Surface Drilling

Surface Drillingin Open Pit Mining

First edition 2006www.surfacedrilling.com

Thinking young takes practice

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Drilling in open pit mining �

Foreword 2 ForewordbyMarkkuTerasvasara,

VicePresidentMarketingSurfaceDrillingEquipmentatAtlasCopcoRockDrillsAB

Talking Technically 3 OpenPitMining 7 PrinciplesofRockDrilling 10 PrinciplesofRockBlasting 12PuttingRotaryDrillingIntoPerspective 15SmartRigTakesControl 17CorrectSelectionof

TophammerRockDrillingTools 20COPRODCombinestheBestofDTH

andTophammerDrilling 25 IncreasedProductivitywithDTHDrilling 28 SelectingtheRightDTHDrillingTools 34EconomicCaseforRoutineBitGrinding 38Ergonomics&Safety 41RotaryClubExpandsWithThiessen 42 InSearchoftheRightBalance 45ProtectionbyROCCare

Case Studies 47AViperfortheCopperKing 49BestPracticeatBinghamCanyon 51RotaryandDTHWorkSidebySide 54TheGoldenTwinsofSouthernMexico 58MineraMaria’sPre-SplitPioneer 61ROCL8GainsFavourinBrazil 65HydraulicTophammersExceedSoquimich

Expectations 67WinningIodinefromtheAtacamaDesert

69 ReplacingRotaryinIronOre 70MultipleTaskinginWesternAustralia 73 ROCL8OutperformsinAssmangIronOre 74 GreaterGeita 78DTHChoiceCutsCostsatNavachab 80 IronOreFromErzbergMountain 82MoreThanaMatchforScotland’sCoal 84ApatiteforExtraction

–CoprodSolutionforSiilinjärvi

Product Specifications 88DrillingMethodGuide 90TophammerDrillRigs 97TophammerRockDrills 99 TophammerDrillingTools110 COPRODSystem111 COPRODCrawlers114COPRODDrillRigs115COPRODDrillingTools118 DTHDrillRigs124DTHHammers126RotationUnits127RotaryDrillRigs131SecorocTriconeBits133SecorocGrinding138DrillRigOptions147ServiceWorkshops148ConversionTable

Front cover:BlastingtimeatAitikCopperMineinSweden.

SmartRig, COPROD, ROC and COP are Atlas Copco trademarks. Atlas Copco reserves the right to alter its product specifications at any time. For latest updates contact your local Atlas Copco Customer Center or refer to www.surfacedrilling.com

Contents

ProducedbytunnelbuilderltdforAtlasCopcoRockDrillsAB,SE-70191Orebro,Sweden,tel+4619670-7000,fax–7393.Publisher Ulf [email protected] Mike [email protected] [email protected] and Specifications [email protected],BoPersson,BrianFox,GöranNilsson,GunnarNord,HansFernberg,JanJönsson,JeanLindroos,JessisNg,JoannaJester,LeifLarsson,LennartLundin,LennartSöderström,LorneHerron,MathiasLewen,ThereseBlomster,[email protected],[email protected],[email protected]

Designedandtypesetbyahrt,Örebro,Sweden.PrintedbyWelinsTryckeriAB,Örebro,Sweden.©2006AtlasCopcoRockDrillsAB

CopiesofallAtlasCopcoreferenceeditionscanbeorderedinCD-ROMformatfromthepublisher,addressabove,oronlineatwww.atlascopco.com/rock.Reproductionofindividualarticlesonlybyagreementwiththepublisher.

� Drilling in open pit mining

ForewordT o be perceived as the global market leader in providing rock drilling products, it is important that our product

and service offering has the competitive edge: that we can assist our customers to generate high profit leading to business expansion. Our growth is a consequence of our customers’ success.

We have also grown by making strategic acquisitions such as the drill rig division from Ingersoll Rand, and by launching new, efficient products and aftermarket programmes during the past five years. Today, our range of drill rigs comprises more than 40 models suited for various surface drilling applications.

Our modern products are equipped not only with key components such as powerful rock drills, engines, pumps and compressors, but also with the latest computer based technology.

We have never before been committed to such a dynamic and intensive product development, giving a whole new dimension to quality and productivity in terms of directing and guiding the equipment to perform drill holes as close as possible to plan, to planned depth and hole bottom locations. This is a prerequisite for optimum fragmentation of blasted rock, even benches and rock wall contours.

High productivity, as a result of outstanding equipment availability and drilling capacity, leads to better utilization of the investment. Our long-standing relationship with Secoroc has allowed us to develop drill string components, bits, and high pres-sure DTH hammers to match the potential of our rock drills and rigs, together with bit grinding to maintain high performance with economy. The second generation of Coprod for straighter small-diameter holes is a prime example of how successful this partnership has been.

Our new computer based rigs are known as the SmartRig concept, emphasizing that they have incorporated state-of-the-art functionality, making them easy to use and maintain. Additionally, we have spent a lot of effort in providing a good working environment inside the operator’s cabin.

We trust that this book, presenting not only our current product offering, but also some examples of best practice at selected operations, will stimulate technical interchange between people having an interest in surface drilling in open pit mining. Those engaged in mining projects, technical consultancy, universities and our own sales and marketing efforts should, hopefully, find a lot of valuable reading material.

Markku TerasvasaraVice President Marketing Surface Drilling Equipment

[email protected]

Talking Technically

Drilling in Open pit Mining �

Open Pit MiningFinding the Best combinationLarge quantities of raw material are produced in various types of surface operations. Where the pro-duct is rock, the operations are known as quarries. Where metallic ore or non-metallic minerals are involved, they are called open pit mines. There are many common parameters in design and choice of equipment, and in the process of finding the best combination of drilling and blasting methods. Atlas Copco has the advantage of long experience in all types of surface drilling operations, with a pro-duct range to match. With its his-tory of innovative engineering, the company tends to think forward, and is able to advise the user on improving design elements of the operation that will result in overall cost savings.

Surface or Underground MiningMining carried out underground can follow and be tailor-made to suit the mineralization zones on a selective higher metal content basis, thereby minimizing the amount of waste rock, which has to be extracted. The amount of ore to be left behind varies depend-ing on mining method between 10-35 percent. Waste to ore ratio is typically 1 to 4. As no orebodies have the perfect conical shape, vast quantities of waste have to be removed from both the hangingwall and the footwall to get access to the ore as it progresses in depth. Waste to ore ratio varies extensi- vely depending largely on the geomet-ry of the orebody. Many open pit ope-rations excavate more than 5 times the amount of waste compared to ore. Figu- re 1 shows a sectional layout of a typi-cal pit. The waste to ore ratio increases as the pit gets deeper. Eventually, for

economic reasons, the open pit will be abandoned, or underground mining will take over. As the ore, compared with under-ground mining, is more diluted and in-termixed with waste and lower grade ore, crushing, screening, milling, flotation etc need high capacity. As mining progresses at depth large quanti-ties of side rock have to be excavated in stages, so called pushbacks. See fig. 2 Aitik.

Open Pit MiningA typical work cycle in an open pit mine consists of a number of work ele-ments. Exploration drilling is conduct-ed to define ore boundaries for future planning. This is commonly combined with in-pit reverse circulation drill-ing to confirm the mineral contents, which is important for optimizing the blasting and the mineral processing. Drilling of blastholes is undertaken in

Figure 1 General principles of open pit mining.

Figure 2 Aitik open pit mine. Hangingwall extractions in stages..

orebody

Talking Technically

� Drilling in Open pit Mining

a predetermined pattern, followed by plugging the drill holes with wooden or plastic plugs to prevent debris from falling down into the holes. When an adequate number of holes have been drilled, preparations for blasting will start. The holes are blown clean with compressed air to remove water and rock fragments, and are then charged with booster bottom charges, detonators and explosives. Stemming (decking) is inserted into the top of each hole, and the detonator leads are connected. Where electric detonators are used, the circuit resistance is checked with an ohmmeter. See fig. 3 charging the blast holes at Aitik The area is evacuated, equipment is moved away, and the round is fired. The size of blasts in an open pit is nor-mally much larger (up to a couple of million tonnes) compared to a quarry

is cleaned of fly rock with a wheel loader. Blasted rock is then loaded and removed with huge sized equipment such as drag line bucket loaders into trucks, and transported to the crusher station. Large boulders are pushed aside, and stockpiled for subsequent secondary breaking. Rock is discharged directly, or via a grizzley for size con-trol, into the primary crusher. There- after, it is transported by conveyor belts for secondary, and possibly tertia-ry crushing. The different products, comprising rock fragments of certain size ranges, are recovered from the process by vibrating screens, and transported to stor-age silos or bunker piles on the ground. A major difference between open pit mining and quarries is the geological conditions and the demand characteris-tics on the blasted material. Whereas quarries deliver the majority of rock via the crushing and screening plant in various size fractions, the open pit mine attempts to deliver the ore as pure as possible via crushers to the dressing plant, consisting of mills, separators, and/or flotation, and/or biochemical systems, and finally to smelters, in order to convert minerals to metals.

Optimum Fragmentation and Pit geometry Without jeopardizing slope stability, it is of prime importance to keep the pit slope angle as steep as possible, maintaining excavated waste at a minimum. The demands on fragmentation of the waste, as it will not pass through the

Production holesØ 315 mm

1 tonnes explosives/hole

Two Boosters

Decking 6 m

Pipe charge 6,5 m

Bottom charge 4 m

Figure 3 Charging the blast holes at Aitik.

where blasts are restricted to a couple of ten thousand tonnes. The individu-al holes and the rows are delayed with short intervals to get good swell for efficient loading. Before loading, the lower pit floor

Qu

anti

ty

Drillhole diameter

Boulders

Fragmentelongation

% fines in blast

Micro cracks infragments

Figure 4 Charging the blast holes at Aitik. Metso Minerals.

Talking Technically

Drilling in Open pit Mining �

crushing/dressing system, are simple. It should merely suit the loading and trucking equipment used for subse-quent removal to the waste dump. On the other hand, good fragmentation of the blasted ore will make great savings in the total costs of the mineral dress-ing process. By contrast to quarries, where the fines fraction are regarded as reject (especially at aggregates), open pits delivering ore to the dressing plant get savings in the disintegration process in case high amount of fines are present. Large holes generate a higher spread of size distribution from more boulders to higher amount of fines-see fig. 4 Blasting will not only break the rock that is planned to be excavated, but

will also cause damage to the slopes that form the boundaries of the pit. The extent of this overbreak is mainly dependent on the size of the individual charge and its proximity. A common means of minimizing overbreak is to use smaller diameter holes, making provision for restricted blasting in the zone next to the planned bench slope. Figure 6 shows two different blast designs. Figure 5 shows a typical drilling pattern to be applied in connection with pre-split blasting, to achieve increased slope stability with reduced back break. The huge Chuquicamata open pit (pro-duction rate 650,000 tonnes per day) in Chile being 8 km long and 2.5 km wide and progressing towards a final

Figure 5 Drilling pattern for presplit in open pit mining.

Figure 6 Savings in waste extraction by increasing the pit slope.

depth of 1,000 metres saves a stagger-ing 150 million metres of rock excava-tion by just making the pit slopes one degree steeper. Consequently there are large savings to be made if drilling and blasting is carried out in an optimum way.

Drilling Patterns and Type of Drill RigsTraditionally, focusing on the drill-ing cost parameter and productivity only, the predominant method in open pit mining is large hole rotary drill-ing using hole sizes in the 250 to 400 mm (10-15.75 in) range. No doubt this implies lower cost for drilling, ignor-ing the expense of excess waste, more explosives and less controllable frag-mentation. A survey of 36 open pit operations in Chile using hole sizes between 75 and 345 mm (3.0-13.75 in) reveals that hole sizes above 200 mm (8 in) do not generate any substan-tial savings in total drilled metres per tonne. This indicates that burden and spacing cannot be increased indefinite-ly. One important reason for replacing rotary with other methods is the inflex-ibility of the heavy rotary rigs, which are restricted to vertical benches and single pass drilling only. Figure 6 shows the advantages relat-ed to using an Atlas Copco ROC L8 rig, having the ability to drill inclined holes close to the bench wall, compa-red to a traditional rotary rig. The best combination of drill rigs might well

Talking Technically

� Drilling in Open pit Mining

Figure 8 Soufflé blasting at Björkdal gold mine. Figure 9 Charging for soufflé blasting.

prove to be large rotary rigs for waste rock and high productivity in the pit centre coupled with flexible DTH rigs for selective mining, pre split of slopes as well as for in-pit grade control drill-ing. See fig 7 Aitik.

Soufflé Blasting

Mining of rich, narrow and irregularly stratified ore zones, such as gold mine-ralizations, requires extra attention, in order not to introduce unnecessary

Figure 7 Drill pattern at Aitik open pit, Sweden.

Production holes315 mm

8-9 m drillpattern15+2 hole depth

2 rows140–165 mm

quantities of waste into the ore stream. Consequently, this type of mining has to be progressed on a selective basis, in close liaison with surveyors and geologists, by taking frequent samples before and after each individual blast. Short benches and small holes are used to cope with ore zone irregularities. A recently-developed method to ensure maximum recovery from each blast is called soufflé blasting. Figures 8 and 9 illustrate this principle of cautious blasting with a minimum of dilution as

practised at the Björkdal gold mine in Sweden. To a depth of merely 5 m, 100 vertical holes are blasted in one round, without free surface for expansion. The firing sequence starts in the centre and, thanks to 2.5 m of stemming, the blasted ore material just swells on site like baking a soufflé. Selective extrac-tion by backhoe loaders facilitates maximum recovery of the rich, narrow gold-bearing zones.

by Hans Fernberg

Talking Technically


Rotary Drilling

Rotary drilling can be subdivided into rotary cutting and rotary crushing.

Rotary cutting creates the hole by shear forces, breaking the rock’s ten-sile strength. The drillbit is furnished with cutter inserts of hard metal alloys, and the energy for breaking rock is provided by rotation torque in the drill-rod. This technique is limited to rock

with low tensile strength, such as salt, silt, and soft limestone not containing abrasive quartz minerals.

Rotary crushing breaks the rock by high point load, accomplished by a toothed drillbit, which is pushed downwards with high force. The bit, being of tricone roller type fitted with tungsten carbide buttons, is simul-taneously rotated, and drill cuttings are removed from the hole bottom by blowing compressed air through the bit.

Drillrigs used for rotary drilling are large and heavy. The downwards thrust is achieved by utilizing the weight of the drillrig itself, and the rotation, via a hydraulic or electric motor, applied at the end of the drill pipe. Common hole diameters range from 8 to 17.5 in (200-440 mm) and, because adding the heavy drill pipes is cumbersome, most blasthole drillrigs use long masts and pipes to accommodate single-pass drilling of maximum 20 m (65 ft). Electric power is usually chosen for the large rigs, whereas smaller rigs are often powered by diesel engines.

Rotation rates vary from 50 to 120 rev/min, and the weight applied to the bit varies from 0.5 t/in of bit diameter in soft rock, to as much as 4 t/in of bit diameter in hard rock.

Recent technical advances include: improved operator cab comfort; automatic control and adjustment of optimum feed force and rotation

speed to prevailing geology and bit type and diameter; and incorporation of the latest technology in electric and hydraulic drive systems.

Rotary drilling, which is still the dominant method in large open pits, has limitations in that the rigs are not suited to drilling holes off the vertical line. As blasting theories and practice have proved, it is generally beneficial to design, drill and blast the bench slopes at an angle of approximately 18 degrees off vertical.

Many rotary rig masts have pin-ning capabilities permitting drilling at angles as much as 30 degrees out of the vertical. However, the inclined hole drilling capabilities in rotary drilling are limited by the heavy feed force required, since part of this force is directed backwards. This causes rig stability problems, reduced penetra-tion, and shorter life of drilling con-sumables. Consequently, most blast hole drilling using rotary drillrigs is for vertical holes.

Percussive Drilling

Percussive drilling breaks the rock by hammering impacts transferred from the rock drill to the drillbit at the hole bottom. The energy required to break the rock is generated by a pneumatic or hydraulic rock drill. A pressure is built up, which, when released, drives the piston forwards. Figure 1

Principles of Rock DrillingDrilling for excavation by Blasting

This reference edition deals with surface rock drilling used for the purpose of excavating rock in qu-arries and construction projects by means of blasting. Other types of drilling, such as for oil and water, mineral exploration and exploita-tion, and grouting, are excluded.

The reader is given a brief ex-planation of prevailing drilling methods, together with an introduc-tion to blasting techniques and the interrelation of drilling and blasting. Also discussed are the main parameters involved when plan-ning and executing blasthole drilling at quarries and civil engine-ering projects.

The range of Atlas Copco pro-ducts, with references to the Atlas Copco websites, are presented and discussed by comparing their suitability and expected productivity related to a selection of applica-tions. Case studies from worksites around the world should prove interesting and beneficial, especially when planning and selecting me-thods and equipment for blasthole drilling applications.

Blastholes have certain unique and important characteristics. These are: hole diameter, depth, direction, and straightness. Drilling produces a circular hole in the rock, the strength of which must be overcome by the drilling tool. Depending upon rock properties, there are several ways to accom-plish this, as shown in the follow-ing article.

Figure 1 Principle of tophammer drilling.

Talking Technically

� Drilling in open pit mining

illustrates the principle of top hammer percussive drilling.

The piston strikes on the shank adapter, and the kinetic energy of the piston is converted into a stress wave travelling through the drillstring to the hole bottom. In order to obtain the best drilling economy, the entire system, rock drill to drillsteel to rock, must harmonize.

Stress Wave

Theoretically, the stress wave has a rectangular shape, the length of which is twice that of the piston, while the height depends on the speed of the piston at the moment of impact, and on the relationship between the cross-sectional area of the piston and that of the drillsteel.

The total energy that the wave contains is indicated diagramatically in Figure 2. To calculate the output power obtained from a rock drill, the wave energy is multiplied by the impact frequency of the piston, and is usually stated in kW. Rock drill designers seek to find the best com-binations of various parameters, such as the piston geometry, the impact rate and the frequency. Two rock drills having the same nominal power rating

might therefore have quite different properties.

The shock waves that are generated by hydraulic (Figure 3) and pneumatic (Figure 4) rock drills are significantly different in shape. Drillrods used with hydraulic rock drills will normally show substantially longer service life, compared with pneumatic rock drills, because of the higher stress level obtained with the pneumatic driven piston.

The reason is the larger cross- section needed when operating at substantially lower pressure, which is 6-8 bars, compared to the 150-250 bars used with hydraulic systems. The slimmer the piston shape, the lower the stress level.

Figure 5 compares the stress level generated by three different pistons having the same weight, but with dif-ferent shapes and working different pressures. The lowest stress, or shock wave amplitude, is obtained with the long slender piston working at high pressure.

efficiency and losses

The shock wave loses some 6-10% of its energy for every additional cou-pling, as it travels along the drillstring. This loss is partly due to the differ-ence in cross-sectional area between the rod and the sleeve, and partly due to imperfect contact between the rod faces. The poorer the contact, the greater the energy loss.

When the shock wave reaches the bit, it is forced against the rock, there-by crushing it. The efficiency at the bit never reaches 100%, because some of the energy is reflected as a tensile pulse. The poorer the contact between the bit and the rock, the poorer the efficiency (Figure 6).

To optimize drilling economy, the drilling parameters for percussion pressure, feed force, and rotation must harmonize.

Percussion Pressure

The higher the percussion pressure, the higher will be the speed of the piston, and consequently, the energy. Where the bit is in good contact with hard and competent rock, the shock wave energy can be utilized to its maximum. Conversely, when the bit has poor con-tact, the energy cannot leave the drill-string, and reverses up the drillstring as a tensile wave.

It is only when drilling in sufficient-ly hard rock that the maximum energy per blow can be utilized. In soft rock, to reduce the reflected energy, the per-cussion pressure, and thus the energy, will have to be lowered (Figure 7).

For any given percussion pressure, the amplitude, and hence the stress in the drillsteel, will be higher with reduced cross-section of the drillrods.

Figure 3 Shock wave generated by hydraulic rock drill.

+

–

s

Figure 2 Stress wave energy.

5200 m/s

2 x piston length

+

–

s

Figure 4 Shock wave generated by pneumatic rock drill.

+

–

s

Figure 5 Stress level generated by different pistons of same weight.

Piston 1– 0,8 MPa

Piston 3 – 20 MPa

Piston 2 – 12 MPa

Shock-wave amplitude

1

2

3

Piston 1 – 8 bar

Piston 2 – 120 bar

Piston 3 – 200 bar

Figure 6 Poor contact between bit and rock results in poor efficiency.

+

–

s

Primary wave

Reflecting wave

Talking Technically


To get the longest possible service life from shank adapters and rods, it is important to ensure that the working pressure is matched to the drillstring at all times.

Feed Force

The purpose of the feed is to maintain the drillbit in close contact against the rock. However, the bit must still be able to rotate. The feed force must always be matched to the percus-sion pressure. Figure 8 illustrates this relationship.

Rotation

The purpose of rotation is to turn the drillbit to a suitable new posi-tion for the next blow. Using button bits, the periphery is turned about 10 mm between blows. Consequently, the rotation rate is increased using higher impact frequency and reduced bit diameter. Using insert bits, the recommended rotation rate is 25% higher.

Setting Parameters

In practice, the driller sets the percus-sion pressure that the rock can cope

with, and then sets the rev/min with regard to the percussive frequency and the bit diameter.

When drilling starts, the feed is adjusted to get even and smooth rota-tion. In case this is not achieved, which will show up in low shank adapter life, the percussion pressure can be progressively reduced, until even and smooth rotation is reached.

The temperature of the adapter sleeve can be checked to ensure that the drilling parameters are correctly set. Immediately after drilling, the temperature should be 60-70 degrees for dry drilling, and approximately 40 degrees for wet drilling.

Drilling problems, mainly related to loose couplings, may arise what-ever parameters are used. In order to tighten the couplings during drill-ing, the friction of the bit against the hole bottom has to be increased. This can be done by increasing the feed, increasing the rotation rate, or chang-ing the bit.

Flushing

Drill cuttings are removed from the hole bottom to the surface by air blow-ing or water flushing. As the power output from rock drills increases, accompanied by increased penetra-tion rate, efficient flushing becomes gradually more important. The flush-ing medium is normally air for

surface drilling, and water for under-ground drilling. The required flushing speed will depend on: specific gravity– material having a density of 2 t/cu m requires at least 10 m/sec, whereas iron ore, for example, having a density of 4 t/cu m, requires an air speed of 25-30 m/sec; particle size – the larger the particles, the higher flushing speed required; particle shape – spherical particles require more speed than flaky, leaf shaped particles.

Productivity and Methodology

During the past century there has been a rapid and impressive increase in efficiency and productivity related to tophammer drilling. Starting from hitting a steel manually by a sledge hammer 100 years ago, today’s hydrau-lically powered rock drills utilize the latest state-of-the-art technology.

Every drilling method has its pros and cons, making an objective com-parison quite cumbersome. In view of this, the table in Figure 9 can serve as a guideline when comparing the various percussion drilling alternatives which Atlas Copco can offer. The choice of best drilling method to apply depends on hole size and type of application.

by hans Fernberg

Figure 8 Feed force must be matched to percussion pressure.

Low percussionpressure

High percussionpressure

Feeding

Figure 7 To reduce reflected energy, percussion pressure is lowered.

Percussion pressure

Soft rock Hard rock

Percussion pressure Hydraulic Drilling method Tophammer DTH COPROD

hole diameter, mm 76-127 85-165 105-165

penetration rate 2 1 3

hole straightness 1 3 3

hole depth 1 3 3

production capacity (tons rock/shift) 2 1 3

fuel consumption/drill metre 2 1 2

service life of drillstring 1 2 3

investment in drillstring 2 2 1

suitability for good drilling conditions 3 2 2

suitability for difficult drilling conditions 1 3 3

simplicity for operator 2 3 1

adjustability of flushing capacity 1 2 3

Figure 9: Comparison for 20 m bench drilling in a limestone quarry. Ratings: fair = 1, good = 2, very good = 3.

Talking Technically

10 Drilling in open pit mining

Blasting

To understand the principles of rock blasting, it is necessary to start with the rock fragmentation process that follows the detonation of the explosives in a drillhole.

The explosion is a very rapid combustion, in which the energy con-tained in the explosives is released in the form of heat and gas pressure. The transformation acts on the rock in three consecutive stages (figures 1-3).

Compression: a pressure wave prop-agates through the rock at a velocity of 2,500-6,000 m/sec, depending on rock type and type of explosives. This pres-sure wave creates microfractures which promote rock fracturing.

Reflection: during the next stage, the pressure wave bounces back from the free surface, which is normally the bench wall or natural fissures in the rock. The compression wave is now transformed into tension and shear waves, increasing the fracturing process.

Gas Pressure: large volumes of gas are released, entering and expanding the cracks under high pressure. Where the distance between the blasthole and

the free face has been correctly calcu-lated, the rock mass will yield and be thrown forward.

Benching

Bench blasting is normally carried out by blasting a large number of paral-lel holes in each round. Considering the blasting mechanics, with a com-pression-reflection-gas pressure stage in consecutive order for each charge, it is of vital importance to have a proper delay between each row, and even between individual holes in each row. A proper delay will reduce rock throw, improve fragmentation, and limit ground vibrations. The blast should be planned so that the rock from the first row of holes has moved about one third of the burden, when the next row is blasted (figures 4 and 5).

The horizontal distance between the

hole and the free face is the burden, and the parallel distance between ho-les in a row is the spacing. The ratio between spacing and burden will have great impact on the blasting result, and 1.25 can be considered as an average ratio. The optimum burden depends upon a number of parameters, such as rock type, required fragmentation, type of explosives, hole deviation, and hole inclination. Nevertheless, as large drillholes can accommodate more explosives, there is a distinct relationship between burden and hole diameter (figure 6).

As the bottom part of the blast is the constricted and critical part for suc-cessful blasting, it is used as a basis for deciding all other parameters. The bottom charge, normally 1.5 x burden, from where the initiation should start, requires well-packed explosives of higher blasting power than is needed in the column charge (figure 7).

