructiontechniquesareselectedinafuturephaseofdesignoftheundergroundinfrastructure.

Thecharacteristicsofthesupportrecommendedforthecrushercavernarebasedontheassumptionoftherockmassisdryandthatdynamicloadingonpermanentliner(e.g.,duetoblastingduringfuturecavingoperations)isneglected.Also,asensitivityanalysisforHoek-Browmparameters,ubiquitousmodelandan incrementof the in situ stresswasconsideredand theproposedsupportwas found tobewithin theadmissiblelimitsoffactorofsafetymentionedearlieron.

Intermsofpermanentsupport,consideringthecriticalimportanceofcontinuousoperationofthecrushercavernforatleast50years,apermanentconcretelinerofatleast0.3metersthicknesswasjudgedappropriate.Thispermanentsupportthicknesswasestablishedbasedoncurrentpracticeusedincivilengineeringtunnelprojects,andnotbasedontheempiricalmethodsdescribedabove.

Acknowledgements

TheauthorswouldliketothankCODELCOandinparticular,Mr.PabloVasquezChiefoftheEngineeringDepartmentofVP-NNMProject,forgrantingpermissiontopublishthispaper.

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VCP 2010c, ‘Validación Diseño de Cavernas’, Technical report T09E205-F1-VCPNNM-36000-NOTGE04-3110-002.(inspanish)

Documents

Geomechanical evaluation of large excavations at the New Level … · 2020. 3. 25. · Caving 2014, Santiago, Chile 486 Geomechanical evaluation of large excavations at the New Level