Principles of Rock Blastingcombination of FactorsBlasting by design results from a large number of factors, all of which need to be brought under control in order to achieve the right result. These include the choice of drillrig and tools, the layout of the holes, the explosive, and the skill of the operators. Geology is the governing factor, and experience is a major ingredient. Atlas Copco produces drillrigs and systems to suit all rock types, and has the experience to recommend the correct approach to all ground condi-tions in order to achieve the optimum result. The following outline of the principles involved in rock blasting is a logical start point in the quest for the perfect round.

Figures 1-3 Rock breaking sequence in a normal blast.

Compression Reflection GasPressure

Figure 4 Delay detonation of a typical bench blast.

Talking Technically

Drilling in open pit mining 11

Stemming of the top part of the hole is used to ensure that the energy of explosives is properly utilized. It will also reduce and control the fly rock ejected from the blast. This tends to travel long distances, and is the main cause of on-site fatalities and damage to equipment. Dry sand or gravel having a particle size of 4 to 9 mm constitutes the ideal stemming material.

Inclined holes give less back break, safer benches and less boulders, when compared to vertical holes.

Types of explosives

The geology frequently has more effect on the fragmentation than does the explosive used in the blast. The properties that influence the result of the blast are compressive strength, tensile strength, density, propagation velocity, hardness and structureIn general, rock has a tensile strength which is 8 to 10 times lower than the compressive strength.

The tensile strength has to be exceeded during the blast, otherwise the rock will not break. High rock density requires more explosives to achieve the displace- ment.

The propagation velocity varies with different kinds of rock, and is reduced by cracks and fault zones. Hard, homo- geneous rocks, with high propagation velocity, are best fragmented by an explosive having high velocity of detona-tion (VOD).

An extensive range of different types and grades of explosives is available to suit various blasting applications. A breakdown is presented in Table 1.

In dry conditions, ANFO has become the most used blasting agent, due to its availability and economy.

The blasthole diameter, together with the type of explosive used, will deter-mine burden and hole depth. Practical

hole diameters for bench drilling range from 30 to 400 mm. Generally, the cost of large diameter drilling and blasting is cheaper per cubic metre than using small holes. However, rock fragmentation is better controlled by higher specific drilling.

The explosives are initiated with detonators which can be electric or non-electric. Electric systems have the advantage that the complete circuit can easily be checked with an ohmmeter to ensure that all connections and detonators are correct before blasting. To eliminate the risk for spontaneous ignition from lightning, non-electric systems, including detonating cord, are used.

by hans Fernberg

Firing patternThisfiringpatternprovidesseparatedelaytimeforpracticallyallblastholesandgivesgoodfragmentationaswellasgoodbreakageinthebottompartoftheround.

Figure 6 Burden as a function of drill hole diameter.

BurdenasafunctionofDrillHoleDiameter

HoleDiameter,mmSpacingEqualto1.25xBurden

Figure 7 Charging for optimum fragmentation.

Boulders and flyrockcomefromthiszone

Back break

Subdrilling= 0.3 x burden

Bottom chargerequireswellpackedhighblastingpower

Column chargeonlylightchargeneededforgoodfragmentation

Stemming(length~burden) Burden

Table 1 Features of common types of explosives.

base type detonation velocity m/s features nitro-glycerine dynamite 5500-4500 highlyadaptablecartridged gelatin excellentinsmallerholes

ammonium- ANFO 2500 lowcost,highsafety,easynitrate topourorblow nowaterresistance, contains5-6%fueloil

water slurry 4000-3000watergel basicallyANFOmadewater resistantgel 5000emulsion stableoil/wateremulsion– heavyANFO rangedependson packagedorpumpable storagetime

Figure 5 Firing sequence in delay blasting.

PracticalValues

Talking Technically

12 Drilling in Open pit Mining

Putting Rotary Drilling into PerspectiveRotary or DTHAtlas Copco now offers a complete range of rotary as well as DTH and tophammer drill rigs for most types of open pit mining and quar-rying applications. But how do these technologies complement each other and how do drillers know which method to choose, and when? As readers of M&C are well acquainted with DTH drilling, this article puts rotary drilling into per-spective.

complete Range

With the acquisition of the Ingersoll-Rand’s Drilling Solutions and Baker Hughes Mining Tools (BHMT) busi-nesses, there is now another way to break rock within the Atlas Copco fa-mily of products. Much of the world’s mining output begins through drilling of holes with rotary drills. Ingersoll-Rand built air-powered rotary drills for many years prior to the introduction of their first fully hydraulic unit, the T4, in 1968.

about Rotary Drills

It is important to note that rotary drills are capable of two methods of drill-ing. The majority of the units operate

as pure rotary drills, driving tricone or fixed-type bits. The fixed-type bits, such as claw or drag bits, have no moving parts and cut through rock by shearing it. Thus, these bits are limit-ed to the softest material. The other method utilized by rotary drill rigs is down-the-hole (DTH) drilling. High pressure air compressors are used to provide compressed air through the drill string to drive the DTH hammer. The main blasthole drilling methods are shown in Fig 1. The primary differ-ence between rotary drilling and other methods is the absence of percussion. In most rotary applications, the pre-ferred bit is the tricone bit. Tricone bits rely on crushing and spalling the rock. This is accomplished through transferring down-force, known as pulldown, to the bit while rotating in order to drive the carbides into the rock as the three cones rotate around their respec-tive axis. Rotation is provided by a hydraulic or electric motor-driven gearbox (called a rotary head) that moves up and down the tower via a feed system. Feed systems utilize cables,

chains or rack-and-pinion mechanisms driven by hydraulic cylinders, hydrau-lic motors or electric motors. Pulldown is the force generated by the feed system. The actual weight on bit, or bit load, is the pulldown plus any dead weight such as the rotary head, drill rods and cables.

More Weight with Rotary

It only takes one look to see that the biggest DTH and tophammer drill rigs are very different to the biggest rotary blasthole rigs. In fact, the Pit Viper 351 rotary drill rig weighs in excess of nine times that of our largest DTH hammer drill rig, the ROC L8. Yet it is drilling a hole that is generally only twice the diameter. Take a typical medium formation tricone bit with a recom-mended maximum loading of 900 kg/cm of bit diameter (5000 lbs per inch of diameter). With a 200 mm (7-7/8”) bit, you could run about 18,000 kg (40,000 lbs) of weight on the bit. The laws of physics dictate that for every action, there is an equal and opposite

By Brian Fox, Vice President Marketing, Atlas Copco Drilling Solutions, USA.

TONS

Fig 1. Drilling meth-ods (1) Down-the-Hole (DTH); (2) Tophammer; (3) COPROD; (4) Rotary tricone.

Talking Technically

Drilling in Open pit Mining 13

Surface Drilling ApplicationsConstruction

AggregateIndustrial Minerals

Gold Coal

CopperIron

Hole Diameter2" 3" 4" 5" 6" 7" 8" 9" 10" 11" 12" 13" 14" 15" 16"

51mm 76mm 102mm 127mm 152mm 178mm 203mm 229mm 254mm 279mm 305mm 330mm 356mm 381mm 406mm

125,000 LB Bit Load PV-351110,000 LB DM-H2

90,000 LB DM-M375,000 LB PV-271/PV-27575,000 LB DM-M2

50,000 LB DMLSP60,000 LB DML45,000LB DM45

30,000 LB T4BH30,000 LB DM30

25,000 LB DM25SPROC L8CM780D

CM760D

KEY:

ROC L6ROC L7/L7CR

Rotary

ECM720ROC F9

Rotary or DTH

ROC F6ECM660III

DTH

ROC F7ROC D3/D5/D7

Tophammer/COPROD

ECM585MCECM470

complete Range

With the acquisition of the Ingersoll-Rand’s Drilling Solutions and Baker Hughes Mining Tools (BHMT) busi-nesses, there is now another way to break rock within the Atlas Copco fa-mily of products. Much of the world’s mining output begins through drilling of holes with rotary drills. Ingersoll-Rand built air-powered rotary drills for many years prior to the introduction of their first fully hydraulic unit, the T4, in 1968.

about Rotary Drills

It is important to note that rotary drills are capable of two methods of drill-ing. The majority of the units operate as pure rotary drills, driving tricone or fixed-type bits. The fixed-type bits, such as claw or drag bits, have no moving parts and cut through rock by shearing it. Thus, these bits are limit-ed to the softest material. The other method utilized by rotary drill rigs is down-the-hole (DTH) drilling. High pressure air compressors are used to provide compressed air through the drill string to drive the DTH hammer. The main blasthole drilling methods are shown in Fig 1. The primary differ-ence between rotary drilling and other

methods is the absence of percussion. In most rotary applications, the pre-ferred bit is the tricone bit. Tricone bits rely on crushing and spalling the rock. This is accomplished through transferring down-force, known as pulldown, to the bit while rotating in order to drive the carbides into the rock as the three cones rotate around their respec-tive axis. Rotation is provided by a hydraulic or electric motor-driven gearbox (called a rotary head) that moves up and down the tower via a feed system. Feed systems utilize cables, chains or rack-and-pinion mechanisms driven by hydraulic cylinders, hydrau-lic motors or electric motors. Pulldown is the force generated by the feed system. The actual weight on bit, or bit load, is the pulldown plus any dead weight such as the rotary head, drill rods and cables.

More Weight with Rotary

It only takes one look to see that the biggest DTH and tophammer drill rigs are very different to the biggest rotary blasthole rigs. In fact, the Pit Viper 351 rotary drill rig weighs in excess of nine times that of our largest DTH hammer drill rig, the ROC L8. Yet it is drilling a hole that is generally only twice the diameter. Take a typical medium formation tricone bit with a recom-mended maximum loading of 900 kg/cm of bit diameter (5000 lbs per inch of diameter). With a 200 mm (7-7/8”) bit, you could run about 18,000 kg (40,000 lbs) of weight on the bit. The laws of physics dictate that for every action, there is an equal and opposite

reaction, meaning that if you push on the ground with 18,000 kg (40,000 lbs), the same force will push back on the unit. Therefore, the weight of the ma-chine must be over 18,000 kg (40,000 lbs) at the location of the drill string to avoid the machine “lifting off” the jacks. To achieve a stable platform through proper placement of the tracks and levelling jacks, the distribution of weight results in an overall machine weight that approaches or exceeds twice the bit load rating. This weight does add cost to the machine, but the size of the components also translates to long life. Even smaller rotary blast-hole drills are built to run 30,000 hours of operation.

The importance of air

A key parameter of rotary drilling is flushing the cuttings from the hole. In most rotary blasthole drills, cuttings are lifted between the wall of the hole and the drill rods by compressed air. Sufficient air volume is required to lift these cuttings. Many types of tricone bits have been developed to meet various drilling needs. Softer formation bits are built with long carbides with wide spac-ing on the face of the bit. This design yields large cuttings which increase drill speed and reduce dust. It is important to have sufficient clearance bet-ween the wall of the hole and the drill rods in order for such large cuttings to pass. If this clearance, known as annu-lar area, is not sufficient, the cuttings will be ground between the wall of the hole and the rods or by the bit itself

Fig 2: The Atlas Copco product range by application and method.

Talking Technically


0

2000

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14000

$-

$1,00

$2,00

$3,00

$4,00

$5,00

$6,00Footage/24 HoursBit Life (ft)Overall Cost/Ft

299 ft/hour, 1500' bit lifeHigh Production

74 ft/hour, 12,000' bit life

Great Bit Life

218 ft/hour, 5300' bit lifeLowest Cost

Foot

age/

24 H

ours

& A

vera

ge B

it Li

fe

Over

all C

ost/F

oot

of air is required. Take for example a Secoroc QL80 203 mm (8”) DTH hammer that is designed to operate at 25 bar (350 psi). Even with our larg-est high pressure compressor with 686 litres per second (1,450 ft3/min), the pressure will only build to 23 bar (325 psi), thus providing less impact energy. In real terms, each blow of the piston is about 45 kg (100 lbs) less than it is designed for. In some cases, this method will still out-perform rotary drilling. For most large diameter blasthole drilling, there is simply not enough air on-board for a DTH to be as cost effective as rotary drilling with a tricone bit. Rotary drilling is still the predomi-nant method of drilling 230 mm (9”) diameter or greater. This is driven pri-marily by the current limitations of tophammer units and rig air systems. Tri-cone bits also become more cost effec-tive as the larger bits are equipped with larger bearings which in turn can hand-le higher loads. These higher loads translate to improved drill rates. Another advantage of rotary rigs is the length of the drill rods that can be carried on board. Longer rods mean fewer connections. Further, some rota-ry rigs are large enough to handle a long tower that enables drilling of the entire bench height in a single-pass. At the largest open pit mines, rotary units are drilling 20 m (65 ft) deep holes in a single-pass to match the bench heights dictated by the large electric shovels which can dig a 17 m (55 ft) bench.

Productivity versus cost

Studies have shown that pure penetra-tion rate will increase linearly with increased pulldown. The same has also been said of rotation speed. So why doesn’t every operation use more of each? Unfortunately, higher pulldown and rpm usually results in increased vibration and lower bit life. The vibra-tion causes increased wear-and-tear on the rig, but more importantly, it cre-ates a very unpleasant environment for the operator. What invariably happens is that the operator reduces the weight or rpm until the vibration returns to a comfortable level. Some operations limit bit load and rpm even if there is

no vibration in order to improve bit life. This is often the wrong strategy as the overall drilling cost per unit, also known as Total Drilling Cost (TDC), should be considered. TDC is calculated using the bit cost per metre/foot and the total rig cost per hour. The unit cost per hour includes labour, maintenance and power, and possibly the capital cost. The drilling speed really doesn’t impact this cost per hour figure. What it does impact though is the cost per unit produced (cost/metre/foot, cost/ton, etc…). You generally want to push the rig harder to reduce the cost/foot, but there will be a point where the rig overloads the bits (see fig's 3 and 4).

large versus Small

There are some drawbacks to rotary rigs. Smaller crawler rigs are more flexible with many advantages such as articulating and extendable booms and guides that allow drilling at many dif-ferent angles. Some models also offer

significantly more technology with automated rod handling systems and automatic drilling. The components on rotary rigs are not enclosed. They are mounted onto the frame in an open layout which makes them extremely easy to service. Looks are not of pri-mary concern for a rig that is subjected to the rigors of breaking rock for more than 60,000 hours. The general trend for 165 mm (6-1/2”) or less is towards the smaller, more flexible units. However, many large scale quarries and small mines still favour the durability, life and simplici-ty of the larger rotary rigs for these small diameters. For the large scale open pit operations that yield a high percentage of the total worldwide mi-neral production, it is anticipated that rotary drilling will remain the primary method for years to come.

Fig 4. The impact of bit life and productivity on overall cost/foot (1 ft = 0.305 metres).

Production Rate (Feet/Hour) 120 138 180Bit Life (Feet) 10,000 8,000 4,000Bit Cost $4,000 $4,000 $4,000Bit Cost/Foot $0.40 $0.50 $1.00Rig Cost/Hour $175 $175 $175Total Drilling Cost/Foot $1.86 $1.77 $1.97

Operator Steady eddie Smart Sam Wild Jack

Fig 3. The table compares three operators on the same drill rig – Steady Eddie, Smart Sam and Wild Jack. The cost chart, using actual data collected at a major copper mine further illustrates the balance required.

acknowledgements

This article first appeared in Mining & Construction No 2, 2005. ■

Talking Technically


control System

Via PC software, the SmartRig controlsystem generates electrical signals tocontrol the hydraulic valves. This intro-duces the concept of a “dry cab”, withno hydraulic pipework and gauges, con-siderably reducing noise for the ope-rator. The number of hydraulic com-ponents has been reduced by 30%, compared with Hydraulic Control Sy-stem, HCS, resulting in higher effici-ency. The need for electrical cables is also reduced.

Control gauges and instruments arereplaced by a display unit. This releasesspace in the cab, increasing visibility, and improving operator ergonomics.

The fundamentals of the rock drill control system are RPCF control andanti-jamming functions. RPCF, or Ro-tation Pressure Control of Feed pres-sure, adjusts the feed pressure accordingto the measured feed pressure. Thiskeeps the joints correctly tightened and

saves drill steel. Anti-jamming uses the rotation pressure to detect a jamming situation, and will reverse the feed of the rock drill and initiate a replacementhole collaring.

Together, this advanced system of drilling control will give maximum life to the entire drill string, while ensuringhigh penetration rates and easy rod ex-traction.

automation in Surface DrillingUsing the laser plane as a reference level, all holes are drilled to the same depth, reducing drilling, blasting and crushing costs by way of better frag-mentation, and cancelling the need forsecondary blasting. A flatter, more uni-form bench surface results, making loa-ding and transportation easier. Automaticfeed positioning reduces set-up timeand cancels out operator error. Moreparallel holes result in better blasting andsmoother bench bottoms. The longerthe hole, the bigger will be the impactof even a small deviation on blasting.For instance, a one degree error will

produce a deviation of 36 cm at thebottom of a 20 m hole. Hence the im-portance of automatic feed positioning,which sets the feed to pre-defined anglesat the touch of a button.

The automatic rod adding system, AutoRAS, enables the operator to drill a hole automatically to a given depth, allowing him to leave the cab to carry out other duties, such as maintenance checks or grinding bits, while keepingthe drill rig in sight. The drilling is su-pervised by the drillsteel break detec-tion system, which shuts down the dril-ling operation if a breakage is detected.The result is better rig utilization, evi-denced by a couple of extra holes/shift.

MWD and ROc Manager

Measure While Drilling, or MWD, is anoptional instrumentation and software package for recording and interpreta-tion of drilling data, and enhanced pres-entation of geomechanical variation ofrock properties. A number of parame-ters, such as hole depth, penetration rate,and damper, feed, percussion and rota-tion pressures are logged at requested

SmartRig Takes ControlhcS to Plc to PcAcronyms are plentiful when it co-mes to automation, but PC-basedwill be the most important acro-nym in the years to come. Eversince Atlas Copco developed Hyd-raulic Control System (HCS) in the 1970s, the search has been on forits successor. Programmable LogicControl (PLC) saw us through the1990s along with the VME-system,but in 2002 the first SmartRigs started to take over. SmartRig isa PC-based control system inten-ded for all kinds of automation insimple and advanced drill rigs. Thehardware is designed to operatein every possible weather condi-tion, and the software can be up-graded at site. SmartRig has built-in logging and monitoring func-tions, together with support fordiagnostics and faultfinding. Thecontrol system is used in all AtlasCopco product families, in both un-derground and surface crawlers,making it easy to move functionsand improvements between diffe-rent products. That’s smart!

Atlas Copco´s Silenced ROC D7C is a sound investment with a noise level of approximately 10 dB(A) below that of other rigs on the market.

• Hole Navigation System (HNS)• Measure While Drilling (MWD)• Automatic rod adding (AutoRAS)• Automatic feed inclination setup (AutoPOS)• Laser Plane• Advanced Drilling System • Silenced• ROC Manager

Talking Technically


intervals while drilling, and this pro-vides input to analysis of the rock properties.

Date, time, hole length, feed angle, and rig identity are logged once for each hole. MWD data can be recorded for every second centimetre up to a maxi-mum penetration rate of 3 m/min. In this way, data is extracted from every production hole to provide very high-resolution rock mass characterization. Typical parameters being reported are rock hardness and fracturing. Detailed information on rock mass properties is available immediately after drilling is completed, without disturbing produc-tion, since logging is carried out auto-matically during the normal drilling process.

ROC Manager is a stand-alone PC- based tool for making drill plans, mea-suring hole deviation, and logging, presenting and reporting drilling data graphically. This information can be presented individually or in combination with other parameters, and used both during drilling operations, and by transferring logged data from the rig. Advan- ced MWD analysis is also possible as an option. Both the SmartRig and ROC Manager 2.0 support the IREDES format for data exchange on performance,

quality and MWD logs, and on drill plans.

In ROC Manager, the MWD data can be illustrated in slices through the bench, with the rock properties identified by contrasting colours, providing a map of the mineral qualities and types. This facility differentiates between good rock and poor rock, for instance, allowing the quarry or mine operator to select rock for excavation, and to prepare for loading and hauling before blasting takes place.

hole navigation System

Real-time satellite-based Global Posi-tioning System, HNS, has been chosen for the highest possible drillrig navi-gation accuracy, within 10 cm in most situations. With HNS there is no need to mark out holes, and the accuracy is such that all holes will be parallel, if required, resulting in a controllable product with better fragmentation and less boulders.

The focus is on road construction applications, but the system can be used in any type of drilling.

Using information on his display, the operator can navigate the rig to the co-verage position for a given hole, and

the computer will provide the informa-tion to place and align the feed exactly over the collaring position.

The drillplan can be provided by ROC Manager, transferred to the rig via a PC card. The time saved by not having to aim visually to set angles, and by being able to drill more than one hole from a single set-up, results in better rig utilization.

Silenced for noise Sensitive areasThe sources and characteristics of noise are complicated, and have to be identi-fied and analysed in order to analyze their spectrum. Atlas Copco designed a concept rig in 2000, and a second prototype rig in 2004, both of which were used as testbeds for various sim-ulations.

These confirmed that noise was not just created by the drilling cycle, but also by elements of the carrier, such as cooling fans, hydraulic system compo-nents, and engine.

The recently introduced Silenced SmartRig is for use in areas where noise levels have to be controlled. Substantial efforts have been put into redesigning components, systems and soundproofing enclosures, resulting in a 10dB(A) ex-ternal noise reduction.

The most visible difference between the Silenced SmartRig and other Smart Rig rigs is its patented feed enclosure. The frame and panels of the enclosure are formed from lightweight aluminium. There are four access doors, which are hydraulically operated from the cab. A rubber sliding skirt at its base encloses the hole, and this can be hydraulically raised for collaring. The whole enclo-sure is designed for demounting when not needed.

The SmartRig system, because it delivers the right amount of power for each phase of the drilling operation, can re-duce fuel consumption by up to 30%. Add this to the productivity increase from automatic rod adding and auto feed alignment, and the Silenced Smart Rig is a really sound investment!

by Jean lindroos

With Silencing Kit Without Silencing Kit

200400

600800

10001200

1400 m

200400

600800

10001200

1400 m

55dB (A) area

The noise carpet shows the difference with and without a Silencing Kit.

Talking Technically


criteria of choice

Since button bits are used for 99% of surface drilling applications, a bit with guiding wings on the bit skirt, the Retrac-type bit, should be chosen to give the straightest possible hole.

The bit front should not be allowed to take on a convex shape during serv-ice life, since this convex front has been shown to give more deflection than a flat or drop centre front.

When a button bit is worn, it is the gauge buttons that always show the most wear. This means that the gauge but-tons lose more height during regrind-ing, leading to the tendency for the bit front to become convex. A drop centre bit, thanks to its lowered centre, will not become convex during the bit life, and is thus the best choice, wherever possible.

If the above criteria are taken into account, the choice of bit, in descend-ing order, should be: Retrac button bit with ballistic buttons and drop centre

front; Retrac button bit with spherical button and drop centre front; Retrac button bit with spherical buttons and flat front; Insert bit, only used when very straight holes are required and nothing else works.

Bit DesignsFlat Front, Standard

The standard bit is most suitable for medium-hard to hard rock, where it gives good performance and long service life in normal condi-tions. Standard bits are easy to regrind, as the front and gau-

ge buttons usually are the same size.

Flat Front, heavy Duty

Hard rock, con-taining quartz and pyrites, often causes considerable wear to the gauge buttons. When drilling in rock with this characteri- stic, it is common practice to use Heavy

Duty bits, Model –20 or –21, where the gauge buttons are larger than the front buttons.

extra heavy Duty

Model –21 has better flushing characteris-tics, due to different clearance angle and shorter head.

Recommended in extremely hard and abrasive rock.

Drop centreExcellent results are obtained with the Drop Centre bit in soft to medium hard rock, with high penetration potential. The Drop Centre bit has outstanding flushing characteristics, and the cuttings are dis-

tributed evenly around the steel body, so minimizing steel wash. The drop centre part of the bit front produces a rock elevation or bump during drilling, which gives good guidance to the bit.

Correct Selection of Tophammer Rock Drilling ToolsOptimizing Penetration RatesIn order to achieve best possible penetration rate, a bit should be chosen where the total contact area between the cemented car-bide and the rock creates the best possible penetration per blow. As a rule of thumb, the following penetration rate index can be used: button bit with ballistic buttons, 130; button bit with spherical buttons, 115; insert bit, 100. However, when bits are compared for hole straightness, a different order emerges, with the insert bit on top, followed by the button bit with ballistic buttons, and lastly, the button bit with spherical buttons.

This article is intended to guide the driller through the range of bits, rods and shank adapters to assist with the best choice of rock tools for the particular job.

Bit designs and rock types

DC = Drop Centre; FF = Flat Front; HD = Heavy Duty; XHD = Extra Heavy Duty.

Talking Technically


Drop centre extra heavy DutyGauge buttons are larger than the front buttons, there are no side flushing holes, and the head is shorter. Recommended in extremely hard and abrasive rock, but can also be used in medium hard rock.

Retrac SkirtThe Retrac bit has cutting edges at the rear of the bit, allowing it to “drill” in reverse. This is an important feature when drilling in loose, broken or fissured rock, where it can be difficult to retract the drillstring due to hole collapse. In addition, the Retrac bit has deep grooves milled along the bit body for efficient cut-ting removal. The good guidance of this bit gives straighter holes.

insert BitsThese are very seldom used, except when very straight holes are required. Cross bits normally have cemented carbide inserts with a carbide grade for high wear resistance. X-bits normally have a carbide grade for improved toughness,

and are preferred where there is a ten-dency for squaring of the hole.

Drillrod SelectionFor bench drilling, three types of drillrods can be chosen: surface hardened rods, in which only the thread parts are hardened; carburized rods, where all surfaces, including the inside of the flush-ing hole, are hardened; and carburized Speedrods, having integrated couplings with male and female threads at oppo-site ends.

Surface hardened RodsSurface hardened rods are the toughest, and can take more abuse than the car-burized rods, but they have the lowest fatigue strength. They are a good choice when drilling in faulted or folded for-mations, when driller abuse, or lack of care and maintenance, are factors.

Tiger RodsThe new M-F Tiger Rods from Atlas Copco Secoroc are specially developed for surface drilling applications. They are composed of selected steels to give increased service life and better performance. The female thread is fully carburized, while the rest of the rod is sur-face hardened. The new Tiger Rods are friction-welded, so that the best steel grade can be selected for each section.

This improved production technology reduces the risks of pitting on the threads, and rod and thread end break-age, while tighter thread tolerance improves the total service life of the whole drill string.

Rigorous tests in various locations have shown that Tiger Rod is a drill string without any weak parts.

carburized RodsA carburized rod has better wear resist-ance and a higher fatigue life compared to surface hardened rods. Demands good treatment, and hole deflection should be limited by putting guiding equipment in the string, at least when drilling holes deeper than 10 m. Their life will be 20%-30% longer if they are handled correctly, and guiding equipment is used when necessary. When lighter drillrods are required for manual rod handling, the carburized hexagonal rod is recom-mended.

When drilling with a number of rods in a string, using standard rods and couplings, the loss of energy in every joint is about 6%, if the connection is tight. If drilling with open threads, the energy loss at each joint can easily climb to 10%. Therefore, it is advantageous to use the maximum rod length possible.

SpeedrodsIf Speedrod carburized rods with inte-grated coupling are used, the energy loss per joint is less, since the mass (weight) of the joint is less than that of standard coupling joints. The energy loss is about 3.5%, which is 60% of that of standard joints.

In practice, the energy advantage of Speedrod joints compared to standard couplings is even greater, since it is easier to keep the Speedrod joint tight during drilling.

Field tests have shown that, when drilling 20 m holes with 4 m rods, the penetration increase is about 15% when using Speedrods.

The faster penetration and easier handling increase productivity, and due to better energy transmission, the joints are easily loosened.

From the point of view of drilling straight holes, rods that are as rigid as possible for the drilled hole diameter are best. For straight hole drilling, a Guide Rod or Guide Tube should be used as the first rod after the bit, to give the drillstring guidance.

Further information about rods is available in the yellow technical specifi-cation pages in this reference edition.

Shank adaptersThe task of the shank adapter is to transmit rotation torque, feed force, impact energy, and flushing medium. It is made from specially selected material to withstand the transmission of impact energy and rotation from the rock drill to the drillstring, and is hardened through car- burizing. Around 400 different shank adapters are currently available from Atlas Copco Secoroc. Shank adapters can be divided into three main types, based on the technique used to transfer the rota-tion motor torque to the drillrod.

by alf Stenqvist

Talking Technically


Atlas Copco Secoroc has extended the range of button bits for surface drilling with two new models for drilling in soft rock formations.

The new models are designated –21–66 and –47–66. The designation –66 means that all the buttons are full-ballistic in shape and protrude 20–25% more than standard ballistic buttons. Model –21 has larger gauge buttons whereas all the buttons are the same size on model –47 .

The longer button protrusion helps the bit to penetrate deeper into the rock with each hammer stroke. Both model –21 and model –47 have excellent flushing capacity for the removal of the cuttings from the front of the bit head. The flushing is concentrated to four large flush-ing holes in the bit front plus equally deep and wide flushing grooves in

the front and sides of the bit head. A shorter bit head and larger clearing angle also allow for better flushing of cuttings on models –21 and –47.

increased penetration rateDuring tests in soft rock in Korea, Malaysia and Australia, these new bits showed much higher penetration rates than standard ballistic button bits, while their service life remained the same.

Model –21–66 bits with drop centre front are available with T38 thread in sizes 76 mm (3 in) and 89 mm (3.5 in).

Model –47–66 bits with flat front design can be supplied with T45 thread in size 89 mm (3.5 in) and with T51 thread in sizes 102 mm (4 in) and 127 mm (5 in).

More sizes and thread combina-tions will follow.

Full-ballistic button bits for soft rock

Secoroc full-ballistic button bit (dia 76 mm.) model –21–66. Drop centre front with larger gauge buttons.

Secoroc full-ballistic button bit (dia 127 mm.) model –47–66. Flat front with same size front and gauge buttons.

The full-ballistic buttons protrude more from the bit body, resulting in faster penetration in soft rock.

ThunderRod T60 – for the most powerful tophammer drill rigs Atlas Copco Secoroc has launched ThunderRod T60, a heavy-duty tophammer drill string designed for greater productivity. Specially designed with a bigger rod cross- section for 102-152 mm holes, ThunderRod T60 is built to handle the most powerful hydraulic rock drills, delivering higher power output for optimization of the drilling pattern. The entire drillstring is more rigid, offering increased hole straightness, higher penetration rate and a welcome boost to drilling productivity and economy. Fewer, but larger, drill holes per blast means higher productivity. Straighter holes result in improved fragmentation and far less secondary drilling and blasting.

The threads on ThunderRod T60 are designed to make the coupling sequence as easy as possible, while at the same time keeping energy losses to an absolute minimum. Fea-turing a cross-section 40% bigger than standard T51 rods, the new ThunderRod is designed to reduce hole deviation in all rock formations. The flushing hole is also bigger, ensuring a 10% increase in flushing capacity for up to 30 m-deep holes.

The new shank adapters for Thun- derRod T60 are optimally hardened, with a balance of core and surface properties designed to withstand the high impact power of modern rock drills such as Atlas Copco COP 2560, COP 2560EX and COP 4050. This leads to unparalleled fatigue and wear resistance.

Talking Technically


introduction

In the simplest of terms, percussive drilling systems go back to manually hit-ting a steel rod with a bit at one end and, as recoil makes the rod jump back, rotating it at a small angle between blows to ensure that the hole is round.

Most drilling for benching operations has been carried out with tophammers, using extension rods connected by threaded coupling sleeves, and an exchange- able drillbit at the bottom end. This

equipment works well for smaller hole diameters in solid rock, but it is not so effective in larger hole diameters, or in deteriorating ground conditions. There are problems in transmitting sufficient energy to the bit, especially in deeper holes, and in obtaining satisfactory flushing.

In tophammer drilling, the thrust has to be applied from the top to keep the

bit in contact with the bottom of the hole. This can cause the relatively slender drillstring to bend, steering the bit off its intended alignment.

Increasingly powerful hydraulic rock drills send more percussive energy down the drillstring, allowing larger hole diameters in benching. However, due to the microscopic movements between mating parts in the threaded drillstring,

COPROD drilling head arrangement.

Rockdrill

COPRODsection

COPRODhead

Tubedriver

20 – 40 kWRotation chuckAnvil

Guide

Drill rod

Guide

Drill tube

Guide

Bit tube

Bit chuck

Drill bit

COP1838 CR/2150CR/COP 2550CR and COP 4050CR rock drills.

COPROD Combines the Best of DTH and Tophammer DrillingThe Rock Driller’s DreamDrillers always dreamed of a system that would combine the straightness and accuracy of down-the-hole drilling with the enormous capacity of hydraulic tophammer drilling. Efforts to com-bine the advantages of the two techniques were unsuccessful, until the development of COPROD by Atlas Copco. COPROD is not only a combina-tion of positive features, it also in-tegrates two types of drillstring for percussive drilling by means of a tophammer. Inner drillrods transmit power and thrust to the drillbit and outer tubes transfer rotation, adding stiffness to the string and improved flushing effi-ciency. These assets achieve high tophammer drilling rates and large hole diameters. The rods in the COPROD sy-stem have no threads and are simply stacked one on top of the other. Laterally, they are centred by the guide bushes in the tubes which surround them, and longitudinally, contact between rod ends is maintained by the thrust from the top. Thanks to the unique double recoil damping system of the COP rock drills, the rod ends remain in permanent contact, energy losses are almost nil, and drilling efficiency is maintained from start to finish of the hole.

CI AA AB

CI AA AB

COP 4050ME-CR

COP 1838CRCOP 1838CR/2150CR/COP 2550CR

COP 4050CR

Talking Technically


energy is lost and heat develops. The energy loss may be considerable by the time the shock wave reaches the bit, and there will be thread wear and reduced life of the drillstring components.

The down-the-hole (DTH) system was developed to overcome some of the problems associated with hole straightness suffered by tophammer drills. Rigid guide tubes, with a large outer diameter, were developed to keep the drillstring on a straight course, and im-prove flushing. With a DTH hammer, a series of tubes offers far greater stiff-ness, and runs closer to the hole walls,

resulting in considerably less deviation than with a tophammer drillstring.

Power with Rigidity

The COPROD system combines the power of the tophammer with the rigidity of the DTH drillstring. COP-ROD rods move longitudinally within each tube, transmitting the rock drill energy to the bit. Lugs on the rods pre-vent them from sliding out during han-dling.

During drilling operations, if the bit enters a cavity and drops down in its

splines in the bit chuck, the hammer senses it, and percussion is interrupted. Rotation is maintained, however, and percussion restarts automatically when the bit meets resistance again.

Flushing air enters the bit via a centre channel, which connects to the cy- lindrical surface in the bit rod. A small amount of air, containing a little oil, es- capes via the splines in the chuck and the bit, and lubricates them. On its way up, the flushing air travels between the smooth outside of the tubes and the hole wall, providing a constant cross section, and ideal conditions for flush-ing the drilling fines.

COPROD offers unique features for drilling holes fast and straight. And the more troublesome the ground becomes, the more the incomparable drilling sy-stem comes into its own.

Thanks to the unique double recoil damping system of the rock drills de-veloped for use with COPROD, the rod ends remain in permanent contact with each other. Thus, there are near-zero energy losses at rod joints, and drilling efficiency is maintained at virtually the same level from the start to the final depth of the hole.

latest on cOPROD

The new COPROD drill string features a wide range of improvements. The thickness of the drill tube has been in-creased to 8.8 mm with a new, strong-er female thread connection to the end piece. This results in increased service life, virtually eliminating tube break-age, and helping to limit in-hole devia-tion.

The end piece of the COPROD section has been made shorter and rede-signed with a new male T-thread con-nection to the drill tube, eliminating thread breakage. The diameter of the CR 76 inner rod has been increased and the end diameter of the CR 89 inner rod matches the anvil to optimize serv-ice life and penetration rate.

In the COPROD head, the bit rod has been redesigned to eliminate the rod guide. Closer tolerances reduce air passage in the bit spline area to a minimum, preventing shank breakage, while improved airflow reduces plug-ging of the bit. The drill bit itself is now

The new COPROD drillstring provide longer life and higher penetration rate.

ROC F9CR retrofitted with second generation COPROD drilling in Belgium.

New bit tube and bit roddesign for improved guidance

New design for improvedguidance and air flushing

New steel gradeincreasesbit service lifeStronger tube,

8.8 mm wall thickness

New rod guide design

New strong T-thread connectionbetween tube and end-piece

COPROD section CR 76 and CR 89 (lenght 3.66 m/12 ft)

COPROD head CR 76-CR 140

Talking Technically


made of a new grade of steel with high impact and fatigue strength.

The diameter of the 89 mm COP-ROD tube can be worn down to 80 mm before replacement, and, with low air pressure of only 12 bar, less airflow in the annulus results in up to 50% longer life.

Fractured Rock in austria

Asphalt & Beton GmbH, the quarrying division of Austria-based Strabag, produces 18 million t/y at 57 quarries in 11 countries. An Atlas Copco ROC F7CR forms the backbone of the operation at the company’s 650,000 t/y Jakomini quarry located on an Alpine slope in the Bleiberg region of southern Au- stria. The operation, which is mainly quarrying fractured metamorphic dia-base of 140-150 Mpa hardness, features seven benches, each around 20 m-high. Blasthole depths range from 20 m to 26 m, angled at 80 degrees. Presplit drilling is carried out to maintain slope stability of the benches.

The ROC F7CR drills 92 mm-diameter holes, using an impact pressure of 120 bar during collaring, and work-ing pressure of 200 bar. Nett penetra-tion is 1 m/min, and each hole takes around 20-30 minutes to drill. After 10,000 drill metres, the wear on the drill tube was 0.5 mm, and five bits had been consumed.

The benches are reached by steep gradients, with inclines of up to 30%, a real test of tractability and stability for any drillrig, but one in which the ROC F7CR excels.

The COPROD system of straight hole drilling is ideal in the fractured rock, which is subject to water influx while drilling. It is also very fuel-efficient at 0.7 litre/drillmetre, just half of that ex-pected from DTH rigs. Within a month of delivery in 2005, the ROC F7CR was averaging 25 m/h, and has since achieved consistent monthly perform-ances of over 31 m/h.

abrasive Rock in Belgium

Belgian company DGO M3 is a mem- ber of the French EPC Group, and one of the largest drilling contractors in Europe. With an annual production

of up to 115,000 drillmetres from 24 quarry sites around the country, the company is heavily reliant on continuous drill rig availability and production. It has a fleet of Atlas Copco rigs, com-prising a new ROC F9CR, a second ROC F9CR retrofitted with the new COPROD system and COP 2150 rock drill, a ROC F7CR, and a ROC L6H DTH rig.

The COPROD rigs equipped with 127 mm-diameter bits are used for hole depths up to 30 m, while the ROC L6H can go down to 45 m-deep. A wide variety of rock types and formations is drilled, ranging from medium-to-hard limestone and sandstone to granite, por- phyry and grit.

With COPROD, the company can drill at any of its operations, giving it the necessary flexibility to obtain very high efficiencies. Using the lower air pressure of 12 bar, the flushing air and cuttings do not destroy the hole collar, and a 20 % higher productivity is ob-tained compared to the 25 bar DTH rig. Rapid bit changeover times also ensure that regrinding and frequent bit

changes do not cause undue delays. At the sites, every drill pattern and blast is designed with Geolaser profiling of the bench, and hole alignment is checked with the Pulsar system.

There are currently ten COPROD drill rigs operating in Belgium, nearly all of which are located in the French-speaking Walloon province. These are served by Atlas Copco distributor SE-MAT, based at Spy, near Charleroi.

SEMAT carries out any major repairs and overhaul work for DGO, whilst the contractor does its own weekly servicing. DGO reports that, over the last two years using the new COP-ROD system, it no longer breaks tubes, and has recorded a 50% improvement in service life of the drill string. Every six months, each rig is taken out of operation for one week for a major ser-vice, usually coinciding with a period of slack demand. Nearly all COPROD rig owners have increased the diameters of their drill bits due to increased confi-dence in maintaining correct hole alignment, allowing less holes to be drilled for the same output.

ROC F7CR in the Jakomini quarry.

Talking Technically


limestone in Taiwan

Ho Ping limestone quarry, at Hualien in Taiwan, has a fleet of six Atlas Copco ROC F9CR crawler drill rigs equipped with the COPROD system and COP 1838 CR rock drills. In operation since 1981, Ho Ping is owned by Taiwan Cement, and produces 12 million t/y of limestone, making it the largest cement quarry in Taiwan.

Located about 1,000 m above sea level, the quarry is one of a number operated by Chien-Kuo Construction Co on behalf of the country's major cement

companies. The company also operates in the People's Republic of China, Viet- nam, Indonesia and the Philippines.

Four Atlas Copco ROC F9CR rigs joined the production fleet in 2001, and another two units were delivered in 2002.

They are proving to be highly pro-ductive at 25 drillmetres/h, and emi-nently suited to the type of rock being mined, which is loose and fractured. They are capable of drilling holes to depths of up to 30 m, and diameters up to 127 mm.

Site layout at Ho Ping is designed to keep noise, vibration and visual impact

to a minimum, by downward excava-tion from the hill. To reduce the noise, dust and danger associated with truck movements, the rock is fed through gy- ratory crushers, and transported along a system of shafts and conveyors to a stocking area at the bottom of the hill. There are three 6 m-diameter vertical shafts, and one 900 m-long tunnel and two 1,100 m-long tunnels.

The altitude causes the quarry to be shrouded in mist quite often, and it can be damp and cold in the winter, affecting the hours and safety of work. Chien-Kuo carries out two blasts each day, 28 days a month.

conclusion

Statistics prove that the COPROD system, in spite of its higher initial cost, offers improved economy, and is some-times the only solution worth consid-ering when drilling becomes difficult due to demanding ground conditions.

COPROD’s superior penetration rate contributes to a lower cost/m drilled than for DTH. In comparison with top-hammer drilling with extension steel, COPROD’s better gross penetration and hole quality provide lower cost/t in dif-ficult rock formations.

Summing up, COPROD offers unique features for drilling holes straight and fast, and it comes into its own in troublesome ground. Due to the number of components involved, a COPROD

Idealized section through Ho Ping quarry.

Ho Ping quarry is located 1,000 m above sea level.

Talking Technically


drill string carries a higher price than comparable extension rod, or DTH, strings.

However, because the holes are drilled fast and without deviation, permitting the drilling pattern to be opened up, COPROD leads to lower costs per excavated volume of rock. Time is also saved in retracting the drill string in broken ground, or through blasting debris left on top of the bench.

The latest COPROD system improves on these advantages, offering longer drill string life and better availability than ever before.

by lennart lundintonnes x 1000

Immaculate conveyor tunnel at Hualien.

Tophammer

Down The Hole

COPROD

• Unbeatableundergooddrillingconditions• Lowfuelconsumption• Lowinvestmentindrillstring

• Straightholes• Deepholes• Verysimplemethodfortheoperator

• Unbeatableunderdifficultdrillingconditions• Straightholesandhighproductivity• Goodpenetrationrates

Strong points of different bench drilling methods

Talking Technically


Quality holes

In the hole range 100-254 mm, DTH drilling is the dominant drilling method today. The main features of DTH drilling in this hole range are: excellent hole straightness within 1.5% deviation without guiding equipment; good hole cleaning, with plenty of air for hole cleaning from the hammer; good hole quality, with smooth and even hole walls for easy charging of

explosives; deep hole drilling capac-ity, with constant penetration and no energy losses in joints; and efficient energy transmission, with the piston striking directly on the bit.

The COP 34-84 series of ham-mers was introduced from 1992, and immediately became the benchmark for productivity within DTH drilling. Over the years, the increase in aver-age drilling pressure, from 17 bar to a current market standard of 25 bar, has improved hammer performance, and productivity has increased proportion-ally to air pressure.

The introduction of the Atlas Copco ROC L8 and L6 series of high- performance, high-pressure DTH rigs

gave another boost to the sales of ham-mers. The flexibility, productivity and manoeuvrability of these rigs, when equipped with a COP hammer, makes them the most productive combination on the market today.

cOP 64 gold

The increase in drilling pressure also had some negative impact on the inter-nal components of the DTH hammer, as the increased stress promoted the

DTh growing in PopularityThe DTH drilling method is grow-ing in popularity, with increas-es in all application segments, including blasthole, water well, foundation, oil & gas, cooling systems and drilling for heat exchange pumps.

DTH competes favourably with rotary drilling in open pit mines, mainly thanks to increased pro-ductivity and flexibility. Open pit mining has adopted smaller holes where rotary drilling has either been replaced by DTH, or where DTH has been introduced to create a better finish to the pit wall, as the method is also per-fect for pre-splitting and smooth blasting, which avoids back-cracking.

DTH drilling offers increased productivity, and is favoured by contractors for production drill-ing. In larger quarries, the opti-mum hole size is 110-140 mm. With today’s demands for strict hole control for safe blasting in populated areas, DTH drilling is a popular choice among quarry operators.

Increased Productivity With DTH Drilling

New Secoroc hammer and bit ready for action on an Atlas Copco drill rig.

Cutaway section of Secoroc COP 64 Gold.

Talking Technically


risk of premature failures. So, in 1998, Atlas Copco Secoroc decided on a long-term strategy to improve reli-ability, while retaining the benchmark status of the COP 64 DTH hammer.

Stage One of this strategy was the development of the second generation six-inch hammer, COP 64.2, intro-duced in October, 2000, which incor-porated newly-designed steel disc spring and lower buffer. Performance was vastly improved, thanks to a dras-tic reduction in the number of internal failures. It was also possible to rebuild the hammer without diminishing its performance, making it even more attractive.

Stage Two was the introduction of the third generation COP 64 hammer, COP 64 Gold, which was unveiled in August, 2001. This version offers sus-tained performance and improved lon-gevity of the external parts. The COP 64.2 resolved internal component reli-ability, while the COP 64 Gold has experienced a dramatic drop in the number of cylinder failures.

COP 64 Gold also boasts improved sustainable efficiency, maintaining an average of 96% of original perform-ance throughout its service life, which is a further improvement on COP 64.2.

Durability improvements, thanks to the higher tensile strength of the new steel grade, are especially noticeable when the cylinder approaches mini-mum thickness limits. COP 64 Gold enjoys a greater durability margin than its predecessor.

With the introduction of COP 64 Gold, hammer life will increase substantially. Less internal and external wear, together with a reduced minimum cylinder wear limit, are key

contributing factors. The hammer is virtually maintenance-free, with no need for an economy kit in most appli-cations. Ultimately, this means cus-tomers can look forward to increased drill rig availability.

The sum total of these improve-ments shows COP 64 Gold to have more than 50% greater service life, in abrasive rock conditions, than its predecessor.

The customer benefits from lower cost/metre drilled, thanks to less down-time and greater abrasion resistance, and 30-50% longer life of external parts.

Higher availability results from less breakage in the threads of top sub and chuck-ends of the cylinder, and there are fewer stoppages for service and maintenance. Improved penetration rate and higher efficiency are a result of reduced friction of the piston, and a greater life cycle penetration rate is the overall reward.

To sum up, the customer can drill more holes per hammer than previously.

applications

COP 64 Gold is a high-pressure hammer, where performance is related to air pressure. A lower limit of 12 bar for deep hole applications is a good rule of thumb. The hammer is designed

for the same types of application as COP 64.2, with special focus on high-pressure applications.

In abrasive formations, performance will be up to 50% better than COP 64.2, in what is an ideal application for COP 64 Gold.

In soft unconsolidated rock drill-ing, the 12-spline chuck concept and the improved durability make COP 64 Gold the perfect hammer. High pres-sure yields higher productivity, and drilling pressures of 28-30 bar are not unusual.

The COP 64 Gold hammer concept offers customers a tool to meet the most exacting requirements.

hammer cylinder

The new cylinder has been redesigned in a number of important ways. COP 64 Gold boasts a cylinder made of low alloy wrought and toughened steel, a new grade with a higher combined Mo- lybdenum and Vanadium content (4.8%) than its predecessor. The result is greater impact strength and higher wear and temperature resistance. All in all, this means greater resistance to breakage, impact, temperature and wear for the new hammer cylinder.

Thanks to the new steel grade, cyl-inder properties have been greatly improved. Wear has been reduced, both internally and externally. Cuttings

Table 1 Comparison of COP 64.2 and COP 64 Gold steel.

COP 64.2 steel COP 64 Gold steel Improvement

Yield point ReL(Mpa) 700 1400 100%Breaking strength Rm(Mpa) 1000 1950 95%Hardness (HRc) 32 42 31%

Table 1 reveals not only that the yield point for the new steel grade is twice as high, but also that breaking strength has been almost doubled.

Secoroc COP 64 Gold.

Talking Technically


and moving parts no longer cause the problems they once did. In effect, the service life of the cylinder has been extended considerably.

The new steel grade possesses greater tensile strength, which means the minimum wear limit can be decreased from an overall cylinder diameter of 132 mm, to 130 mm.

The result is a hammer that main-tains performance far longer than its predecessor, while being, in effect, maintenance-free.

Longitudinal milled slots have replaced the circular undercut found in COP 64.2. The piston now enjoys 100% guidance throughout its stroke, as opposed to the older undercut that let it partially move freely at the end of

the downward stroke. Thanks to these slots, wear on the porting edges of the cylinder undercuts and piston has been eliminated. That means air leakage is down to a minimum, and so are noise levels!

The polygon-shaped piston pro-vides a ten-point guide system, while retaining excellent force on the bit. It is sturdier than its forerunner, fitting hand-in-glove with the milled slots to provide superior guidance and airflow all the way through the hammer.

The QL 60-style chuck, together with a 12-spline bit, add up to a stronger bit shank. This is especial-ly useful in soft and unconsolidated rock conditions, where bits tend to move axially in and out in the chuck

during drilling. This may lead to greater friction between chuck and splines, causing premature spline wear. Furthermore, the increase in the number of splines, from eight to twelve, leads to greater surface contact between bit and chuck, lessening stress on the splines.

The high demand for COP 64 Gold hammers, particularly in applications where performance and reliability are major considerations, has led Atlas Copco Secoroc to add the COP 54 Gold to this increasingly successful range.

by leif larsson

Increase in service life of COP 64 Gold, which has a 50% longer life than its predecesssor.

Total improvement

Due to wear resistance

Due to wear limit change

Due to less cylinder failure

Results of comparative tests with COP 64.2 and COP 64 Gold. The COP 64 Gold drilled 50% further.

New MaterialOld Material

16 000

14 000

12 000

10 000

8 000

6 000

4 000

2 000

0146 145 144 143 142 141 140 139 138 137 136 135 134 133 132 131 130 129 128

Dri

ll m

etre

s

Cylinder OD (mm)

Talking Technically


Relevant applications

QuarryingCompanies producing in non-abrasive rock formations should consider ham-mers such as Secoroc Quantum Leap or Secoroc COP. Both are time-tested and field-proven designs offering good productivity and ease of service.

Producers demanding the highest productivity and/or drilling in abrasive formations should consider either the Total Depth or Secoroc COP Gold hammers. These incorporate the latest technology

and are the most reliable and produc-tive hammers on the market. For cus-tomers who are happy with rebuilds, Total Depth is recommended, while for those who typically run hammers until they wear out, Secoroc COP Gold has unbeatable wear resistance and will be the first choice.

Dimensional stone quarrying demands consistent hole straightness, and such operations typically use smaller size holes of 85-90 mm in limestone, granite and marble. Here the TD 35 and COP 32 hammers are the best choice

constructionCivil engineering drilling subcontrac- tors and drilled foundation contractors will be attracted to the improved performance of both Secoroc Quantum Leap and Secoroc COP hammers. Both of these balance good productivity with ease of service. For applications

demanding the finest performance, the choice will be between Total Depth and Secoroc COP Gold hammers. At the other end of the scale, rental companies will appreciate the Secoroc DHD as a tried and tested hammer that is rugged, reliable, and easy to repair or replace.

Mineral explorationMineral exploration generally occurs in very remote locations, requiring robust hammers capable of running high pressures, in sometimes dirty environments.

For true reverse circulation drilling with face collection in mineral explo-ration and in-pit grade control, the Se- coroc RC50 Reverse Circulation Ham- mer, incorporating the Quantum Leap cycle, performs particularly well.

Geotechnical Environmental moni-toring applications will appreciate the Secoroc DHD, or possibly the Secoroc Quantum Leap or COP hammers.

Selecting the Right DTH Drilling Toolscovering every applicationAtlas Copco Secoroc now has the most comprehensive range of DTH hammers, bits, and related equipment of any supplier in the world, backed by the strongest support network in the industry. Whether the call is for reliable hammers to keep investment to a minimum, or for the highest productivity to ensure maximum rig output, Atlas Copco Secoroc has the solution. The company is the only manufacturer to offer both first and second choice solutions in almost all typical DTH applications on a price vs performance basis. For premium performance and advanced technology, Total Depth and COP Gold hammers are offered. For an optimum blend of features and cost, COP and Quantum Leap can be the solution, and for high reliability at economical price, no-thing beats DHD hammers. Total Depth, COP Gold, Quan- tum Leap, and COP and DHD Clas-sic hammers are also energy efficient, consuming less fuel and with lower energy cost per drilled metre than other DTH hammers. This enormous choice of DTH drilling tools is backed by a reli-able network of distributors and customer centres that offer a complete range of parts, service and support.

Quarrying application

Talking Technically


Drilling of holes for foundation, an-choring or drainage demands reliable, inexpensive hammers like the Secoroc DHD range.

Open Pit MiningMining operations typically have high equipment utilization, drilling up to 80% of the working day with DTH. The typical applications are normal 130-203 mm-diameter blast holes, 140- 165 mm buffer holes, or 115-140 mm

pre-split holes. Companies should con-sider either the Total Depth or Secoroc COP Gold hammers. These incorporate the latest technology, and are the most reliable and productive hammers on the market. For customers who are happy with rebuilds, Total Depth is recom-mended, while for those who typically run hammers until they wear out, Se- coroc COP Gold will be the first choice.

Well and geothermalWater wells generally use a larger dia-meter, cased and sealed surface section, followed by a 70-250 m-deep and 4.5-6.5 in-diameter drilled well bore. For smaller, family-run companies, the ideal hammer will last as long as possible, with minimum maintenance. For larger companies with more rigs, performance, reliability, and availability of service and support become more important.

Geothermal drilling is similar, but may be carried out in remote locations, so the emphasis may be on the need to keep the hammer working as much as possible.

Once again, Total Depth, with its Air-Select System, is the fastest and most reliable, while Quantum Leap and Secoroc COP offer excellent perfor-mance with minimum maintenance.

Shallow Oil and gas (cBM)In this application, the customer uses a larger diameter 12.25 in - 17.5 in cased and sealed surface section, fol-lowed by a 500-2,500 m-deep drilled

well bore with final diameter of 6.5 in. For these projects, performance, reli-ability and availability of service and support become most important.

Once again, Total Depth, with its Air-Select System, is the fastest and most reliable, with a minimum of maintenance.

Selecting the Right hammerThe optimum range of hole size for DTH drilling is 90 mm to 254 mm. Smaller holes are generally drilled using tophammer, and larger holes generally use rotary machines. However, DTH has an expanding position in the larger hole sizes up to 750 mm. As a rule of thumb, the smallest hole diameter a DTH hammer can drill is its nominal size. A 4 inch hammer will drill a 4 inch (102 mm) hole. The limiting factor is the outside diameter of the hammer, because, as hole diameter reduces, air-flow is restricted. Maximum hole size for production drilling is the nominal hammer size plus 1 inch, so for a 4 inch hammer the maximum hole size is 5 inch (127-130 mm).

Choosing the right hammer is largely determined by hole size and type of rock formation. Ideally, the size of the hammer should match the required hole dimension as closely as possible, leaving just enough space for cuttings to evac-uate the hole.

Secoroc hammers are purpose- matched for all rock types and applica-tions. Where high performance is the main criterion, Secoroc COP Gold and Secoroc Total Depth hammers are rec-ommended.

In deep hole drilling applications, the Total Depth hammer has proven superior performance and adaptability to different air requirements, thanks to the Air-Select System.

Where proven technology is required, the Secoroc COP and Quantum Leap hammers are known for their reliability and longevity, and for a reliable work-horse, the Secoroc DHD is practically bullet proof, with a 30 year history of continuous improvement.

The Standard design for COP 54 and COP 64 Gold hammers can be used down to a depth of 330 ft (100 m)

Clusterdrill for construction work

Changing a Secoroc bit.

Talking Technically


using a Standard bit size, making it useful for production drilling in quar-ries, shallow waterwell drilling, and un-derground blasthole drilling. HD is si-milar to Standard, but with heavy duty chuck and wear sleeve, and a top sub fitted with tungsten carbide buttons for wear protection in harsh and abrasive conditions. These also protect the top sub from excessive wear when rotating out of the hole through broken rock.

Selecting the Right Bit

Atlas Copco Secoroc has a compre-hensive range of DTH drill bits to matchall conceivable applications. Each bit is made from quality alloy steel, and has been precision machined to pro-duce a perfect body, heat treated to therequired hardness, given surface com-pression for fatigue resistance, and fittedwith precision buttons manufactured in-house.

Five basic designs are available: CV Bit, FF Bit, SpeedBit, CC Bit, and Rocket Bit. These are designed forspecific applications for all rock types, hardnesses and conditions.

Bit life and rate of penetration are the most important criteria in selecting the right bit for a particular application.In most cases, the focus is on produc-tivity, so the fast cuttings removal

features of the SpeedBit and Convex/Ballistic designs are preferable, to en-sure the buttons are cutting clean, with the minimum of re-crushing.

In hard and abrasive formations, however, the flat front (FF) HD design offers best bit life, having strong gauge rows with large spherical buttons whichare easy to regrind and maintain. The SpeedBit offers improved productivitywith the same gauge as the FF HD, butwith ballistic buttons in the front for faster penetration. An alternative is the Concave design with spherical buttons.

The Rocket Bit can be dressed with ballistic buttons for use in soft to me-dium hard formations where fractured rock can be expected, or can be sup-plied with spherical buttons for hardand abrasive formations. Bits are manu-factured to match all diameters of AtlasCopco Secoroc hammers.

Secoroc hammers

highest performanceThe Secoroc COP Gold and Total Depth hammers are designed for the most

Bit designs and rock types.

Soft rock Medium hard rock (220 Mpa/32000 psi) Hard rock

Flat front HD

SpeedBit

Convex/Ballistic

Concave

Concave DGR

Rocket bit ballistic

Rocket bit spherical

Waterwell drilling.

Talking Technically


demanding drilling conditions and for those applications requiring premium performance. These hammers feature state-of-the-art technology and deliver both maximum productivity and profit.

Secoroc cOP gold• Superior longevity and reliability.• Easy to service and rebuild.• Best suited for production drilling because of its excellent external wear resistance and longevity.• Internal components coated for wear and corrosion protection. Permits multiple rebuilds.• Three start chuck thread for easy bit changes.• Bit replacement possible without using drill rig break-out chains and wrenches.• Unique air cushion reduces wear and tear on drill string and rig.

Secoroc Total Depth• Provides the industry’s highest power output.• Best suited for deep hole applications.• Industry-leading simplicity and serviceability, resulting in very low operating costs.• Features modular components, snap-in cylinders, a reversible casing, backhead saver sleeves, and many options.• The hybrid valved/valveless design maximizes air compressor productivity.

Proven TechnologySecoroc COP and Quantum Leap®

hammers combine strong performance with years of field proven technology. These hammers are known for reliability and longevity.

Secoroc cOP• Mainly used in mining, including underground, quarrying, and geothermal well drilling.• High reliability.• Internal components coated for wear and corrosion protection.• Can be rebuilt frequently for longer service life.• Three start chuck thread for easy bit changes.• Unique air cushion reduces wear and tear on drill string and rig.

Bit designs Facts

convex/Ballistic front design Convex front with large cutting grooves and ballistic gauge and centre buttons. For soft to medium hard non-abrasive formations. The bit is designed for maximum penetration rate. Also, an alternative in hard abrasive formations, if high penetration rate is called for.

SpeedBitFlat front design/ballistic centre buttons. Flat front with spherical gauge buttons and ballistic centre buttons. For high penetration in medium hard to hard abrasive formations.

Flat front design – hDFlat front with large spherical gauge buttons for hard and abrasive formations. Also, front flushing grooves for effi-cient cuttings removal.

concave front designConcave front with spherical buttons Perfect choice for medium hard to hard, less abrasive, fractured formations. Minimizes effect of hole deviation.

concave front design – hDConcave front with spherical buttons, with larger gauge buttons. Ideal for medium hard to hard, abrasive and frac-tured formations.

concave DgR front design Concave front with double rows of spherical gauge buttons. Only available for 8 in bits and larger. The rein- forced gauge gives superior protection in medium hard to hard, abrasive and fractured formations.

Rocket bitSuper high penetration in soft to medium hard formations with low silica content. The Rocket bit also handles difficult formations with clay intrusions where other bit designs will not work.

The Secoroc range of DTh bits ensures that every driller can demand a solution for every application.

Talking Technically


Secoroc Quantum leap®

• The industry’s first hybrid- combination of valve and valve-less air cycle.• Mainly used in water well deep hole, production drilling and large diameter construction projects.• Wide range of available diameters.• Many options, including Hydrocyclone® and bit retrieval systems for application flexibility.

Reliable WorkhorseSecoroc DHD hammers are practically bullet proof, having been proven by continuous, successful operation in the industry for over thirty years.

Secoroc classic DhD• Many parts are common to those used in the Secoroc Quantum Leap®.• High reliability.• Cost-effective.• Time-tested performance

Selecting the Right Tube

Key features of a high quality DTH tube are durability, accuracy and man-ageability. Atlas Copco Secoroc tubes are made from cold drawn tubing, providing a superior surface finish and tolerance compared to conventional tubes made from hot rolled tubing.

This drastically reduces the risk of scaling from the tubes entering the hammer, a major cause of premature ham-mer failure.

The joints are friction welded to achieve maximum strength, and the threads of the end-pieces are heat treated for optimum durability and strength of the thread profile. This not only ensures long thread life, but also makes coupling and uncoupling quick and simple, reducing drilling time.

Tube diameter should be close to the hammer diameter to provide opti-mum flushing, reducing the chances of getting stuck.

In most applications, Atlas Copco Secoroc standard API threads will be the best choice.

Atlas Copco Secoroc also offers a wide range of subs and crossover subs to meet an array of demands, all man-ufactured to the same standards as the tubes.

Quality Standard End piecesAPI grade N-80 tubes and adapters

Lower yield limit N/mm2 min 550 min 550

Tensile strength N/mm2 min 650 min 700

Elongation A5 min % 18 21

Core hardness HB 190–230 210–250

Surface hardness HRC 58–62

Drill tube Wall 23/8" 23/8" 27/8" 27/8" 31/2" OD (mm) (mm) RD 50 API Reg API IF API Reg API IF API Reg

70 3.6 ■ ■

76 3.6 ■

76 5.6 ■

89 3.7 ■

89 5.7 ■ ■ ■

102 5.7 ■

114 4.3 ■ ■

114 5.7 ■

114 7.9 ■

Secoroc COP 54 Gold Express - the production driller´s best friend.

Talking Technically


Premium Plus DTH Bits - tough bits for a tough lifeThe latest Atlas Copco Premium Plus DTH bits address the age-old problems of shanking and chunking, making them so uncommon as to be considered rarities.

Since their introduction, a 10-30% increase in life has been reported for Premium Plus DTH bits over their predecessors, with up to 50% in some formations! Add a 5% increase in penetration rate, and this range represents the best DTH-bit concept on the market.

The design uses a tougher steel grade for improved fatigue properties. Furthermore, the buttons have been positioned for faster penetration, and protrude more, for improved cuttings removal, less secondary crushing and easier bit grinding. To reduce the risk of jamming in the hole, the taper on the bit head is shorter, with a larger clearing.

The Premium Plus range offers bits for 4/5/6 inch hammers, available in the following configurations: Flat front HD, SpeedBit, Convex front with ballistic buttons and Concave front.

cOP Backhammer

The COP Backhammer is a tool that can save and recover a drillstring stuck in a hole. It can be easily fitted in a suitable tube joint between the drill support and the rotation head to provide an effective combination of back-ward hammering and vibration to lo-osen stuck drill strings.

Service and Support

Atlas Copco Secoroc service, support and training follows every purchase, to ensure that customers extract maximum productivity from their drill-ing operations. Having a knowledge- able and available Secoroc drilling engineer on site or on-line makes the difference between going it alone and tapping the experience and know-how of a world-class partner. For example, Secoroc knows that using higher productivity bits reduces the cost of each drilled hole, and the

simplest way to cut costs is to drill holes faster. This has been a focus of product development, and is at the core of Secoroc technology, ensur-ing that every generation of products drills faster and more efficiently. It takes a support team to apply this knowledge, so that customers can be assured they run a profitable and efficient

drilling operation in an increasingly competitive business climate. The bottom line is that the customer can count on Secoroc service and sup-port, supplied by the largest, most de-dicated manufacturer of DTH drilling tools in the world.

by leif larsson

With on site support, the choice of DTH equipment is even easier to make.

Talking Technically


grinding Methods

There are two different methods of bit grinding to restore the buttons. The preferred method uses a diamond coated profiled wheel, and the other, a grinding cup.

The profiled wheel provides a smooth and efficient grinding operation,

which, throughout its life, maintains the correct button shape and protrusion. It features correct centring on all buttons, producing a high quality cemented carbide surface, with no risk of cemented carbide nipple. Long bit life, and higher penetration rates, will result from good grinding quality.

Disadvantages of using the grinding cup are that it may produce an incorrect button shape and protrusion. It is difficult to centre the grinding cup over the gauge button, and there is also a risk of producing a sharp cemented carbide nipple on the button, and a possibility of scratches due to the larger diamond grain used. Reduced bit life will result from poor grinding quality.

Several tests have been carried out to find which method gives the best bit performance. The grinding wheel gives the correct shape to the button, regardless of the amount of wear on the wheel, ensuring that the bit will

The Economic Case for Routine Bit Grinding

cutting hole costsThe button bit was originally developed to do the job of an insert bit, without the necessity for frequent grinding. However, it was soon found that the service life of a button bit increased con-siderably if the cemented carbide buttons were ground.

Nowadays, it has become extremely important to grind button bits at proper intervals, in order to extend the service life of the rock drilling tool, maintain penetration rates, and drill straight holes.

In all rock excavation opera-tions, the cost is usually expressed in cost per drilled metre (cost/dm), in cost per cubic metre (cost/cu m), or in cost per tonne.

The cost to produce a hole depends on how fast it can be drilled, and how many tools will be consumed. The cost to produce a cubic metre of rock is dependent upon the cost of the hole, and the cost of blasting. If the blasthole is of poor quality, then more explo-sives will be consumed in blasting the rock. Unsharpened bits very often give a poor quality hole with deviation.

Grinding constitutes around 2% of the costs of the entire drill-ing operation. To run the busi-ness without grinding could multiply this cost, with up to 100% added when production losses are taken into account. Labour and material are the high-est costs, while the machine investment cost is low when utilization is high, with a large number of bits to be ground.

Diagram 1: Typical bit life grinding at different intervals.

Total bit life drill metres

700

600

500

400

300

200

100

0

10 20 30 40 50 60

10 regrindings per drill bit

Grinding interval drill metres

The Secoroc Grind Matic BQ2 grinding machine can handle drill bits up to 127 mm in diameter.

Talking Technically


achieve standard penetration rate throughout its entire life. It has also been shown that bit life is increased considerably when grinding wheels are used, rather than grinding cups. Wheels also excavate steel around the button, simplifying the grinding task, and giving the bit a more exact profile.

Bit life

With so many parameters involved, it is difficult to estimate bit service life. First, a proper grinding interval must be established, preferably at the stage when the button has a wear flat of one third of the button diameter. When the number of drilled metres to reach this stage has been established, then a calculation of bit life can be made, by multiplying by the number of times it can be reground. As a general rule, a bit can be reground 10 times, but smaller bits may achieve slightly less than this figure, while larger bits may achieve more. So, if the grinding interval has been established as 60 drill metres, then the average bit life will be 660 drill metres (diagram 1). If a bit is overdrilled, and the wear flat is more than half of the button diameter, there is a tendency towards cracked buttons.

There is always a sharp edge created on the button, and this becomes sharper the more the bit is overdrilled. This sharp edge, especially on ballistic buttons, is very brittle. Once the edge cracks, pieces of cemented carbide

break away and circulate in the hole, causing secondary damage to the buttons.

When a bit doesn’t show any visible wear flat, it may be suffering from micro cracks on the cemented carbide surface. This is known colloquially as snakeskin, and can be clearly seen when using a magnifier. In this case, the surface has to be ground away, otherwise the micro cracks lead to more severe damage on the buttons. Likewise, buttons which protrude too much must be ground down to avoid damage (diagram 2).

Penetration Rate

When the right bit has been chosen for the rock condition, it will provide maximum penetration rate, along with acceptable hole straightness. In rock conditions like Swedish granite, with a compressive strength of around 2,200 bar, the bit gets a wear flat after just 1020 drill metres, accompanied by a small drop in penetration rate. When it has a wear flat equivalent to onethird of the button diameter, the penetration will have dropped by 5%. If the bit is used further until it has a twothirds wear flat, the penetration

Diagram 2: Risk of total loss when a bit is overdrilled.

Diagram 3: Penetration rate drops as the button profiles flatten.

Talking Technically


will have dropped more than 30% (diagram 3).

When a bit has a heavy wear flat it tends to deviate, and, by the time it reaches the bottom of the hole, it will have deviated far more than planned. As a result, the blast will produce coarse fragmentation, and much secondary blasting may be required.

In slope hole drilling, it is of utmost importance that the holes are straight. If the holes deviate, the slope walls will be uneven, making rock reinforcement more difficult than expected.

Rock formations with different layers and joints are often characterized by heavy hole deviation, putting extra stress on the remaining rock tools in the drillstring. A sharp bit always

cuts better, and will prevent both deviation, and its disadvantages.

grinding Machines

Two parameters guide the selection of the right grinding machine: the number of bits to be ground; and whether the machine should be portable or stationary. Several kinds of grinding machines are available to satisfy these parameters. In most cases, a simple machine will suffice for a small operation, grinding only a few bits. The semiautomatic machines are more suitable for larger operations, such as mines and construction sites, where the machine can be stationary, and the rocktools can be brought to it.

Grind Matic HG is a water or aircooled handheld machine for grinding cups. Both spherical and ballistic cups are available. The machine is driven by up to 7 bar compressed air, and is suitable for a small grinding operation.

Grind Matic Manual B is an airdriven portable grinder using diamondcoated grinding wheels for spherical and ballistic buttons. The machine is mounted in a box fitted with wheels and handles for easy set up. It is mainly for threaded button bits, but small downthehole bits can be ground in this machine. A steel spring is mounted in the profile of the grinding wheel, where it functions as a centring device, allowing for easy grinding.

Grind Matic Manual BDTH is similar to the Grind Matic Manual B. It is mainly intended for downthehole bits, but can also be used for threaded bits with a special bit holder. As an optional accessory, the machine can be equipped with a belt grinder for gauge grinding.

Grind Matic BQ2 is the latest semiautomatic machine, with many features such as autoindexing device, timer control, automatic feed, and an automatic centring arm. These features, coupled to an ergonomic design, ensure high productivity, and the machine is designed to handle large volumes of threaded button bits. Cooling water is recycled after the

Cost of grinding reduces dramatically with volume.

Annual grinding volume – buttons. Figures

on the left side of the diagram show cost per

button in SEK.

9

8

7

6

5

4

3

2

1

0

Labour cost

Grinding material cost

Machine cost

5 000

10 000

25 000

50 000

75 000

100 000

Diamond grinding wheels. Grind Matic Manual B.

Talking Technically


waste product has been separated in a container.

Grind Matic BQ2DTH is the latest grinding machine for mainly

downthehole and Coprod bits. It can also be used for threaded bits with a special bit holder. The machine has the same features as Grind

Matic BQ2, and can grind bits up to 7 indiameter.

grinding advice

The Grind Matic machine’s secret of success is that both the grinding table and the diamond grinding wheel rotate. The result is perfectly ground button surfaces, regardless of whether the buttons are spherical or ballistic.

In addition, the machine’s unique diamond grinding wheel is designed to ensure even wear on its grinding surface, while still retaining its profile. This, in turn, guarantees the button shape throughout the life of the wheel.

Secoroc’s advice is to use Grind Matic grinding machines, with profiled diamond grinding wheels, for grinding button bits. It is the only solution able to consistently deliver perfectly shaped buttons on customers’ bits.

Correct grinding is important for every drilling operation, particularly in these days of cost consciousness and fierce competition. It can make a world of difference to the bottom line.

by Bo Persson

Comparison of grinding wheel with grinding cup.

Grind Matic Manual B-DTH. Grind Matic BQ2-DTH.

Talking Technically


Operator’s cabin

The interplay between man and ma-chine starts in the operator’s cab, and Atlas Copco has spent a great effort in the development of a well conceived, purpose-built cab. Even the smallest details have been considered to produce a modern workstation, not only in terms of mechanical function, but also paying attention to the requirements of ergo-nomics, safety and the environment.

The cabin offers a superb view of the drillhole from the operator’s seat, facilitating accurate collaring and control of the drilling operation. The angled, laminated glass windscreen is equipped with a large wiper, as are the right hand side and roof windows, and improved air ventilation effectively clears conden- sation mist from all of these windows. A jumbo-sized rearview mirror gives good visibility and safer rig moving. For

additional safety a back camera may be installed. In addition, the spacious cab gives good moveability and comfort for the operator, with easy-to-read instrumentation that is simple to learn and to use. A mechanized tube-permutation system enables any damaged drill rods to be identified from the operator’s cab. The service hatches are easily accessed, but are also lockable, as a good security precaution at isolated worksites. The cabins are even equipped with a 12-volt outlet for mobile telephone.

ergonomics and environmentThe cabin is laid out so that the opera-tor can monitor and control the entire

drilling process without changing body position. This relieves neck, shoulders and back from strain. The ergonomically-designed seat is vertically and laterally adjustable, with control levers and control panel located in, or in close proximity to, the collapsible arm rests. The seat is slewable for easy entry into the cab, and the door is fitted with a safety stop that prevents crushed fin-gers.

Good insulation affords a noise level below 80 dB, and rubber-damping of the cab mounting reduces vibration and gives greater comfort during tramming. The cabin has an efficient CFC-free air conditioning system for both cooling and heating, and many surfaces are textile covered for greater comfort. The cab

Ergonomics and SafetyDrilling efficiencyEfficient drilling is a function of many individual aspects, both mechanical and human. While it is necessary to have a powerful and easily-manoeuvrable drill rig, it is also important to take good care of the operator’s needs, and those of the external environment. What value is a machine that is too no- isy, or cannot be operated in harsh weather? Operator comfort and safety has to be planned into the modern drill rig at the drawing board stage of design. To get maximum return on investment, the owner needs to be sure that the drill rig is designed to work in all conditions, without the operator getting unduly tired, and with minimum disturbance of the envi-ronment in the neighbourhood of the site. All Atlas Copco drill rigs are designed with these parame-ters in mind. In addition, a whole array of options is available to control the inclination, alignment and depth of drillholes, in order to get the maximum rock breaking effect from the minimum drilling effort, reducing noise and dust, and sa-ving time, money, and materials.

Perfect view from the operator’s cabin on ROC series drill rigs.

Talking Technically


complies with the European and international safety demands for Roll-Over Protective Structure (ROPS) and Falling Object Protective Structure (FOPS).

With regards to the environment, exhaust emission values of all new Atlas Copco drill rigs are in compliance with latest international standard, as are the noise values. There is efficient dust collection and coarse separation, the feeds are fitted with collectors for lubricating oil, and biologically degradable hydraulic oils are available as options.

hole alignment

Regulations governing rock blasting in open-air excavations are found in countries all over the world. Rock exca-vation by drilling and blasting is a particular menace in quiet, urban areas, and it is strictly governed with respect to allowable levels of pressure shocks and ground vibrations.

Productivity, and the need to control ground vibrations, means that capable and precise instruments are required to guide the driller. Faults in blasthole di-rection, hole deviations, and variations in hole depths must be minimized, if efficient production is to be obtained. Instruments for angle setting and hole depth control increase drilling accu-racy and reduce human error.

There are various ways for a contractor to comply with the blasting rules, without increasing costs for rock excavation. Several benefits can be obtained from improved blasthole alignment and

drill depth control. Improved accuracy in the application of the drilling pat-tern saves time, drillmetres, and explo-sives. At the same time, less boulders need to be broken, and less crushing of oversize is required. All this means reduced operating cost, and money saved. A modern hole alignment instrument offers: more precise drilling with a reduction in cost/hole; automatic depth control; better fragmentation; automatic drill feed stop; flat benches after blast-ing; and less overdrilling. By guaran-teeing a perfect blast result, there is no need for the contractor to return and clean up rough surfaces, or condition overbreak.

Much blasting inconvenience can be reduced by special drilling patterns, which distribute the explosive charges evenly, and limit the level of ground vibrations, so as not to harm property

in the vicinity. To achieve this, it is crucial to collar the hole on the right spot, maintain the correct alignment, and drill to a pre-determined level.

Depth control

The alignment instrument confirms the hole angle, while a laser sensor moni-tors drilling to the proper depth, regar-dless of the surface conditions. All this comes together for a successful blast, breaking rock to a level floor, with minimum ground vibration, and even frag-mentation.

The angle setting instruments, used with the aiming device, help set the correct angle of inclined holes.

The angle and hole depth reader function controls the length of a blast hole, from the start of the hole on surface, to the preset bottom elevation.

The instrument does not require any assistance from the operator, and comes with an automatic drill feed stop func-tion for optimum drilling accuracy. The instruments feature automatic compen-sation, regardless of the drilling surface ground conditions.

A beacon, mounted on a tripod, generates a horizontal reference plane across the worksite by a rotating laser beam. A sensor, fitted to the rock drill cradle, reacts to the signal generated by the rotating laser beam. The HQS 12 instrument provides a reference plane for all holes, automatically adjusting hole depth to match the plan, with an accuracy within 5 cm.

Blasting creates a bottom elevation with an optimum flat surface.

The HQS system uses a rotating laser beam to provide a reference plane for hole depth.

Angle and hole depth screen display.

Talking Technically


easier Drilling

Atlas Copco ROC crawlers are designed for stable and accurate positioning of the drill holes, featuring a rugged carrier, with a flexible boom system mounting a rigid feed beam with double drill steel supports for the drill rod.

Hydraulic drillsteel supports are used for safe and easy jointing and break-out of the drillstring. Fitting a double drillsteel support allows the operator to raise the sliding support for better vis-ibility of the collaring surface, and for simplified evacuation of water from the drillholes. This also results in easier disconnection of the drillbit where the surface rock is broken up. The double drillsteel support also contributes significantly to the straightness of the drill-hole, by guiding the drillsteel at the critical collaring stage, and throughout the drilling of the hole.

Inclination instruments provide the opportunity of achieving rapid and accurate alignment in the drilling direction and hole inclination. The devices are mounted on the feed beam of the drilling unit, and can be read from the driller’s position next to the feed beam, or from the rig cabin. The least deviation from the desired hole inclination is clearly illustrated on the dials

of the instrument. Hole depth and drilling angle are also easy to set and adjust.

Atlas Copco has a very fast and well proven rod handling system that saves on operator time. The system also relieves the operator of heavy lifting work, helping maintain high productivity. It is well-proven, and is standard on crawler rigs fitted with an operator’s cab.

A winch set simplifies driving, and secures the set up, in steep terrain where wet clay, snow or ice may create a risk of slipping. The winch set includes a swing arm with winch and traction controls.

Dust control

The DCT range of dust collectors creates a dust-free working environment, for the benefit of both personnel and equipment on site. Some 80% of all the drilling dust is initially separated in a coarse strainer, and the remainder, including highly injurious particles less than 5 micron in size, is effectively se-parated in the filter unit.

DCT dust collectors operate contin-uously and automatically. Most versions commence dust separation as soon as the flushing air control for the rock drill is opened, and filter cleansing occurs automatically when the control is closed.

The drill dust and cuttings empty straight into a plastic sack, or alterna- tively through a rubber dust collector. Dust collectors ensure dust-free worksites, are efficient and reliable, and boost flushing capacity. They can be air- powered or hydraulic operated, and result in improved productivity.

When drilling with larger bits, or when drilling in formations carrying water, the cyclone-type precleaner extends the use of the dust collector, and the service life of its filter system.

A water mist system is available to provide a better working environment. Water is injected into the airflow to stabilize the hole and bind the dust on the ground.

by lennart lundin

Dust collection arrangement on ROC F7.

Improved cabin layout.

TALKING TECHNICALLY

DRILLING IN OPEN PIT MINING 41

Rotary Club Expands with ThiessenPart of SecorocAtlas Copco recently finaliezed theaquuisition of Canadian drilling consumables manufactures Thies-sen Team. The company has be-come part of the Secoroc division and will operate under the Atlas Copco brand.

Acknowledgements


High Quality Products

Drill string components, including the drill string itself, are manufactured by Thiessen. The acquisition means that Atlas Copco is now able to offer a complete range of surface rotary drilling equipment from drill rig to Tricone bit.For more than 50 years, Thiessen Team Rotary Drilling Products has success-fully serviced its global customer base with innovative, high quality products and dedicated service. Their prod-uct range includes sub-adaptors, drill strings, breakout wrenches, roller sta-bilizers and deck bushings. The acquisition of Thiessen includes the company’s global manufacturing and refurbishment facilities with cen-tres in Canada, Australia, South Africa and Chile.

“We are very happy to include the well-known Thiessen products in our range,” says Graeme McKenzie, Product Line Manager of Secoroc Rotary Drilling Products. “The prod-ucts fit very well with our own Tricone bits and have the same high quality.”On the significance of the acquisi-tion to Atlas Copco’s Construction and Mining Technique division, Bjorn Rosengren, Business Area President commented: “It will allow us to further develop our rotary drilling consuma-bles market for surface mining and strengthen our position in raise boring

“We are delighted to welcome Thiessen.” Graeme McKenzie, Product Line Manager – Secoroc Rotary Drilling Products.

Perfect partners: a Thiessen EZ-Drill Roller Stabilizer and a Secoroc Tri-cone bit.

Rugged, repairable and with a replaceable inner sleeve: Thiessen’s Centeroll rotary deck bushing.

consumables. It will also help us to increase our customer share with key customers.”

Rugged, repairable and with a replaceable inner

Talking Technically


In Search of the Right Balanceexploration DrillingChips or cores? That’s the question often faced by geologists and con-tractors in deciding which method of exploration drilling will get the most effective and economical re-sults. These days, the answer is quite likely to be: “a combination of the two”.

By Jan Jönsson, Product Manager, Atlas Copco Craelius.

Selecting Method

Since man first started searching for minerals and precious metals, three key factors have consistently proved decisive for success: time, cost and confidence. In other words, the time required, the cost of getting the job done, and confidence in the quality of the samples brought to the surface for analysis. This is more a question of basic technology and logic than one of science. But it is interesting to see these three factors expressed as a mathematical formula: confidence over time multip-lied by cost, equals profit. With profit, as always, as the driving force. Conventional core drilling – the technique which produces cores of sub- surface material – is the most com-monly used method of obtaining infor-mation about the presence of minerals or precious metals as well as rock for-

confidencetime x cost

= profit

Chips from RC drilling can be an alternative to conventional cores.

mations. However, reverse circulation drilling (RC) – which produces sam-ples as chips – is gaining ground. The reason is easy to see. RC drill-ing is a faster and more economical way of “pre-collaring” in order to get down to where the orebody is located. Once there, the driller can then decide whether to continue with RC drill-ing to extract chips for evaluation or whether to switch to a diamond core drilling rig to extract cores. In this way, RC drilling becomes the perfect complement to conventional core drill-ing (see fig 1). Selecting which method to use for actual sampling work depends largely on the preference of the geologist. But it also depends on the confidence that he or she places in the quality of the samples. Today, RC drilling has become so advanced that more and more geologists believe that chips are perfectly sufficient as a means of determining ore content. The commer-cialization of RC drilling started in the 1980s but the technique has certainly been around for much longer.

early birds

As early as in 1887, Atlas Copco Crae-lius had developed a rig that could “take” cores at depths of 125 metres. Confidence in these samples among geologists was also at its highest pos-sible level. They were able to evalu-ate a piece of solid rock. Time was not necessarily of any great importance and consequently neither was cost. Manpower was inexpensive and readi-ly available. However, the demand for such prod-ucts quickly increased and availability had to keep pace. This is very much the case today with sharp market fluc-tuations and so technology innovators have to find ways to optimize profit in all situations.

The time factor

Hammer drilling with down-the-hole hammers was invented in 1936. It be-came popular during the 1970s mainly for water well drilling applications. But it was soon clear that the method was also very useful for prospecting. The cuttings were already there at the top of the borehole and therefore it was possible to make an initial evalu-ation on the spot.

Talking Technically


iV iiii i i

Fast and econo-mical Rc drilling without taking samples.

PRe-collaRing

Mineralized zone: chip samples from Rc and / or cores for evaluation.

Figure 1. Based on geological data from the boreholes I and II, substantial savings can be obtained when drilling boreholes III and IV.

Total drilling programme 80 holes, 400 m deep. Total 32,000 m of drilling (fig 2).

Scenario 1100% core drilling 70m core / 24 hours with 1 core drilling rig 457 days

Scenario 250% RC (pre-collars only), 50% core drilling 70m core / 24 hours with 1 core drilling rig301 days

Scenario 375% RC (pre-collars & full holes), 25% core drilling 70m core / 24 hours with 1 core drilling rig223 days

In case three core drilling rigs would have been available in scenario 1, expected time is 152 days compared with 457 days.In case three core drilling rigs would have been available in scenario 2, expected time is149 days compared with 301 days.A rough conclusion gives that the RC rig is somewhat faster than 3 core drilling rigs together.

cost ratios (fig 3).

457 days 2,580,000 USD301 days 1,740,000 USD223 days 1,320,000 USD

Approx. cost of RC drilling – 30 USD / meter Approx. cost of core drilling – 80 USD / meter

Hammer drilling offers a consider-ably higher drilling speed compared to core drilling. To use this method and further develop it to increase the per-formance became an obvious task for R&D people. The higher air pressure and high availability of the hammer are two factors that make it possible for technicians to speed up the “jour-ney” down the hole. Another factor is the durability of the bit inserts. The more metres drilled with the same bit without having to take up the drillstring, the more effec-tive the time on the hammer. Another factor, and perhaps the most important of all, is the logistics surrounding the drilling programme. The availability of parts, fuel, casing, water, consumables etc., has a direct influence on the number of metres drilled per shift. Significant time savings can be achieved by using RC and core drill-ing in a balanced combination (see fig 2). Here we can see that one RC rig can be used to drill enough pre-collars to keep three core drilling rigs running 24-hours a day. The time factors show obvious time benefits using a combi-nation of the two methods. In this sce-nario, a minimum of 25 per cent of the total metres drilled were specified as core drilling.

The cost factor

The cost perspective does not have any negative surprises in store as the costs are mostly related to the time factor. The investment in RC rigs and equip-ment is higher compared to those of core drilling. But as we can see from the table in fig 3, the costs are reduced when a combination of the two meth-ods is used. In this example, we can see that time as well as costs are in favour of RC drilling. The figures are obvious and easy to evaluate and vary depend-ing on the location and the local con-ditions. But the relativity remains the same and is strongly reflected in the development of the exploration drill-ing process. So, how can we further shorten time and cost in the future? Immediate results from on-site evaluation is one

way and a scanning process is already available although probably not yet adaptable to local site conditions. But do we need to drill at all in order to get sufficient information about the orebodies beneath us? It is the manu-facturer’s challenge to develop equip-ment and technologies with no limits, but with the least amount of environ-mental impact.

The confidence factor

Meanwhile, we have a third variable in our equation – the confidence factor. In-

vestors as well as geologists place strict demands on contractors to deliver high quality information about the geologi-cal formation to be explored. Investors want the highest possib-le return on their investments in the

Talking Technically


0

20

40

60

80

100

canada latinamerica

Russiachina

australia Se asia USa africa

Rc drillingcore drilling

% Figure 4. Ratios between core and RC drilling. The figures reflect total exploration expenditures from national statistics for surface and underground.

Principles for RC drilling showing flow of compressed air and chips. The sampling collection box is integrated into the cyclone.

shortest possible time. For example, whenever a gold nugget has been found, others may take over to conduct the drilling and blasting operations. As these are not the same people, the reli-ability of information plays a critical role. Below, a few reasons why geolo-gists should choose their drilling method carefully:● If there is no need for continuous information about the geological for-mation on the way down, there is no need for samples. It is just a matter of minimizing the drilling time. The geometry of the orebody is already known and just a reconfirmation of the bound-aries is necessary. In this case, RC drilling is an efficient method to use. ● A first scanning of virgin territory is being done where the goal is just to obtain a preliminary indication of pos-sible content. In this case, the geolo-gist is not relying on any mineralized structure or geometry. With an evalua-tion giving positive results, a programme of core drilling is the logical way to continue in order to bring the pro-ject to a resource / reserve status. ● If the mineralized structure is identified but the geometry and rate of con-tent varies, RC drilling is used as an indicator for ensuring continued grade control. ● The geologist wants dry and rep-resentative samples in order to make optimal evaluations. RC drilling below the groundwater table was previously believed to undermine sample quality. Core drilling therefore remained the only viable method for these depths. Today, the availability of high pressure compressors and hammer tools makes it possible for RC drilling to reduce costs even for these depths. These days, professional contractors

deliver dry sampling down to depths of 500 m. By sealing off the bit from the rest of the hole it can be kept dry. A correct selection of shroud vs bit tolerance maintains a pressurized zone around the bit. Boosted air pressure is needed to meet the higher water pres-sure on its way down the hole. In addi-tion, a dry bit drills faster.● It must be remembered that infor-mation from a core is crucial in esti-mating the period of mineralized structures. The core helps the geologist to calculate the cost of extracting the mineral from the ore. Large volumes of rock have to be excavated to obtain just a few grammes of a valuable min-eral.● Cores also yield geotechnical data. Data about slope stability can be of the highest importance. ● Ground conditions are naturally also of great importance and may produce

questionable samples if some of the information from fissured zones is left behind in the hole and not collected. In such circumstances, core drilling could be the only alternative.

Rc on the increase

RC drilling is increasing. Judging by its growth rate in recent years it may well account for 55 per cent of all the metres drilled in 2008. Figure 4 above shows some estimat-ed ratios between core and RC drilling in different parts of the world in 2002. In total, RC accounts for 50 per cent and core drilling for 50 per cent of metres drilled. Tradition and the environmental impact play a large role. RC rigs are heavy, assembled on trucks or track carriers. This fact tends to favour core drilling rigs which are lighter and even adaptable in order to be flown into remote and sensitive environments. In areas with extremely cold clima-tes and where permafrost is present, RC drilling may have its limitations. Antifreeze rock drill oil help to keep the hammer and bottom of the hole free from ice. Other, purely practical issues determine the choice of one or the other drilling method. An intelligent, balanced choice bet-ween the two methods is the key to optimal results. Here, the geologist plays an extre-mely important role in finding this balance and so do manufacturers such as Atlas Copco which will continue to provide the right tools for the job.

acknowledgements


Talking Technically


key ingredients

ROC CARE scheduled service ensures consistent drill rig performance, hour after hour, day in, day out. Supported by inspection protocols with recommended actions, and extended warran-ty to protect against the risk of extra costs if a major component fails, the customer is given the required service at the recommended intervals over the full duration of the agreement, for which he is invoiced at the agreed low month-ly amount.

This translates into scheduled serv-ice without financial penalty, encour-aging both parties to concentrate on preventive maintenance rather than risk costly breakdown.

ROC CARE is tailor-made for the quarry and construction business, protec-ting all that is essential to the drilling operation. It guarantees regular inspec-tions and service, giving security and peace-of-mind for at least 5,000 engine hours of drilling. By focusing on breakdown prevention, rather than un-planned repair, it helps keep operating costs to a minimum.

Scheduled Service

Scheduled inspection and maintenance is a key element of ROC CARE, with the drill rig being serviced according to each original equipment manufacturer’s

maintenance schedule. ROC CARE covers all parts needed for scheduled maintenance, including oil filters, air filters and fuel filters. The service is carried out by fully-trained and professional Atlas Copco engineers, who know every part of the equipment, and can submit recommendations to prevent potential

future problems. Indeed, at each serv-ice occasion, the engineer hands the customer a detailed rig inspection pro- tocol, reporting the rig condition and identifying any corrective measures. These can then be carried out at the next scheduled service, or at a time chosen for least disruption to production.

Protection by ROC CAREScheduled ServiceNowadays, drill rigs are considered to be a major capital investment, and their owners, whether one- man contracting businesses or large corporations, have to be satis-fied that their investment is being correctly serviced. In this way, they can get the best possible re-turn on investment by maximizing availability, while preserving long- term value. This is where ROC CARE, the new value-for-money service package for Atlas Copco surface drillrigs, comes into play.

Replacing air filters at the scheduled interval improves efficiency.

Talking Technically


Such measures minimize breakdowns and contribute to savings in overall cost of ownership.

The general extended warranty that accompanies every ROC CARE agreement provides protection against the breakdown of key components, such as the diesel motor, compressor, hydraulic pumps, feed motor, traction motor and

traction gears. In addition, all fabrica- ted major mechanical components such as the wagon frame, track frames, boom support, booms, boom head and feed holder are included.

Procom

ProCom, included in ROC CARE, knows

when each drill rig next needs service. It is a global, satellite-based system that monitors rig status, facilitating remote viewing of engine hours, impact hours, and time-to-service. On certain models such as ROC RRC, HEC 3, and Smart- Rigs ROC D7, ROC D9 and ROC F9, ProCom also transmits details of dril-led metres. The system works world-wide, monitoring rigs wherever they are located. By knowing exactly when each rig next needs attention, Atlas Copco can schedule service with minimum disruption to drilling.

Because every effort is made to plan ProCom inspection and service visits to cause as little drilling downtime as possible, Atlas Copco service engineers are conscious of a happier reception at site. In turn, they no longer have to plan their working lives around emer-gency breakdown callouts, resulting in a decrease in stress for both customer and engineer, and more satisfaction all round.

by göran nilsson

ProCom knows when drill rigs next need service, allowing efficient forward planning.

ProCom monitors rig status around the world.

Drilling 50-ft BenchesThe vast Phelps Dodge Morenci copper mine in Arizona, USA, is the larg-est of its kind in North America, pro-ducing more than 240 million tons of blasted material per year including 31 million tons of ore. Contributing to the mine’s productivity is a Pit Viper rotary blasthole drill rig which has drilled more than 2.2 million feet in the past four years.

A Viper for the Copper King

Ten Thousand Holes per Year

The Morenci mine in the south eastern part of Arizona started its life in the late 1800s underground. Today, it is a major open pit operation and the largest copper mine in North America. It is a massive operation covering an area of 3,055 acres, which will increase to 4,683 acres in 2006. A total of 4.37 mil-lion feet of blast hole drilling is carried out annually including 570,000 feet in ore – the ideal proving ground for the rotary rig Pit Viper 351. Weighing 375,000 pounds, measuring 53 feet long and equipped with seven on-board computers, the Pit Viper 351 was the largest and most advanced rig of its kind on the market when it was introduced at the MINExpo show in Las Vegas in 2000. After the fair, Morenci took the pro-totype and put it to work in a fleet of 16 rigs from a variety of other manufacturers. Today, four years down the line, it is still performing to expectation. Since April 2001, the rig has been in production full time and operates on a cost- per-foot basis. By August 2004, it had drill-ed 2.2 million feet and is currently averag-ing about 60,000 feet per month, although in some months it has drilled more than 80,000 feet. In fact, the rig has been so productive that the unit number “20R” has had to be changed towards the end of each year because the rig drills more than 10,000 holes per year and the mine’s automated, annual hole-numbering system stops at 9,999. Most of the production rigs at the site are

electric, which, due to their power cables, makes them difficult to move from bench to bench. The PV 351, however, with its Cummins 45-litre diesel engine (1500 hp at 1800 rpm) moves easily and frequently between the benches. Also contributing to the rig’s productivity is the hydraulic design that uses one gearbox and five pumps for the complete unit as well as the cable-feed system and positive lubrication oil pump for the air compressor.

Dependability Essential

The mine operates 12-hour shifts, 24 hours per day, seven days per week so rig dependability is essential. Not only is the PV 351 powerful and dependable, it is also

The tri-cone, tungsten carbide bit: Supplied to the Morenci worksite by Baker Hughes Mining Tools, now Atlas Copco Secoroc.

morEnci coppEr minE, USA



Acknowledgements

This article first appeared in Mining & Construction, No 3, 2004. ■

sophisticated. The seven on-board comput-ers operate via a controller-area network (CAN) to handle all of the inputs and out-puts. It features production monitoring, rock recognition and GPS systems, which are designed to allow for easy technology up-grades. A GPS navigation system enables the drill pattern to be transmitted to the rig via a radio network. The hole location is shown on a touch-screen display and guides the operator in positioning the drill to within three centimetres of its target. This also eliminates the need to manually stake holes and survey the “as drilled” location. But more importantly, it ensures that the hole is drilled where it was designed to be, in order to optimize fragmentation. When drilling on Morenci’s 50-ft bench-es, typical holes are 12 inches in diame-ter and 57 feet deep. They are drilled in a 28-ft square pattern. Although the rock is igneous, it only takes 17 minutes to drill a hole, of which 13 minutes is actual drill-ing. Generally, 90,000 pounds of weight is placed on the bit. Thanks to the 350 hp rotary head, rotation does not stall, even with the heavy load. Fuel consumption is 0.174 gal/ft. Baker Hughes Mining Tools, one of Mo-renci’s drill bit suppliers, has developed a tungsten-carbide tri-cone bit to handle the power of the PV 351. This HD53CA bit has an average life of 9,500 feet and this con-tributes to the Pit Viper’s low total drilling cost – the lowest in the Morenci fleet. Brian Fox, Vice President, Marketing for Atlas Copco Drilling Solutions (formerly Ingersoll Rand Drilling Solutions) says: “We are thrilled with what we’ve accom-plished at Morenci with the Pit Viper 351. To go from being an outsider at a major mine to being a valuable part of their pro-duction speaks well of the product design and of the capabilities of our Arizona-based support team, which keeps the rig available 90 per cent of the time.”

“We are thrilled with what we have accomplished for Morenci.” Brian Fox, VP Marketing, Atlas Copco Drilling Solutions.

Total control in the pit : A GPS navigation system enables the drill pattern to be transmitted to the rig via a radio network.

conversion factors1 acre = 4047 m2 1 ft = 0.305 m 1 hp = 735.5 W1 pound (lb) = 0.4536 kg1 US gallon = 3.785 litres

FAcTFiLE The Morenci mining district, located in southeastern Arizona, is part of a forma-tion that extends from western Arizona to south western New Mexico and south to Mexico. Mineralisation is hosted primarily in igneous rocks. It is 85% owned by Phelps Dodge, whose share of the output accounts for one-third of its annual copper production of 1 mil-lion tons. The operation consists of three pits: Metcalf (43 benches down, 230,000 tpd) Coronado (21 benches down, 370,000 tpd) and Western Copper (6 benches down, 50,000 tpd). At more than 2,100 feet, Metcalf is the deepest.

A VipEr For THE coppEr KinG

BINGHAM CANYON MINE, USA


Copper Giant ShineBy focusing on the total effect on productivity, rather than on the tech-nical performance of individual prod-ucts, the world’s second largest open pit copper mine is getting impressive results.

Total Approach

All mining companies in the Rio Tinto group met in Australia last year to discuss “Improving Performance Together.” The aim was to identify the areas of mining ex- cellence and best practice at individual sites that could be adopted globally. Among several shining examples was the Bingham Canyon Mine near Salt Lake City in Utah, USA. Bingham Canyon, owned by Kennecott Utah Copper, knows a thing or two about rock excavation. Over the years, it has mo-ved more than 6 billion tons of rock and earth to produce 17 million tons of copper – more than any other mine in history. It has also grown to become the second largest open pit on earth, after Chuquicamata in Chile. But it is not size that has kept the mine on top. It is its management approach – a continuous focus on total productivity improvement characterized by close co-operation with sub-suppliers. Mine Superintendent Ted Himebaugh explains: “The key element in evaluating something is ‘greatest value in use.’ We look at feet drilled per dollar spent. How much did we get out of what we bought? At this site, performance goes before bit life, and service goes beyond making the customer happy to making the most out of the product.” Himebaugh adds that the concept of de-manding continuous improvement from a supplier also goes beyond price. One of the suppliers that consistently meets these standards is Atlas Copco, now into its second three-year contract supply-ing blasthole tricone drill bits and services. The mine uses eight drill rigs equipped with any one of six different Secoroc tri-cone bits. Two sizes are used, 10 5/8” (trim

Best Practice at Bingham Canyon

blast, wall control) and 12 1/4” (produc-tion), each in three different formation ty-pes, 50s, 60s, and 70s. The 50-60-70 series denotes different hardness of the bits to suit different formations. And continuous improvement is the yardstick against which nearly everything is measured. Bruce Jones, Pit Superintendent says: “Every contract we do these days, from a major piece of equipment to consumables, has a continuous improvement compo-nent. We provide technical specifications that have to be met, but we also have high expectations of what service and quality should be.” There are 17 different rock types at the site. Dan Benfield, Operations Engineer explains: “Our geological scope is so varied. It used to be the old Bonneville sea-bed and, if you look at it, it’s all curved and bent and twisted. So you could be going through great material for the first 20 feet of the hole, hit harder-than-heck material the next 20 feet, and then be back in really nice material again. “Usually you get a couple of holes of good, and a couple holes of tougher mate-rial, and the white limestone is obviously the worst. You can literally punch a hole and get a penetration rate of 200 feet per hour.

The new medium formation tricone bit: Designed to stay sharp longer.

BEST PRACTICE AT BINGHAM CANYON


Valuable Resource

Personal service is highly regarded at the mine and Jim Wheeler, Senior Area Mana-ger of Atlas Copco, has been closely asso-ciated with the mine for more than 12 years. “Jim has great historical knowledge of our mining,” says Benfield. “He remem-bers being in this white limestone before and can pull up the data and show what we did last time. That is just invaluable, as he has data that helps us decide which type of bit we should be using.” This high service level includes both recommending suitable bits from the exten-sive Atlas Copco Secoroc range as well as the development of new bits for specific tasks. Atlas Copco also keeps the mine supp-lied with bits when the need unexpectedly surges. “When we hit this commercial lime-stone it was much harder than we anticipat-ed,” Benfield recalls. “We went through a lot of bits, and Jim did everything to ensure procurement and non-stoppage of work up here – including getting bits from the Atlas Copco warehouse, through the factory and flying in bits from overseas.”

And production is substantial: Approxi-mately 250,000 feet (76,200 m) are drilled every month, generating 14 million tons of material that’s loaded and hauled. This is a combination of overburden and ore, the latter a low grade copper with significant quantities of gold, molydemum and silver gained as byproducts. Improvements to date include the intro-duction of the MAG53C bit which has re-sulted in 25 per cent improvement in bit life, increased penetration rate and much lower total cost-per-foot drilled. The mine is also testing a new Secoroc design concept – a medium formation bit with technically advanced carbide grades. This bit is designed to improve penetration rate by keeping the cutting structure sharp longer to maintain its original profile and reduce the rounding of gauge inserts. “Bit performance tests are a good example of customer support,” says Mike Wickers- ham, Superintendent, Production Support. “We recently did pull down tests to see what the design of the bit could handle and Atlas Copco was involved in that. We’ve tested many different bits and the relationship has endured all those trials. Jim always works hard giving us what we want, when we want it.” Concludes Dan Benfield: “All manufacturers should be trying to improve their product’s productivity. What I care most about is that Atlas Copco is putting time into developing new bits to increase our productivity. That’s real continuous impro-vement.”

Acknowledgements


Ted Himebaugh, Mine Superintendent: “Greatest value in use.”

Inspecting the bits: Bob Endter, Sales Manager for Tricone Bits, Atlas Copco USA.

Highly personal service: Jim Wheeler, Atlas Copco Area Manager.

Keeping the dull bits for future improvement: Altas Copco inspects and evaluates them prior to disposal.


SteeperSlopesReducing the amount of waste in open pit mining is the key to good pit economy. The combination of high-performance rotary drilling rigs and Atlas Copco smallhole rigs has led to new cost savings and production effi-ciency. The Betze-Post gold mine in Nevada is a typical case.

Rotary and DTH Work Side by Side

BETZE-POSTGOLDMINE,USA

PreciseDrillingandBlasting

A critical factor in a mine’s economic feasi-bility is the grade of the ore. For hard rock open pit mines, the amount of waste that has to be removed by drilling and blasting, loading and truck haulage in relation to the extracted ore is also a major factor in operating costs. For gold mine operators, hauling a large tonnage of waste is a necessary evil as the low grade of the ore means that the cost per ounce of gold for haulage to the con-centrator is high to start off with. To max-imise profitability, it is essential to keep the amount of waste to be blasted and removed to a minimum. Keeping the high wall as steep as pos-sible reduces the amount of waste to be removed, thus reducing operating costs (see diagram, next page). However, keep-ing the rock face stable as well as steep requires precise and careful drilling and blasting. For this reason, the Betze-Post gold mine in Nevada has recently added an Atlas Copco down-the-hole drill rig to its fleet of Ingersoll-Rand rotary DTH production units. Here, the combined fleet must work through about 4.6 million feet (1.4 million drillmetres) per year.

SteepandStable

The pit is Barrick Gold Corporation’s first operation on the Goldstrike property and mines various ore types. In 2003, Betze-Post produced 1.6 million ounces of gold at a cost of USD 232/ounce, taking cumulative

The 270SP, the prototype of PV-271 Pit Viper, launched at MINExpo 2004 in Las Vegas. Fitted with onboard drill monitoring and GPS locator system, it was up and running within minutes at the Betze-Post pit.

output to some 20 million ounces. Mineral reserves at year-end were reported to be 15.7 million ounces. On average, the mine moves up to 430,000 tons (390,000 tonnes) of waste and ore daily, making the strip ratio – the tonnage of waste in relation to the tonnage of ore – 10:1.


rOTAryANDDThwOrkSIDEBySIDE

The ROC L6H has been brought in to drill smaller hole sizes than the previously assembled fleet, and these smaller holes are for pre-split drilling to keep the high wall as steep as possible with a clean break. A four-row trim is used for the high wall: three parallel lines of buffers accom-pany the one row of pre-splits. And the ROC L6H is drilling 4-inch holes on a 5-ft spacing using a Secoroc COP 44 hammer and Secoroc concave Speedbits. Moving from a completed hole through set-up to the start of drilling at the next hole takes 22 seconds. Mine Superintendent Roy McKinstry says that the majority of drillers who are experienced with the Ingersoll-Rand rigs learned to use the ROC L6H quickly, most of them taking about an hour to familiarise themselves with the controls.

ANewAddition

Another recent addition at the Betze-Post open pit is a single-pass drill rig – the 270SP, the prototype of IR’s PV-271 Pit Viper also exhibited at MINExpo 2004 in Las Vegas. In 1994, the mine already wanted to switch to light-weight and single-pass capable rigs that would be more powerful and up-to-date. But at that time, neither Ingersoll-Rand nor any other supplier was able to offer such a rig. With the intro-duction of the Pit Viper in 2000 and sub-sequent rises in gold prices, the mine and manufacturers were able to work together on a suitable solution. In April this year, the 270SP went to work in the open pit, adding to the existing fleet of five IR DM-M2 double-pass units and two DM45/HP drill rigs.

McKinstry explains that the DM-M2 rigs normally work on 40-ft high benches, drilling 9-inch holes in patterns of 24 x 24 ft or 32 x 32 ft, and the DM 45 units on 20-ft high benches, drilling 8-inch holes in 16 x 16 ft or 18 x 18 ft patterns. The rigs typically operate in rotary mode but occasionally with Ingersoll-Rand DTH drills, bits and pipes. The penetration rate is 86–140 feet/hour, says McKinstry, but can be as high as 500 feet/hour or as low as 20 feet/hour, depending on rock hard-ness, which is highly variable. According to Drill Foreman Jim Owen, when the 270SP was delivered to the mine in three sections, it was reassembled and then taken down into the pit where it was driven off the trailer and started drilling within minutes. The 270SP has been rap-idly and thoroughly evaluated by the mine and by Drilling Solutions ahead of series production. The mine’s goal is to improve precision and reduce costs by drilling longer holes. Where the standard 40-foot high benches are being mined, the rig will drill 44-foot holes. For this application, the 270SP is set up for high bailing velocity rather than high pressure and equipped with a GPS/VDU positioning system. Says McKinstry: “The 270SP has per-formed excellently, consistently drilling up to sixty 44-foot holes, almost 2,700 feet in a single shift – and that’s without pushing it anywhere near its limits.”

ImpressivePerformance

The first IR rotary blasthole drill went into service at Goldstrike in 1988. Since then, a total of 17 IR rigs have been in service, accumulating more than 800,000 hours of

STEEPErSLOPESMEANBETTErECONOMyPre-split DTH drilling using ROC L6/L8 creates higher

and narrower benches. This contributes to steeper pit slope and less waste rock to be extracted. The advantage

of this is a low waste-to-ore ratio, which means higher pro-ductivity and better overall pit economy. The method has been

successfully used at the Chuquicamata mine in Chile and is now being adopted in the gold mines of Nevada, USA.

For more information, see M&C 1/2002, Technically Speaking. This article is also available on the Internet at:

www.miningandconstruction.com

Benchesusingpre-splittingandDThdrilling

rOCL6/L8

Benchesusing tra-ditionalmethod

wasteexcess


rOTAryANDDThwOrkSIDEBySIDE

Acknowledgements


operation. Excluding the new 270SP, the other 16 rigs have operated over 50,000 hours on average. Several of the DM-M2s still in operation are at more than 65,000 hours each. Hours pile up quickly at Goldstrike as evidenced by the new 270SP, which clocked more than 1,200 hours in just over two months of operation. The mechani-cal availability of this unit, less preventive maintenance, is 99.3 per cent. Brian Fox, VP Marketing for Rotary Blasthole Drills at Atlas Copco Drilling Solutions, says: “We are fortunate to have a great relationship with Goldstrike. We are happy they patiently waited for the pro-totype to be developed, especially since they had so much input to its design. It is a world-class operation as evidenced by what they get out of their rigs.” All of the IR rigs at Goldstrike were sup-plied and are supported by Cate Equipment Company, one of Atlas Copco Drilling Solutions’ largest dealers covering Nevada, Utah, Wyoming and Idaho. ■

Best in test: The ROC L6H proved to be the most effective rig for pre-split drilling to keep the wall as steep as possible.

The 40-foot high benches at the Betze-Post open pit mine in Nevada, USA, where small-hole drill rigs and rotary units now work side by side.

One of five IR DM-M2 double-pass drill rigs at the Betze-Post gold mine.

DRILLING IN OPEN PIT MINING

LOS FILOS, MEXICO

The Golden Twins of Southern Mexico

Going for Gold in GuerreroTwo open-pit gold mines located 200 km south-west of Mexico City in Guerrero State, Los Filos and Ber- majal – collectively known as the Los Filos Gold Project – are set to become the largest gold mining operations in Southern Mexico. Prepara-tion work to reach the deposits, an estimated five million ounces of gold, is already under way.

Large Scale Project

This region of Mexico has never had a large-scale open pit mining operation be-fore. “We’re setting a precedent here,” says Roberto Díaz Colunga, Manager of the Los Filos Project, and explains: “In two years this will be the largest gold mining opera-tion in the south of Mexico. The project already provides more than 1,200 direct and indirect jobs and once we reach our steady production rhythm, we’ll be able

to refine over 300,000 ounces of gold per year.” The Los Filos Project is located 8 km from the village of Mezcala, approxima-tely 200 km southwest of Mexico City in Guerrero State. The project is owned by Luismin SA. de CV, a Mexican com-pany fully owned by Goldcorp of Canada. Goldcorp is investing USD 232 million to bring the project into production. A fleet of Atlas Copco equipment is already working at the site, with more units due to arrive. Seven DM45HP blast-hole drill rigs and two CM760D crawler drill rigs have been acquired by Luismin. The project’s main contractors, Materiales La Gloria and Desarrollos ROD, also use Atlas Copco equipment in their key pre-production tasks. “Before entering commercial produc-tion, Los Filos will have had two years of pre-production development and Bermejal one. This is a key phase for the project and it’s important that we have the right type and quantity of equipment in place,” says José Caracheo Brunel of Los Filos Mine Planning Department.

Two Deposits, One Project

The project comprises two separate gold deposits, Los Filos and Bermejal, which occur in adjacent hills approximately 1,200 m above Mezcala. A feasibility study was originally com-pleted in 2005. This study was recently expanded to include the adjacent, and sub-sequently acquired, Bermejal deposit. The Los Filos and Bermejal deposits will be developed as a twin open pit, heap leach operation, using two different ore proces-sing methods depending on grade. The mine reserves and resources total over five million ounces, of which four and a half million ounces are in the proven and probable reserve categories. Higher grade ore (1.50 g/t of gold) from the Los Filos deposit will be crushed to 80 per cent at –19 mm and agglomerated before being conveyor stacked and heap leached,

“Performance has matched our plans.”Roberto Díaz Colunga, Manager of the Los Filos Project.

BERMBACKBREAK

HOLES

Los Filos

United States of America

MEXICO CITY

Pacific Ocean

Gulf of MexicoMEXICO

Minera Maria

54


whereas lower grade ore (0.55 g/t of gold) from the Los Filos and Bermejal deposits will be hauled from the open pit directly to the leach pad to be bulk heap leached. The recovered solution will be treated to obtain a final gold ore product on site. Exploration drilling continues on pit ex-tensions and, in particular, on identifying higher grade areas.

200 m Tonnes of Ore

The mine development plan envisages a sequence of five mining phases over a 10- year period for both deposits. Under the plan, a total of 200 million tonnes of ore will be mined with an average gold grade of 0.69 g/tonne and an overburden strip ratio of 1.5 to 1. The stripping will entail the removal of 300 million tonnes of over-burden to access the gold bearing ore. The project will process 24 million tonnes/year of ore. A pre-production of 14 million tonnes/year is required for each deposit. To develop the orebodies, conven-tional open-pit mining methods will be employed using 12–15 m3 capacity loaders and shovels and 91 to 146-tonne capacity trucks. The pit design for both deposits incorporates 12 m-high waste benches and 6 m-high production benches. Final average slope angle will be 48–52 degrees depending on the type of rock.

“We expect almost all the material will require blasting; the reason for blasting the ore on 6 m benches is to provide better ore control and limit dilution,” explains Caracheo Brunel. The operational cycle will start with the drilling of 175 mm and 114 mm diameter blast holes in the waste and mineral strata respectively. To achieve this, Luismin has ordered a total of seven DM45HP blasthole drill rigs. The DM45 is a high pressure, crawler mounted, hydraulic tophead drive, multi-pass rotary blasthole drilling rig spe-cifically designed for production blasthole drilling. Operation of the drill is performed using electric over hydraulic controllers, ergonomically located so that the operator faces the drill centralizer while drilling. Two of the seven units ordered were delivered in 2005 and are already hard at work on the site, equipped with Secoroc ballistic button bits. A third unit arrived in May with two further units arriving in June and then two more in August. “We only ordered the last five machines once the Bermejal deposit was acquired. Some of these units will work in the Los Filos depo-sit and some at the Bermejal deposit,” says Caracheo Brunel. “We acquired the DM45 model because it is the ideal size and capa-city for the production volume we’ll be managing here.”

“This is a key phase for the project.”José Caracheo Brunel, Mine Planning Department, Los Filos.

THE GOLDEN TWINS OF SOUTHERN MEXICO

5 m5 m

5 m

5 m6 m

ø 6"ø 11-12 ¼"

72 º

15 m

The drilling and blasting pattern at the Los Filos mine showing the angle of the drill holes.

PRODUCTIONHOLES

BACKBREAKHOLES

BERM

55



Specifically designed for production blasthole drilling: One of seven DM45HP drill rigs used at Los Filos to keep the project on schedule.

Demanding Topography

The two CM760D crawler drill rigs with DTH hammers were delivered in 2005. “These machines are very useful. They are currently working on bench development but later we plan to use them for pre-split-ting,” says Caracheo Brunel. Díaz Colunga, Project Manager, adds: “We had seen the CM760 working before; they have the versatility needed to access this demanding topography, which doesn’t offer many possibilities of large spaces during the opening of the benches. Because of this, they are ideal for preparation tasks. Also, we required a machine able to con-duct detailed work such as pre-splitting and road construction. These units are good for these jobs.”

Díaz Colunga continues: “We have also chosen these machines, both the DM45 and the CM760D, because of Atlas Copco’s proven experience. This reassures us of the equipment’s good performance to gua-rantee the drilling, which is the first, most important step in the whole production cycle.” About 25 contractors are at work on the project. Materiales La Gloria – a main contractor – is a regular Atlas Copco custo-mer and its fleet of equipment at Los Filos includes T4BH, ECM 350 and ECM590 drill rigs. Recently, the company ordered two CM780D crawlers with DTH ham-mers. Meanwhile, another major contrac-tor, Desarrollos ROD, has a fleet of 15 ECM350 rigs operating at Los Filos. Asked about the performance of the Atlas Copco equipment, Díaz Colunga says: “So far we are satisfied as their performance has matched our plans and expectations.” He notes that the project hasn’t yet reached a normal production rhythm: “We believe we will be more satisfied with the drilling results if we together look after two very important factors – the discipline in the operating habits that we transmit to our personnel, and the meticulous respect for the preventive maintenance programme. Other factors are covered by engineering design and Atlas Copco’s experience, in which we have complete faith.”

Specialist Support

Madisa, the local Atlas Copco distribu-tor is responsible for technical support at Los Filos and is supported by specialists from Atlas Copco’s Mexicana’s office. Juan Carlos Gómez, Atlas Copco Product Manager, explains that upon delivery of a new drill rig, an Atlas Copco specialist will train operators on the use of the rig. “At the same time, Madisa sends its mechanics and instructors so they can participate in the training and become even more fami-liar with the machine.” This training is now even more impor-tant for Madisa, which has secured a full Maintenance and Repair Contract (MARC) at Los Filos. Operators of the recently deli-vered DM45 and CM760D rigs are trained in a three-week programme and technical visits help to reinforce their knowledge. Javier García Adame and Rosalino Carreia Soto are two of the operators of theDM45HP rotary rigs. García, who has been

56


Two of the 15 ECM 350 drill rigs belonging to Desarrollos ROD, which is in charge of constructing the leaching pad at Los Filos.

operating the DM45 for nearly four months when M&C visited the site. “It was a com-prehensive training process but easy to take on,” he said. “I have no problems with the machine and feel I know it quite well now.” Carreia, who has been working at the project for six months, is still going through the training process: “There are lots of things to learn but it is not compli-cated at all. And the specialist giving the training is good too. I’m looking forward to finally operating the machine all by myself!” Díaz Colunga reaffirmed the importance of the training. “We have had the benefit of the specialist training that Atlas Copco instructors have given to our operators,” he said. “I am convinced that in the future this link will be crucial to strengthening the success of our operations.” The project is at an advanced stage of development. Construction is well under way and is expected to be completed by the end of 2006 with commercial produc-tion planned to start in the second quarter of 2007. Commercial production for that year is expected to be 200,000 ounces of gold, rising to 350,000 ounces by 2008.

Acknowledgements


57


Drilling in Open pit Mining

MINERA MARIA, MEXICO

58

Minera Maria’s Pre-Split Pioneer

Small Diameter Holes

Minera Maria S.A. De C.V. is located in the Cananea District of the north-western state of Sonora, one of the most important copper producing states in Mexico. The operation is owned by the Frisco group of companies. Acquisition of a ROC L8 rig by this group marks the first time that Grupo Frisco has employed drilling equipment specifically to drill small diameter holes at one of its surface operations. “Maybe the fact that we have less com-petent rock at this site made us feel that there was a need for such equipment here,” says Humberto Garibay, Mine Manager. “Now that we have this machine, we can’t imagine working without it. In pre-splitting it has performed much better than we had expected, it has helped us in production blast drilling in areas where we can’t use the rotary rigs and we have planned to use it in exploration drilling to confirm proven ore reserves.”

Ricardo Ornelas, of Atlas Copco Mexi-cana, says: “More advanced and larger equipment such as hydraulic DTH rigs have steadily been introduced into the country. The ROC L8 is a good example of this. This is the first machine of its type in Mexico for pre-splitting applications and Minera Maria is making the most of it.”

Reviving Maria

Minera Maria was previously an under-ground, high-grade copper and molybde-num mine, which was in production for most of the 1990s. After depletion of reser-ves, the mine was closed in 1998. Grupo Frisco re-started operations in July 2003; this time as an open-pit operation achieving copper recovery through a solvent extrac-tion electro-winning (SX/EW) process. The final product is copper cathodes. Currently, Minera Maria produces around 88 tonnes/day of copper cathodes with a purity of 99.99 per cent. Mining takes place in three different areas: Maria pit, the main production area, which is being exploited in four phases; La Verde pit, located northwest of the Maria pit, adjacent to what will be the fourth phase of the main pit and which currently contributes about ten per cent of the daily production; and Lucy pit, located about 9.5 km from Maria and which will be in pro-duction in the near future.

Modern MethodsOpen-pit mining at the revived Mine-ra Maria mine is forging ahead. Mo-dern surface drilling methods and efficient recovery of the copper ore are breathing new life into this once abandoned mine.

“We can’t imagine working without the ROC L8.”Humberto Garibay, Mine Manager.

The Atlas Copco ROC L8 at work in the open pit at Minera Maria.


Having completed Phase I, the Maria pit is presently producing from its second and third phases. “Our production plan was designed in this manner in order to exploit the highest grade areas first and obtain the best cash flow possible from the mine during the first few years,” explains Garibay. Given the relatively shallow depth of the pits and the great volume of low grade material that has to be moved, mining is carried out using conventional truck and shovel methods. Minera Maria moves 75,000 t/day of material, of which approx-imately 35,000 t/day is ore and 40,000 t/day is waste. The average ore grade is 0.42% of Cu. “So far, we have extracted about 17 million tonnes of ore from 57 mil-lion tonnes of reserves,” says Garibay. Among the mine’s equipment fleet are 12 trucks of 150 tonne capacity and two electric shovels of 25 tonne capacity. For blast hole drilling, Minera Maria employs two rotary drill rigs with the capacity to drill 11–12 11/4 inch hole diameters.

Pre-Split Process

In October 2005, an Atlas Copco ROC L8 rig was added to the fleet. This machine was specifically acquired for pre-splitting work, which was previously done with the rotary rigs. Today, all the pre-splitting work is done with the ROC L8 unit. Pre-splitting is carried out by establis-hing a free surface in order to preserve the stability of the pit face. A series of closely spaced holes along an agreed cut line are drilled, charged and detonated prior to the bulk charges in the production area. This pre-split forms a fracture plane along the agreed extraction line and ensures that any disturbance to the rock beyond the agreed line of extraction is minimal. At Minera Maria, the pre-split takes place between the final wall and the buffer blast line. The ROC L8 drills 6” diame-ter holes every two metres at an angle of 72 degrees. Miguel Miramontes, Head of Blasting, explains that the charge for pre-splitting is done in a ‘sausage string’

Minera Maria’s ROC L8 is averaging 38 m/h, sometimes reaching 48 m/h.

MINERA MARIA'S PRE-SPLIT PIONEER

59

Drilling in Open pit Mining60

“We use the ROC L8 specifically in areas that are too small for the rotary rigs.” Miguel Miramontes, Head of Blasting.

Acknowledgements


fashion, with emulsion of 2” x 16” and with a spacing between each charge of one metre. “In each drill hole we use eight pieces, which weigh 0.96 kg each. We use detonator cord for connecting the charges and an instant fire sequence.” Minera Maria is particularly pleased with the symmetry of the drilled hole line and the shape of the slopes after blas-ting with the ROC L8 as this has a good effect on the blast waves as these expand. “Those waves die then and there – they don’t go beyond the established line,” says Miramontes.

Big Advantage

Garibay adds: “With diameters of 11–12 inches, the holes drilled by our rotary rigs are far too big for pre-splitting. The smal-ler the diameter, the better the pre-splitting. Also, it’s very difficult for the rotary rigs to drill at an angle. So having a rig with the capacity to drill such hole diameter, and at that inclination, is a big advantage for us.” Although currently drilling 6” diame-ter holes, the ROC L8 has the capacity to drill holes of 41/2-7”, which will also be useful to the mine in the near future as the management is now planning to reduce the diameter to 41/2”. Explains Garibay: “This will allow us to use lower density explo-sives and by doing so, there will be less damage to the final wall.” With an average utilization of 24 per cent (which will increase once the machine is employed in the Lucy pit), and produc-tivity of 38 m/h, the ROC L8 has had no problems at Minera Maria. Says Garibay: “To be completely honest we didn’t expect it to get such good results. We did a cost/benefit analysis before the purchase and we estimated that it would give us a productivity of 34 m/hour. The machine is currently achieving an average of 38 m/h but sometimes we get 48 m/hour.” Because of the success attained with the machine, the management at Minera Maria is now keen to experiment with what they call ‘double height bench drilling’. Instead of 15 m benches, 30 m benches would be used.

Versatile Rig

The ROC L8 has impressed the mine with its versatility. In addition to pre-splitting,

the rig is sometimes used for production blast drilling, using a vertical drilling pat-tern of 5.0 m x 6.0 m at a depth of 16.5 m. “In this application we use the ROC L8 specifically in areas that are too small for the rotary rigs,” says Miramontes. The drill rig will be increasingly used for production drilling once the exploitation of the Lucy pit starts. “Because there are no electric services in the Lucy pit, we have now planned for all the production and pre-splitting work in this area to be done with the ROC L8 machine,” says Garibay. The ROC L8 can also be used for sample drilling and there are plans to use the mach-ine in exploration drilling to confirm block models. “This is to be even more certain of our proven ore reserves,” says Miramontes. Atlas Copco’s Ricardo Ornelas explains: “The ROC L8 can perform sampling work through reverse circulation drilling, giving the machine great flexibility in surface operations.” The management is keen to look after the ROC L8. Says Garibay: “It is an excel-lent machine and very useful for us.” The ROC L8 is equipped with a COP 54QHD hammer using Secoroc 6” spheri-cal button bits. Ernesto Romo Villarreal of Atlas Copco Mexicana Technical Services, explains that the first hammer was changed after 22,000 m and the bits are lasting an average of 4,100 m. Romo assisted with the training of the operators as well as the mine’s mechanics and electrics technicians. Says Garibay: “We thought that the operators were going to find the machine too complicated. It has been the complete opposite.” This was confirmed by operator Jesus Gavino Rivera, who has been working at Minera Maria for over three years. Interestingly, he has also been an operator of the rotary blast drill rigs. “It was very easy to learn how to operate the ROC L8,” he says. “I’ve had no problems.” Rivera is also very pleased with the machine itself. “By the time I started operating it, it was nearly the end of the year and after wor-king with it I said it was a Christmas pre-sent for the mine. The ROC L8 is a great machine, it drills very fast and I’m very happy with it!”

MINERA MARIA'S PRE-SPLIT PIONEER


chileandbrazil

Pre-Splittingatchuquicamata

Located some 200 km north of Antofa-gasta, and 2,800 m above sea level in the desert of northern Chile, the Chuquicamata copper mine is the most important of the five divisions in the state-owned Codelco company, the world’s largest copper producer. It is a huge open pit, some 8 km-long, 2.5 km-wide and 750 m-deep, requiring a half-hour drive to get to the bottom.

Chuquicamata contributes 180,000 t of the 640,000 t of ore mined by Codelco every day. During 2001, the pit is expected to yield 620,000 t of refined copper and 13,500 t of molybdenum.

Mining started at the site 85 years ago, and it is estimated that there are still suffi-cient reserves for another 25 years of production at today’s rate. There are also plans to go underground by 2008.

Pre-splitting operations in the open pit have previously been carried out by large and heavy drillrigs. However, big hole blasting and heavy explosive loads result in irregular and unstable benches, which tend to reduce efficiency. In addition, the mine management was aware that, just by increasing the pit slope by one degree, the production of waste rock over the life of the mine could be reduced by a staggering 150 million cu m.

In an attempt to relieve this problem, three smaller, more manoeuvrable Atlas Copco ROC L8 rigs have been introduced by drilling contractor Jaime Navarette SA. This specialist in pre-splitting technology is applying the new rigs for 6 in DTH drill-ing of 18 to 24 m-long holes inclined at 20 degrees. The outstanding drilling accu-racy of the rigs, when applied to properly-formulated pre-split patterns, reduces the amount of explosives required to form the pit slope. This minimizes the shock waves reflected into the rock wall, reducing crack-ing and potential spalling, and resulting in safer benches and more stable slopes.

The ROC L8 rigs are also giving the

ROC L8 Gains Favour in South AmericaFlexibilitywithManoeuvrabilityThe ROC L8 drillrig from Atlas Copco is up to 7 t lighter than the rigs it is replacing in the world’s open pit mines, yet its drilling capacity is up to 35% greater. However, perhaps the most important attribute of the ROC L8 is its ability to drill with side incli-nation, enabling this high efficiency to be applied to both pre-splitting and production work. The lighter weight and better manoeuvrability of this top-of-the-range DTH rig facilitates multitasking, so that a single machine may handle the entire drilling needs of quite large operations. Hence, at the 7 million t/y Saiva quarry in Brazil, one ROC L8 replaced two large rotary rigs, and now drills the whole 7,000 m/month required to subtend full output. A similar story attends the changeover to DTH for pre-split-ting at Chuquicamata in Chile, one of the largest open pits in the world. Wherever DTH replaces rotary, the customer benefits from higher pro-ductivity and lower costs, with less drillrigs required to do the job.

One of the three Atlas Copco ROC L8 DTH drillrigs at Chuquicamata.

DRILLING IN OPEN PIT MINING62

mine improved rock fragmentation and better drilling flexibility. They are operat-ing 24 h/day in three shifts, each drilling 12,000 m/month at penetration rates of 35 m/hour, and giving 85% availability. Tests have also been carried out using the 8 in- diameter Secoroc COP 84L DTH hammer.

Maintenance of the rigs is the respon-sibility of Atlas Copco, under a contract involving a 10-person team. A second contract covers supply and maintenance of the Secoroc rock tools used in the operation.

The rig operators were impressed at the rigs’ drilling capacity compared to their larger predecessors. In one month, before delivery of the mine’s third ROC L6, two of the rigs drilled 31,000 m, with a best day of 1,200 m, and an average of 450-500 m per 12 h shift. The mini-mum drilling output for the two rigs was 22,500 m/month.

The characteristics of the ROC L8, compared to the conventional drillrigs used at

the site are: weight, 18 t compared to over 25 t; length, 7 m compared to 11-14 m; fuel consumption, 50-55 lit/h compared to 70-75 lit/h; tramming speed, 3.6 km/h compared to 2.5 km/h; and drilling capac-ity, 100 drill m/h compared to 75-80 drill m/h. An additional bonus is that, unlike the larger rigs, the ROC L8 can also drill with side inclination.

FlexibleProductionatelSoldadoEl Soldado, run by Anglo American Chile, is a tightly integrated operation consisting of an underground and an open pit copper mine, a concentrator and an oxide plant. The El Morro open pit section of the mine was started in 1989. The property is located 132 km north-west of Santiago, Chile, on the western slopes of the Coastal range, at about 830 m asl. In 2002, El Soldado pro-duced 62,800 t of copper in concentrate, and 5,500 t of copper cathode at an aver-age cash cost of 43 US cents per pound. Reserves at El Soldado are estimated to be 115 million t grading around 1% copper. Production of 18,000 t/day is split 49% from surface and 51% from underground, where the grade is slightly higher. The cur-rent capacity of the sulphide plant is 6.5 million t/y.

The El Soldado deposit is located in the Lower Cretaceous Lo Prado formation, and is thought to be of epigenetic origin. The main host rocks are trachytes, followed in importance by andesites and tuffs. Copper mineralization occurs as numerous isolated orebodies, with a strong structural control, located throughout an area 1,800 m-long by 800 m-wide. The main gangue miner-als are calcite, quartz, chlorite, epidote and albite. Rock hardness is 150 Mpa.

Production from El Morro open pit is 3.5 million t/y of ore, using a bench height of 24 m. Two Atlas Copco ROC L8 rigs are the mainstays of the drilling fleet, handling pre-split drilling of 162.5 mm (6.5 in) holes at 1.5 m spacing. Their net penetration rate is 1.2 m/min at 22 bar pressure, and they drill each hole in 35 minutes. It then takes one minute for the ROC L8s to move between set-ups.

Because the ROC L8 can drill at an angle, the mine can maintain ideal slope inclinations of 85 degrees in ore and 65 degrees in waste. Pre-splitting produces smaller amounts of large boulders, offers

View of the benches at 750 m-deep Chuquicamata open pit.

Atlas Copco ROC L8 crawlers drilling 250 mm presplit holes at El Morro open pit at El Soldado.

rOcl8gainSFavOurinSOuthaMerica


better stability, minimizes slope damage, and reduces global mine cost.

The rock drilling tools (RDT) supply contract at El Morro is based on a fixed cost/m, including DTH hammers. Average bit life is 1,500 m; hammer life 8,000 m; and tube life, 6,500 m. The bit grinding service uses a Secoroc Grind Matic BQ2.

The differences between the ROC L8 and conventional rigs are: weight 18 t vs 25 t; length 7 m vs 10 m, or more; fuel saving 25% to 30%; and higher drilling capac-ity 20% to 25%. In addition, at El Morro, the ROC L8 offers easier tramming across rough terrain; needs no hydraulic jacks for stability; and features greater production flexibility. The conventional rotary rigs at El Morro consume 72 lit/h of fuel, whereas the ROC L8s need only 52 lit/h, a saving of 28%. Higher productivity results in the ROC L8s drilling 2,400 m/month more than the conventional rigs.

As the El Morro open pit is situated immediately above the underground mine, an integrated mine plan is required, in which the sequence of extraction, both in the open pit and underground, needs to sat-isfy safety and efficiency criteria. In partic-ular, the design and extraction sequence of underground stopes have to be managed in such a way that they do not affect the open pit operations, and minimize disturbance to unmined areas, enabling maximum resour-ce recovery. It is also essential that the sur-face rigs have mobility and dependability, in order to switch quickly between drilling areas, as dictated by the mine plan.

limestoneforriobranco

The Saivá quarry in Brazil is another oper-ation to benefit from the introduction of the ROC L8. It is one of several open pits which supply the Cimento Rio Branco cement factory with limestone from sites in the southern part of the country, near the small city of Rio Branco do Sul in the state of Paraná. The mine belongs to the Votorantim Group, the largest cement pro-ducer in the region.

Saivá recently replaced two large rotary drillrigs with a new ROC L8 drillrig from Atlas Copco, and found that it was able to cut costs while sustaining productivity. The comparison between the performances of the two rotary rigs and the new DTH drillrig demonstrates that the Atlas Copco equipment has a huge advantage.

Initially, it was not believed that a com-paratively light machine like the ROC L8 could produce such high performance. However, its drilling capability has been proved in practice, and the machine now supplies the whole Saivá quarry output of 7 million t/year.

The Saivá quarry formerly drilled 6.5 in-diameter (165 mm) holes, but now, with the new ROC L8, 5.5 in-diameter (140 mm) holes are sufficient, yielding a 6% reduc-tion in the consumption of explosives.

The rig is equipped with a COP 54 QHD down-the-hole hammer, having an average life of 12,000 drill metres. The 5.5 in-diameter ballistic bits, which last for some 5,000 m, are supplied by Secoroc. The ROC L8 works two 8 h shifts/day, 300 days/year, drilling a 4.8 m x 8.0 m pattern.

The benches are 15 m-high, and the drill holes are 15.5 m-deep. Hole inclination is 15 degrees. Some 7,000 m are drilled each month.

Quarry data shows that the original drill-ing cost/m has been reduced by 46% for the ROC L8. Productivity has increased by 100%, accompanied by a large annual cost reduction.

Atlas Copco is providing labour, spare parts and drilling consumables, which include the DTH hammer, under the terms of a cost/metre contract. The customer is extremely pleased with the continuous after-sales service, and plans to extend the system to other quarries in the group.

Atlas Copco’s positive attitude in help-ing to solve problems has created an inno-vative partnership. Votorantim has since purchased a second ROC L8 unit to use in

Atlas Copco ROC L8 doubled productivity at Saivá quarry.


DRILLING IN OPEN PIT MINING64

another quarry in the state of Sao Paulo, and a ROC L6 for limestone production at Cimento Tocantins, Sobradinho, in Goias State.

PowerfulSpecification

Atlas Copco’s ROC L8 is a high produc-tion down-the-hole crawler with ample power to deliver high penetration rates and deep holes. It has a rod handling capacity for hole depths of 54 m (176 ft). The great advantage of the ROC L8 is that it can be used for both pre-splitting and production, making it a total solution for drilling in quarries and open pit mines.

The ergonomically designed ROC L8 cab, with its superb all-round visibility and user-friendly layout, reduces operator fatigue to a minimum, and increases safety to the maximum. The seat is fully adjust-able, and the cab meets all international safety requirements.

The ROC L8 is equipped with a high performance down-the-hole hammer for fast and straight drilling. As an option, a back hammer system can be added to take care of stuck drill tubes. The ROC L8 also features a hydraulic break-out table and double drilltube support, which helps the operator thread and unthread drilltubes, saves on drilltubes consumption, and helps drill straighter holes.

The feed and the rotation unit are mounted on a flexible, single-section boom with a ±30 degrees wide feed swing to right and left, and forwards.

The drillrig is powered by a 317 kW

(431 hp) Caterpillar diesel engine, with sufficient power for normal drilling and tramming. It therefore lasts longer, is low on fuel consumption, and has more than enough power for fast drilling in the most demanding rock.

Straightholes

An onboard Atlas Copco 405 l/s (858 cfm) screw compressor delivers up to 25 bar of air pressure for extra-high penetration and strong flushing, giving straight clean holes that are easy to charge. This unit is well up to the task of delivering top perform-ance, even when drilling holes as large as 165 mm (6.5 in) down to depths of 54 m (176 ft), and flushing them clean for charging.

An electronic system for hole inclina-tion and depth control ensures that blast-holes are perfectly aligned.

The machine is mounted on heavy-duty tracks with 18 degrees (–8 degrees/+10 degrees) of oscillation, for excellent tram-ming and site manoeuvrability.

The ROC L8 can be fitted with a range of Atlas Copco down-the-hole hammers such as COP 44, 54 and 64 (4 in, 5 in and 6 in). These are among the fastest on the market.

Their high performance, together with great functional reliability and outstanding service life, gives first-class drilling econ-omy. The superior penetration rate of these DTH hammers is due to a more efficient impact mechanism, and better use of com-pressed air energy. Flexible suspension of the central control tube enables the piston to be manufactured with much closer toler-ances. This minimizes internal air leakage, and optimizes the transmission of energy.

Two important benefits result: a higher penetration rate, and lower fuel consump-tion per metre drilled.

acknowledgements

Atlas Copco is grateful to its clients in Chile and Brazil for their contributions to this article, which first appeared in Atlas Copco Surface Drilling, First Edition, pub-lished in 2002. ■

Straight holes give better slope stability.


AtAcAmA, chile


Hydraulic Tophammers Exceed Soquimich Expectationslong Service contract for DrillrigsAs the world’s sole producer of natural nitrates, and one of the largest producers of mineral salts, Sociedad Quimica y Minera de Chile (Soquimich) has to be competitive in order to maintain its position. Somich, the company’s operating subsidiary, has four mines and seven processing plants in the Atacama Desert region of northern Chile, located between the coastal cities of Iquique and Anto fagasta. The first mine, El Toco, commenced production in 1927, and the latest, Nueva Victoria, came on stream in 1996. Despite consistently high out put over the years, reserves are esti mated as sufficient for another 50 years. Some 58 wagon drills were required to satisfy production demands in the early years of operation. By 1981, for an output of 15.5 million t/y, Somich had reduced this number to 23 units, of which five were Atlas Copco ROC 302 pneumatics. Nowadays, just seven Atlas Copco ROC F7 crawlers are employed to produce 18 million t/y. The switch from pneumatic to hydraulic production drilling equipment has brought other benefits, not least of which is more comfort for the operators. Soquimich has signed a fiveyear service and maintenance contract with Atlas Copco, which allows the company to maintain a constant level of drilling costs over long periods.

One of seven Atlas Copco ROC F7 rigs working in the Atacama desert.

Location map showing Somich installations in Chile.

PamPa blancaPamPa blanca

el tocoel toco

nueva victorianueva victoria

Natural Nitrates

Sodium and potassium nitrate are used as basic ingredients for fertilizer manufacture and as preservatives. The nitrate deposits occur within a 700 km-long belt located some 15 to 60 km from the Pacific coast of northern Chile, in the Atacama Desert. For the last 15 million years, this has been one of the driest regions in the world.

In the 1830s, Chile began supplying much of the world’s commercial nitrate require-ments from these deposits. Soquimich was established in 1968, and took over the nitrate

assets of the Chilean state-owned develop-ment organization Corfo and the private company Anglo Lautaro. Soquimich was subsequently floated on the Santiago stock exchange, and, by 1988, the company was entirely in private hands.

hyDrAulic tophAmmerS exceeD Soquimich expectAtioNS

66 DRILLING IN OPEN PIT MINING

Two graphs show the progressive increase in Somich drilling capacity with the introduction of new technology over the past 22 years.

Since then, the Chilean nitrate industry has been modernized by the addition of better processing facilities and improved min-ing equipment.

mine production

Soquimich employs 800 direct workers and 300 contract operatives on its four mines.

The mines are: Pedro de Valdivia, which started operations in 1931 and pro-duces 12 million t/y of crude nitrate; El Toco, started in 1927 and producing 6 mil-lion t/y; Pampa Blanca, started in 1995 and alternately producing 5.0 million t/y; and Nueva Victoria started in 1996 and producing 5 million t/y.

The crude nitrate ore is conventionally mined in open pits by drilling and blast-ing, and is hauled by trucks to the crush-ing plants, where it is reduced to 12 mm no minal sizing. Some 70% of the product is then leached in shallow pans to recover nitra tes, iodine, sulphates and other salts. The remainder is transferred to leaching stacks.

Each mine has its own production plant, and Soquimich has a further two plant facilities at Coya Sur and Salar de Ataca-ma. The collective output of the plants is 980,000 t saltpetre; 6,500 t iodine; 60,000 t

sodium sulphate; 600,000 t potassium chlo-ride; 250,000 t potassium sulphate; 16,000 t boric acid; and 20,000 t lithium carbonate.

Drilling capacity

In 1983, the remaining 18 wagon drills at the mines were replaced by another five Atlas Copco ROC 302 rigs. With the demise of pneumatic machines for main-stream production, the 302s were replaced in 1992 by seven hydraulic Zoomtrack 600 crawler drills, and these, in turn, were replaced with the seven current generation high capacity Atlas Copco ROC F7 rigs.

Atlas Copco offers a choice of Cater-pillar or Mercedes diesel engines to power its ROC F7s. Those at Somich are equipped with Mercedes engines delivering 170 kW. They also feature the powerful COP 1838 rock drill, which returns an average 65 drill m per diesel engine hour, or over 100 drill m/h, using 76 and 89 mm ballistic bits and T45 rods.

The mine management confirms an increased mineral production performance, compared with the previous generation crawler rigs. Performance is 20% better, and the number of effective operational hours has increased by 5%. With a drilling rate of production now running at 450-m/shift, three shifts/day, Somich is able to keep one rig on standby, and still meet the demanding targets. In order to stabilize the holes for charging, water mist flushing has been introduced to replace the previous air flushing system on the drillrigs.

Atlas Copco provided training for the drillrig operators on the advanced ROC F7, and taught Somich fitters how to maintain the Mercedes engine.

Drillrig availability is over 90%, a level which the mine accepts as very satisfac-tory. The ROC F7 drillrigs were accom-panied by a five-year mainten ance and repair contract, under which Atlas Copco is responsible for all maintenance.

Acknowledgements

This article first appeared in Atlas Copco Surface Drilling, First Edition, published in 2002. ■

Key Industry

DSM Minera S.C.M. is one of the busi-ness units of DSM Fine Chemicals, which in turn is owned by DSM, the Dutch pro-ducer of speciality chemicals. Ironically, the name DSM originally stood for Dutch State Mines, a coal mining company founded by the Dutch government in 1902. DSM first became involved in DSM Minera in 1991, when it acquired a 30% interest. The remaining 70% of the oper-ating company was acquired in 1997, and in 1999 DSM installed its own manage-ment team. Present reserves stand at 7-10 years, although this figure is expected to increase, as the company owns mining rights in nearby areas, which still have to be developed.

DSM Minera’s main activity is the production of iodine, which is used as a feed-stock in the manufacture of iodine deriva-tives for a diverse range of applications, including disinfectants, agrochemicals, food and feed additives, heat stabilizers, and for X-ray diagnostic purposes.

The global market for iodine is around 19,000 t/y. Chile is by far the largest pro-ducer, where it is normally extracted as a by-product or co-product associated with natural nitrates. These days, the Chilean nitrate mining industry is relatively small, though in its heyday, more than a century ago, it completely dominated the fertilizer

industry, and vast fortunes were made. The remains of many of these old mines are still to be found, preserved in the dry desert air.

Effective Process

The production process at DSM Minera is simple, consisting basically of drilling, blasting and leaching operations. The first part of this process, drilling and blasting, is carried out by Chilean contractor HIT, under a five-year contract signed with DSM Minera.

Blasting, mainly with ANFO, is carried

IquIquE, chIlE


HIT has two ROC D7 drillrigs.

Blowing out holes ready for charging.

Winning Iodine from the Atacama DesertWorld’s largest Located in the Atacama Desert region of Northern Chile, near the city of Iquique, DSM Minera S.C.M (Sociedad Contractual Minera) operates what is claimed to be the world’s largest iodine production facility, processing over 400,000 t/month of ore. Here, two Atlas Copco ROC D7 hydraulic drillrigs, some of the first units of this type in South America, are being employed by contractor HIT as the main production drilling equipment.

out to prepare the material located in each ‘mancha’, the Chilean name for the desig-nated area to be drilled and blasted. Once HIT has drilled and blasted, the material is leached in-situ, draining to lower areas through pipes to specially-made canals leading to the recovery plants. This has been a very cost-effective method, in which the ore is irrigated with water for 6-8 months to produce Iodate solution. Within the plants, which are ISO 9002-certified facilities, a series of chemical processes are applied to the solution to obtain high purity iodine. DSM uses 40% of this iodine to make deri-vatives, and the rest is sold into interna-tional markets.

DSM Minera operates several process plants, with a combined output of over 2,000 t/y of iodine. An additional new plant, with an output of 600 to 1,000 t/y, was recently commissioned, facilitating an increased ore throughput from the current 400,000 to 700,000 t/month.

Tough Drilling

The contract between DSM Minera and HIT specified 400,000 t/month of ore, for which the contractor had to drill 50,000 m/ month of rock. In order to satisfy this objective, HIT acquired two Atlas Copco ROC D7 tophammer hydraulic drillrigs. HIT, which is a family company run by father and son, Hernán Iribarren Torres, general manager and Alejandro Iribarren, operations manager, respectively, has been operat-ing for five years, and has a workforce of 22 people. The company already had two ROC 203 pneumatic rigs, which it used

for secondary drilling on other contracts. This equipment was not powerful enough for primary drilling work, so the company decided to invest in new hydraulic rigs.

The ROC D7 machine is one of the newest models in the Atlas Copco series of tophammer rigs, and the units employed at DSM Minera are some of the first of this type working in South America. Apart from Chile, the ROC D7 is also working in Mexico and Brazil.

With a hole diameter range of 35-102 mm, the ROC D7 rig features a powerful engine, good flushing capacity and flexible booms with extra long reach. The machine comes with a COP 1800-series rock drill with a maximum impact power of 20 kW, a fuel-efficient Caterpillar engine deliv-ering 149 kW, and an Atlas Copco screw type compressor with a working pressure of 10.5 bar (152 psi).

In addition to the HIT ROC D7, Atlas Copco ROC L8DTH and F7 tophammer crawler drillrigs are operating in north Chile.

The hydraulic winch on the ROC D7 makes drilling a lot easier in the rough ter-rain of the Atacama Desert, as it has more power and strength. One-man operation is also a major bonus on these new generation machines, which offer many advantages in capability and mobility.

By increasing the drilling diameter from 63 mm to 76 mm, HIT has been able to eliminate 168 holes, or 437 m of drilling, to obtain the same tonnage/month. Also, by changing the grid pattern, the explosive was found to perform more efficiently.

The ROC D7 rigs are drilling between 60 and 70 m/h on each shift, with an avail-ability of around 85%, while the operators familiarize themselves with the rigs. Atlas Copco Chilena has been instrumental in training the rig operators, using a full time technician. The company also has a main-tenance contract with HIT, and supplies the Secoroc drill steel. HIT has taken delivery of a third ROC D7 unit to support DSM Minera’s plans to increase ore throughput to 700,000 t/month.

Acknowledgements

Atlas Copco is grateful to DSM Minera and contractor HIT for their help and assistance in the production of this article which first appeared in Atlas Copco Surface Drill- ing, Second Edition, published in 2004. ■

WInnIng IoDInE from ThE ATAcAmA DEsErT


The ROC D7s drill out a “mancha” ready for blasting.

shuichang, china


Atlas Copco ROC F9 crawler rig, one of four working at Shuichang iron ore mine.

Replacing Rotary in Iron Oresmall is BeautifulThe large Shuichang open pit iron ore mine is located near the Luan River, about 200 km east of the Chinese capital, Beijing. It is one of the major sources of raw materials for the Ca-pital Iron & Steel Company, and was once the largest open iron mine in Asia, with an annual output around 15 million t of ore, and 45 million t waste stripped.

Shuichang is a subsidiary of the Mining Company of Shougang Corpo-ration, and is a state-owned enter-prise.

For some 30 years, large rotary rigs had formed the main drillrig fleet, when two Atlas Copco ROC F9 crawl-ers were introduced. To the great sur- prise of the local operators, they out-performed the rotary rigs, resolving presplitting problems in the very weathered rock, while creating a much safer loading and hauling environment.

acknowledgements


geology and Operations

Shuichang started operation in the early 1970s, mining magnetite as the primary mineral in the ore, with martite as a secon-dary product. The natural ore deposit is composed of four constituents: magneti-tic quartzite, pyroxene-magnetitic quartzite, magnetitic pyroxenolite and hematitic quartzite. Mineral size in the ore is usually 0.062-0.5 mm, with a moisture content general-ly between 0.10% and 0.20%, averaging 0.143%. The average porosity of the ore is 4.08%, and its average weight/unit volume is about 3.24 t/cu m.

Shuichang Iron Mine is rated as a lowgra- de iron deposit. The average geologic grade is 26.71%, and the average iron silicate con-tent in the ore is 1.73%. From these data, the Fe grade is calculated to be about 28.44%. Geologic grade varies greatly with depth.

The main associated gangue minerals are quartz and mussite, with hypersthene, horn-blende, garnet and black mica as secondary constituents.

More than ten rotary drilling units have been used from time to time for presplitting and production work. The bench height is about 12 m, and the hole diameter drilled by the rotary rigs is about 310 mm.

Two ROC F9-11 folding boom crawler rigs were delivered to the jobsite in No-vember, 2002. These were equipped for drilling 115 mm holes to nearly 30 m depth. At first sight, the mine staff had great difficulty in accepting that the ROC F9-11, which is physically a much smaller rig than the equivalent rotary machine, would be a suitable replacement.

However, the new rigs soon proved their worth and, after six months operation, the customer was very satisfied with their flexibility and performance. The opera-tors are very happy with the ergonomic layout of the cab, finding it comfortable, and making it easy for them to operate the rig. The management has expressed sat-isfaction with the high penetration rate, and the output of almost 400 m/day. They have also found the rigs to be very flexible, drilling at all angles to meet their presplit requirements.

The dieseline consumption is also much lower than expected, leading to better over-all costs.

As a result, the company has taken delivery of a further two Atlas Copco ROC F9 rigs, and another five iron ore produc-ers in the region have expressed interest in buying this type of rig in the near future.

kimberley and laverton, australia


Drilling cablebolt holes at Argyle.

Multiple Tasking in Western Australia

diamonds and GoldAccording to official statistics, the annual export value of minerals and metals accounts for nearly 30% of the total exports of goods and services from Australia. The remote Kimberley region of Western Australia makes a valuable contribution, with diamonds and gold high on the list, from open pit mines that have some of the toughest working conditions on earth. In such difficult locations, the client places more reliance on manufac-turers, not just to supply the most flexible, robust and reliable equip-ment, but to assist in commission-ing, training, ongoing maintenance, and the resolution of any abnormal parts and service problems that may occur. Atlas Copco engineers and fit-ters regularly visit each mine, and the client can call them for advice at any time. They have demonstrated a high degree of product and industry knowledge, and are proving to be a valuable source of information, keep-ing the clients up to date on prod-uct developments. Access to such relevant expertise helps keep the machines working at their very best.

rock engineering at argyle

Australian company Rock Engineering specializes in the contract supply and installa tion of ground support products in

underground and open pit mines and civil construction applications, and is one of the first to offer this service.

Rock Engineering has a large portfolio of projects, both in Australia and over-seas. These include the ground support programme at the Argyle Diamond Mine, located 130 km south of Kununurra, in the isolated Kimberley region of Western Australia. The Rock Engineering fleet on site was strengthened by the addition of an Atlas Copco ROC F9 surface drill-rig in May, 2002. As the first Atlas Copco machine to be used by the company, there was great interest in its performance!

The Argyle mine was commissioned in 1985, following a long period of exploration that initially commenced in the Kim-berley more than a decade earlier, in 1972. It now produces more diamonds than any other mine in the world, and is renowned for being the only source of the rare and valuable pink diamond.

For what is now a large open pit mine, Argyle has relied on Rock Engineering to provide ground support and pre-splitting of the final walls for nearly four years. Currently eighteen months into the two-year second phase of the ground support fixed-price contract, Rock Engineering has been on site for around three years in total, having completed Phase One prior to the current contract. Mine life for the open pit is predicted for another four years, with the potential to commence underground opera-tions after that time.

To perform its work on site, Rock Engi-neering owns and operates a fleet of under-ground and surface equipment.

rugged and reliable

The ROC F9, along with all of the ma-chines in the Atlas Copco Open Pit Series, has been designed for rugged conditions, with enough strength and flexibility to handle the most demanding tasks. Thanks to its folding boom, the ROC F9 boasts the longest vertical and horizontal reach of any similar machine. It is also equipped with the most powerful tophammer in its class.

multiple taskinG in Western australia


Atlas Copco’s ROC L8 at work at Sunrise Dam open pit.

The rig is powered by a 231 kW engine and an Atlas Copco screw compressor de-livering 188 lit/sec.

The design facilitates more holes per rig set-up, because less time is spent tramming, making more time available for drilling.

Rock Engineering’s decision to purchase the ROC F9 was based heavily on its versa-tility, because the folding boom is suitable for both drilling cablebolt holes, and for pre-splitting. At Argyle, cablebolt holes are drilled at 89 mm-diameter to a depth of 23 m, while pre-splitting is carried out to a depth of 25 m. As well as these two main functions, the machine is also occasionally used for drilling blastholes, and pit holes for dewatering. The company appreciates this versatility, but has also found that the ROC F9 outperforms its predecessor on all functions. This is partly credited to the ang-ling capability of the drillrig’s mast, which allows the operator to insert bolts quickly, and with minimal manoeuvring of the unit.

The operators are also able to see all of the rods from the cab, which they report has led to more efficient drilling.

Good Company

The ROC F9 drillrig is used at Argyle on a 10 h shift basis and, even in the site’s vari-able rock conditions, is meeting all require-ments placed upon it. It was recently joined by a ROC L8, another machine from the current Atlas Copco series, which arrived on site during May, 2003.

This latest addition is being used to drill 150 m-long dewatering holes at a 5-degree upward angle, and 200 m-deep vertical ho-les, although it is also capable of pre-split and production drilling. The rig uses a 5 in hammer, 89 mm drill pipes, and 140 mm bits, and the carousel has been modified to allow for re-load of pipes every 48 m.

The Australian drilling contractor mar-ket has a reputation of being one of the most demanding in the world, with some of the toughest working conditions. In sum- mertime, the operators face ambient temper-atures above 55 degrees C in the pits. The rock stores the heat, and radiates it at night. The Atlas Copco rigs have been customized to handle these sorts of conditions, together with the contractors’ specific needs. Widened application range, exceptionally low running cost, and enhanced reliability are the main reasons for the rapid acceptance of the ROC L8 in Australia.

Fitted with a Caterpillar C12 317 kW engine, the ROC L8 provides powerful down-the-hole drilling with COP 44, 54 and 64 Gold hammers, which are among the fastest on the market.

Combining manoeuvrability, strength and precision, the rig can drill accurately throughout a large range of angles. An op-tional electronic inclination instrument and depth controller ensures perfectly aligned and orientated holes to a preset depth.

Heavy-duty tracks, a fuel-saving device, and a dust collector and pre-separator are among the many standard features of the unit. Many other options are available, including an electronic refuelling pump, engine pre-heater, and hydraulic support leg.

The ROC L8 was purchased on its own merits, but Rock Engineering experience with the ROC F9 obviously had some influence on their decision. The ROC F9 has reported very few of the teething prob-lems normally associated with the commis-sioning of a new machine, and achieves 90% availability.


multiple tasking at sunrise damThe Sunrise Dam gold mine, located 50 km south of Laverton, Western Australia, has been operational since 1997. It has gone through numerous upgrades and expan-sions, and the open pit has now reached a depth of 460 m. Since 2000, conven-tional open pit mining has been carried out by Roche Mining, the mining division of Downer EDI, one of Australia’s major providers of mining services, and winner of the inaugural Gold Industry Supplier of the Year in 2003. Roche Mining introduced the new Atlas Copco ROC L8 crawler in November, 2002 to help rescue the steadily declining output.

In early 2002, approximately 1.4-1.6 million bank cubic metres were mined per month, an output already declining with increasing pit depth and decreasing strip ratio.

To obtain this output, Roche Mining operates a range of large trucks, excavators and drillrigs.

Traditionally, separate machines have been required to perform the various drill-ing functions, particularly grade control drilling, where normal production rigs were unsuitable because of the requirement to blow air back up the drilltube.

However, the revolutionary Atlas Copco ROC L8 DTH rig is designed to handle

reverse-circulation grade control, pre-split, and production drilling.

With this in mind, Roche Mining took delivery of a new ROC L8 towards the end of 2002, proposing fast changeover times to enable their operators to fully utilize the multiple functions of the rig, without com-promising on performance.

The ROC L8, powered by a robust Cat 317 kW (430 hp) diesel engine, is compat-ible with some of the fastest DTH rock drills on the market, including the COP 44, 54 and 64.

Heavy-duty tracks with 18 degrees of oscillation, low centre of gravity, good weight distribution, and good ground clear-ance all contribute to the impressive terrain and tramming abilities of the ROC L8. During 2003, the ROC L8 is easily meet-ing the target figures, while satisfying ini-tial expectations, and is achieving drilling rates equivalent to the outputs of Roche’s larger machines.

The machine currently performs reverse circulation, blasthole and pre-split drilling, a flexibility of operation that is praised by the owner. A fast changeover time ensures that the multiple functions of the rig are used efficiently, and there is no compro-mise on performance.

versatile asset

The ROC L8 at Sunrise Dam has proved to be a versatile asset that is meeting all requirements, and is building a reputation as a well-designed machine that facilitates multifunctional use in mining. During the first two months of operation, an Atlas Copco technician attended site full time, to ensure that everybody was at ease with the new arrival, and confident with its func-tions and use. Roche Mining now receives a weekly visit, to ensure that everything is working at its best. Based on the machine’s merits alone, the company is looking for-ward to including more units into its fleet in the near future.

acknowledgements

Atlas Copco is grateful to the management and contractors at Argyle and Sunrise mines for their inputs to this article, which first appeared in Atlas Copco Surface Drilling, Second Edition, published in 2004. ■

Air conditioned cab is essential at Sunrise Dam.

multiple taskinG in Western australia


ROC L8 Outperforms in Assmang Iron OreTestingConditionsWherever the Atlas Copco ROC L8 DTH drill rig has been introduced, it has quickly earned a reputation for independence and flexibility. Capable of drilling large-diameter holes to great depth, the story has been the same in all applications: more holes for less money. At Assmang iron ore mine at Postmasburg in South Africa, a 250% increase in drilling output was registered by the ROC L8 under test conditions, and its new owners were so delighted with its perform-ance that they ordered three more. Built-in reliability, combined with At-las Copco service and spares support, is ensuring that this new generation of drill rigs is recording high levels of availability, even when drilling around the clock in remote situations.

POSTMASBURG,SOUTHAFRICA

WinningatAssmang

When drilling contractor Booysen Bore secured a contract at Assmang, a mine with an iron content of 65% and a strength of 650 MPa, they purchased an Atlas Copco ROC L8. The penetration rates and production capabilities of the ROC L8 quickly became apparent, causing Booysen Bore to order three more similar machines to replace their ageing fleet of waterwell rigs. At Assmang, 165 mm holes are being drilled in bench heights varying from 8-13 m, and in different grades of ore. Bits need to be sharpened every metre when drilling into the top grade of iron ore, and every 6 m when drilling into waste. The ore:waste ratio in the pit is 80:20. Nevertheless, the ROC L8s, which are predominantly used for production drilling and some minor secondary drilling, are each achieving a net penetration of 33.8 m/h, with an overall average of 19 m/h for the four rigs.

Contractor’sDream

Booysen Bore drills 43,000 m/month, on a 24 h/day, 5 day/week cycle. Their ROC L8 rigs are equipped with 6 m-long tubes,

so that most holes can be drilled with just two tubes, reducing the number of joints in the drill string and keeping tube changing to the bare minimum. Faster drilling rates and less tube changing means they require 60% less manpower to get the job done. The drillers are finding the rigs easier to operate than the old fleet, and really appre-ciate the comfortable cabin on cold nights. The ROC L8 is versatile, with boom movements that are able to drill 30 degrees left and right for pre-splitting, and forward, if necessary. The onboard depth and incli-nation meter is a contractor’s dream for recording metres drilled. The rig is also equipped with an EMS that measures engi-ne speed, temperatures, coolant levels, bat-tery voltage and other useful information. The company is very happy with the after sales service, consignment stock and training programme, all of which have assured 85% mechanical availability.

Three ROC L8s presplit drilling at Assmang, South Africa.

Acknowledgements

Atlas Copco is grateful to Booysen Bore and the owners of Assmang Mine for assistance in the production of this article, which first appeared in Atlas Copco Surface Drill- ing, Second Edition, published in 2004. ■

tANZANIA, gEItA gOLD MINE


GoldProduction

Located in north central Tanzania, 1,200 km by road from Dar es Salaam, Geita Gold Mining Limited (GGML) is owned by giant miner AngloGold Ashanti. With an impres-sive production of 24 t/y of gold, Geita is the largest of AngloGold Ashanti’s 11 open pit gold mines, eight of which are located in Africa. Since its inauguration in August 2000, Geita has shown an impressive performance, greatly exceeding expectations. The mine’s gold production record so far has been: • 176,836 oz in 2000• 545,561 oz in 2001• 570,043 oz in 2002• 661,000 oz in 2003• 692,000 oz in 2004

Geita has a forecast for well over 600,000 oz in 2005. This represents almost half of Tanzania’s annual gold production. Geita Gold Mine now contributes about 6% of the national GDP. This growth pattern is also reflected in the company’s reserve base. When commissioned, Geita had a 4 Moz reserve, a 7 Moz resource, a 10 year life and a plant capacity of 4 Mt/y.

Today these figures have increased to 8.4 Moz reserve with an average grade of 4.28 g/t, 12.7 Moz resource with a grade of 4.46 g/t, a 16 year life and a 6.3 Mt/y capacity plant.

MiningatGeita

Mining operations at Geita (which has an ISO 14001 environmental certification and a NOSA 4 star safety certification), involves the stripping of over 20 million m3 of rock, using standard open pit mining methods, with drill and blast followed by hydraulic excavators loading into 100 t trucks.

Geita Gold Mine is the largest of AngloGold Ashanti´s 11 open pit gold mines.

Greater GeitaImpressiveperformanceThe largest fleet of ROC L8 drill rigs anywhere in the world is hard at work in Tanzania at the Geita Gold Mine, one of Africa’s largest open pit gold opera-tions. An astonishing 14 of these machines are employed in blast hole drilling while two other units, rented by the exploration contractor, are used in reverse circulation drilling. Being extremely flexible and reliable, particu-larly in adverse weather and rock conditions, this is yet another example of the ROC L8 Down-The-Hole crawler’s high success around the world. And the Atlas Copco presence at Geita doesn’t stop there: Four CS1000 rigs complement the exploration drill-ing fleet and two Drilling Solutions DML rigs for large blast hole drilling will arrive shortly at the mine.

The first ROC L8 rig arrived at Geita December 2001. Some of the machines have now clocked up over 15, 000 hours of drilling but still work an average of 21 hours per 24 hours of work.



ROC L8´s at some cleaning up work of boulders from an old ramp.

Production comes from several open pits; the Nyankanga pit (the largest and where about 30% of the pit production is sourced from, with an output of over 900,000 BCM’s (bank cubic metre) a month; Geita Hill (an interesting challenge as the area being mined is located above a network of old underground workings), Lone Cone (North, Central and South), Kukuluma and Matandani. Fu- ture pits to be mined are Chipaka, Area 3 West, Roberts, Ridge 8 and Star & Comet. The latter three pits will go into production in 2008 and will be located about 30 km from the processing plant. The mining operation is vast and complex, with roads and other infrastructure, including a dam, waste dump, tailings dam, air-strip and numerous buildings spread over a large area. In a change of strategic direction, from August 2005, AngloGold Ashanti has taken over direct responsibility for the mining operations at Geita, which were previously supplied by a contracting company. Mr Ettiene Smuts is responsible for the mining department, where a team of mining engineers, supervisors, surveyors, mine geologists and other assistants work together to define the gold bearing ore, design and schedule the pits and waste dumps, and then mark out this information in the field.

The fleet of drilling equipment comprises 14 Atlas Copco ROC L8 Down-The- Hole drill rigs all of which are used for blast hole drilling. Blasting, using ANFO and emulsion, takes place every day. Most of the drill rigs are employed in the large Nyan- kanga pit and moved to the other working areas as and when needed. GGM has ordered two Atlas Copco Dril- ling Solutions DML rigs which will be delivered at the end of 2005. These units will be used for large blast hole drilling in the Nyakanga pit as the cuts get back further, requiring more material to be removed. Blasthole diameter is 130 mm but the drill pattern varies from pit to pit depending on the ground conditions and hard-ness. Current drilling patterns used are:• 4 m x 4.5 m x 10 m bench with a sub drill of 1 m• 4 m x 5 m x 10 m bench with a sub drill of 1 m • 5 m x 5 m x 6 m bench with a sub drill of 5 m in the softer areas.

The first ROC L8 rigs arrived at Geita in December 2001. As temperatures can get very high in this part of the country, the machines’ cooling system was modified with an extra cooler in order for the rigs to achieve optimum performance in the severe heat.

Mr Gathuru Mburu is Atlas Copco´s Branch Manager in Tanzania.



A high emphasis is placed on machine availability and the technical support is being provided directly by Atlas Copco Eastern Africa

Some of the machines have now clocked up over 15,000 hours of drilling but still work an average of 21 hours per 24 hours of work. Thanks to the Down-The-Hole method, these rigs are particularly good when drilling in the water areas around the pits. This method also helps keep the drill con-sumables cost to a minimum. The high air pressure delivered by the ROC L8s improves air flushing and consequently the penetra-tion rate. This large fleet of equipment needs constant back-up and technical support, mainly when considering that the machines are working in a remote area where one of the major problems is logistics. In conjunction with the engineering manager, Errol Drake, Atlas Copco Eastern Africa is further optimising the supply and stocking of parts and consumables. There is also a rebuild programme planned for the coming months with major components on the older rigs being replaced. Geita’s Purchasing Managers K. B. Wilson and Simon Dominic say: Because of logistics, supply can be a problem. How- ever, unlike with other manufacturers, we do not have supply problems with Atlas Copco. The company’s local support is very good.” A high emphasis is placed on machine availability and now that technical support is being provided directly by Atlas Copco

Eastern Africa, a new target has been set to increase the rigs’ average mechanical availability to well over 80% in the next 18 months. In order to reach the high monthly targets and keep a strong connection with the drilling team, Atlas Copco Eastern Africa is now responsible for training the person-nel in the maintenance and drilling division.

StanleyMiningServices

Stanley Mining Services, part of US-based Layne Christensen - one of the largest exploration drilling companies in the world

Blasting notification at the Geita Airstrip.



- is responsible for exploration and grade control drilling at Geita. Stanley has operated in Africa for nearly 10 years and apart from Tanzania, it has offices in Ghana, Guinea, Mali and Zambia. Geita mine was the location of the company’s first drilling programme in Tanzania, where difficult ground conditions make the work particularly challenging. GGM awarded Stanley a contract starting in June 2001. One of their largest contracts, in terms of the work carried out – exploration and grade control - equipment deployed and number of people. At Geita, Stanley has a workforce of 115 people and has its own facilities, including a workshop, store, training room and a large fleet of equipment on site. This fleet includes four Atlas Copco CS1000, skid mounted rigs and two Atlas Copco ROC L8 rigs. The ROC L8s are on rental from Atlas Copco Eastern Africa. Stanley’s fleet in Tanzania comprises 15

Atlas Copco Christensen surface core drilling rigs (model CS 1500, CS 3000 and CS 4000 using Craelius

diamond bits and Craelius rea- ming shells), 10 RC drilling rigs

and a number of Atlas Copco compressors. Stanley’s ROC L8 RC rigs are allocated to grade control drilling in the pits.

They are fitted with RC drill rods and face sampling Down-The-Hole

hammers. For grade control (which is undertaken every 20 m), the machines drill 11 m holes at 60° angle. The choice of ROC L8 was influenced by the fact that the mine already had a large fleet of these machines. Atlas Copco has a team of service engi-neers on site to provide 24-hour support to Geita’s and Stanley’s fleet of ROC L8 rigs. With a 2005 budget of US$5.6 million, exploration at Geita is carried out to generate replacement resources at an equivalent rate to which they are depleted by mining operations. The core drilling rigs are used

for exploration (core samples) in the field and the RC equipment is used both for exploration in the field and for grade control in the pit. Based on the outcome of the exploration with the RC rigs, the diamond rigs can be deployed to obtain an exact repli- cation of the ground conditions with a solid core sample. This information is given to the mine for the modelling. Diamond drill holes are normally between 300 and 500 m.

AtlasCopcoEasternAfrica

With a presence in Nairobi, Kenya since 1936, Atlas Copco has its own sales, logistics and aftermarket support customer centre in this country. This centre is also the Group’s Regional Headquarters for East Af- rica, covering Tanzania, Uganda, Ethiopia, Eritrea, Sudan, Mauritius, Madagascar, So- malia and Djibouti.These markets are supported via a group of skilled sales, logistics and service personnel, trained at factory level to market and service all of the Atlas Copco products and support the distribution network. In order to extend its service to customers, a new Atlas Copco branch was established in January 2003 in Mwanza, Tan- zania, with the aim of strengthening the support to mining, construction and indu- strial customers in the Lake Victoria region.

Acknowledgement

This article was prepared for the Atlas Copco press lunch in London, December 2005. ■

AngloGold Ashanti continue to invest in new equipment.

Gold bullion processing.

Mr Greg Kelly is the Drill & Blast Superintendent at Geita Gold Mines


navachab, namibia

DTH Choice Cuts Costs at Navachab

Reducing Operational costsThe Navachab gold mine in Namibia has the potential to reduce its opera-tional costs with the introduction of down-the-hole drilling. The mine is aiming for a higher ore-to-waste ratio and substantial savings in loading and haulage.

The extended main pit at Navachab: Mining is carried out on 5 m-high benches.

“The full service contract gives us the availability we need to achieve our targets” Angula Kalili, Pit Superintendent.

Substantial Savings

AngloGold Ashanti is proving that sub-stantial savings can be achieved by moving from contractor mining to owner mining. In 1998–99, AngloGold Ashanti had planned a pit extension programme at its Navachab gold mine that would support production until 2013. At that time, the plant treatment capacity was 170 tonnes per hour, with an ore throughput of 1.4 mil-lion tonnes per year, averaging 1.55 grams of gold per tonne. The low price of gold at that time per-suaded the company not to proceed. But after a feasibility study, Navachab approved the Western Pushback, which made up half of the original expansion project. This extension of the main pit from 2000 to 2001 extended the life of the mine (LOM) from 2003 to 2005. In 2002–3, another fea-sibility project was launched to mine the Eastern Pushback. Through reduced costs and a strong gold price, this project was approved and it increased the LOM to the current 2013. In 2003, the mine decided not to renew

the mining contractor’s contract and to convert all mining operations to owner mining. This involved the purchase of new mining equipment, including three ROC L8 drill rigs with DTH hammers. Pit Superintendent Angula Kalili exp-lains: “The aim of selecting DTH drilling was to make the drilling process more accu-rate, to gain better control of the amount of ore/waste, and to reduce the costs of loading and hauling through better fragmentation.” Once the Western Pushback (main pit) is complete, it will be 900 m long (extended by 85 m), 375 m wide and 220 m deep (extended by 40 m). Mining of the Eastern Pushback started at the beginning of 2006 and is expected to continue to 2013. All mining blocks (ore and waste) in the main pit are mined out on 5 m high benches. This interval will be the same for ore blocks on the Eastern Pushback but here, waste blocks will be increased to 10 m benches. The rock is classified as soft, hard and very hard, and each mining block amounts to about 12,000 m3. A dedicated diamond drilling rig works ahead of mining to define the mineralization zones and maximize ore definition. Navachab also operates a comprehensive geotechnical programme including in-pit mapping of structural data to ensure slope stability and provide a safe working environment in terms of geotec wall stability. Blasting is done with megamite explo-sives for the pre-split holes and emulsion (High Energy Fuel HEF) for production blast holes, using a powder factor of 0.7 kg/bank m3 in hard rock. Non-electric de-tonators are used but electronic detona-tors are being tested for slope stability and vibration control.

achieving the Objective

As a key factor in the switch to DTH drill-ing, Navachab selected three Atlas Copco ROC L8 drilling rigs equipped with COP 44 hammers for ore drilling and COP 54 hammers for the bigger diameter holes in the waste. These rigs provided exactly the capability Navachab was looking for – high

78


DTH drilling under way: The ROC L8s being used for pre-split drilling on a 1.2 m spacing.

The drilling team: from left, H Nel, Site Foreman, R Rust, Product Support, J Pietersen, Mechanic (all from Atlas Copco), D Stini and M Beukes, Navachab operators and Mathues Pointer, Navachab.

Keeping up the good work: During their first year, the ROC L8s were maintained with an Atlas Copco full service contract.

acknowledgements


precision drilling, flexibility in feed positioning and a high degree of mobility on the pit’s narrow benches. Kalili explains that the main reason for choosing DTH was to achieve straighter, parallel pre-split holes drilled at the angles required (65–80 degrees) to optimize the slopes. Other fac-tors included good penetration rate and low cost-per-metre. The rigs have not only achieved those objectives but have also significantly reduced the proportion of blastholes that needed re-drilling prior to blasting, from the 20 per cent previously recorded using top hammer drilling to only five per cent with DTH. The rigs drill pre-split holes on a 1.2 m spacing, using the COP 44 DTH hammer and 115 mm Secoroc ballistic Speedbits. In waste, the diameter is increased to 140 mm using COP 54 with a 3.5 m x 3.5 m spac-ing/burden pattern. The benches are drilled with 1 m sub-drill. The daily target drilling rate for all three rigs is set at about 1,000 m corresponding to 20,000–21,000 m/month.Penetration rate has averaged 35 m/hr, mainly with the COP 44 in soft to hard rock. Overall, Navachab has found that the bal-listic cone-shaped button bit (Speedbit) performs best in the prevailing conditions. The on-site team regrinds the bits using an Atlas Copco Grind Matic and the bit service life is about 600 m. Atlas Copco supplies the drilling consumables on a contractual basis and is compensated per drill metre in three different rock categories.

Focusing on Full Service

The mine emphasizes the importance of full service and easy maintenance. The rigs arrived in April–May 2004 and training was conducted with nine operators. The Atlas Copco service team maintained the rigs for the first year on a full service con-tract. Mechanics check the oil levels at the start and end of each shift and carry out scheduled workshop services. “As drilling is crucial for the whole downstream operation, the full service contract gives us the availability we need to achieve our targets,” says Angula Kalili. Experience has shown that it is possible to deliver the mine’s planned production rate using only two of the three units for blast-hole drilling, and Kalili would like to see this become routine, freeing the third rig for pre-split drilling and back-up duties.

79

DTh chOice cuTS cOSTS aT navachab


EisEnErz, AustriA

Iron Ore From Erzberg Mountain

roman OriginsThe Erzberg mountain in the Austrian Alps has a history of iron ore mining that dates back to Roman times. The current open pit operation at Eisenerz was started more than a century ago, with 40 benches, each 12 m in height. It survived to become the only iron ore mine still operating in Austria, with probable reserves in excess of 100 million t. Today, the benches are 24 m-high, and the mine consistently produces around 2 million t/year working three, 8 h shifts/day. For produc-tion drilling, just a single drillrig is needed. This is a ROC L8 from Atlas Copco.

improved Capacity

The ore at Eisenerz has an iron content of 33.6% and a manganese content of 2%. Recovery rate is 45%, and the beneficiated ore is shipped by rail to the nearby Donawitz and Linz steelworks, where self-fluxing sinter averaging 50% iron and 3% manganese is produced.

The operation at the open pit is impres-sive by any measure, and much of its suc-cess can be attributed to clever choice of drilling equipment, perfectly matched to the job. The ROC L8 is used for just one shift/day, and performs so well that only occa-sionally, due to quality variations, is there need for an extra shift of drilling. The rig capacity is 40,000 m/year, corresponding to an annual production of 4.4 million t.

Prior to investing in the ROC L8, mine owner Voest Alpine Erzberg GmbH used several other rigs. However, the ROC L8 has increased nett drilling capacity at the mine by 100%, up to 50 m/hour.

Fuel consumption during operations, including both drilling and tramming up to 2 km/shift, is 40 lit/h.

Rig planned maintenance is carried out by mine personnel at the regular service intervals. This is supplemented by an in-spection and service by the operator at the start of each shift. This keeps rig availability at 95%.

Sampling device fitted to the dust pre-cleaner of the ROC L8.

Atlas Copco ROC L8 drilling at Erzberg.

80


When the ROC L8 was first put to work at the site in 2002, it was equipped with a 6 in DTH hammer, 165 mm bits and 140 mm drill pipes. However, due to the mixed rock conditions, the drillers ran into difficulties, both with flushing of the holes and with the drill string getting stuck.

In co-operation with Atlas Copco, the miners switched to a Secoroc COP 54 DTH hammer with 152 mm bit and 127 mm pipes, and the situation improved due to increased air velocity. In addition, Atlas Copco modi-fied the feed of the ROC L8. A more po-werful rotation unit, the DHR 48H68, was fitted, giving a maximum torque of 3,600 Nm, together with an upgraded feed motor with a pullout force of up to 5.5 t.

Computerized Planning

Every drill hole is planned on computer and the basic drill pattern has a burden and spa-cing of 6.5 x 6.5 m. Depending on the geo-logy and ground conditions, this is changed from a minimum of 6 m, up to a maximum of 7 m. Hole inclination is 22 degrees off

Erzberg open pit with its 24 m-high benches.

vertical and the hole depth, when drilling 24 m-high benches, is 28-29 m. No toe holes are required.

The 152 mm bits with ballistic but¬tons are used without regrinding, and have an average life of more than 5,000 m. In homo- genous rock, drilling at the rate of 1 m/min is carried out at an air pressure of 25 bar. In mixed ground, the air pressure is reduced to 21 bar to obtain a better balance between penetration rate and flushing capacity.

A sampling device fitted to the dust precleaner on the ROC L8 collects powdered iron ore for quality analysis, giving the ma-nagement an early indication of the expec-ted grade from each hole.

The modern miners at Erzberg have since pushed their productivity levels even higher, with Atlas Copco's latest DTH hammer, the COP 54 Gold Express.

Acknowledgements


irOn OrE FrOm ErzbErg mOuntAin

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glentaggart, scotland

82

More Than a Match for Scotland’s Coal

exceeding expectationsIn the difficult terrain of Scottish Coal’s 150-year-old Glentaggart open cast coal mine, an Atlas Copco ROC L6H is proving more than a match for the larger rotary drill rigs the company operates at its other mines.

drilling in sandstone

Formerly a room-and-pillar mine, Glentag-gart is now recovering remnants of deep mines along its outcrop at a rate of 500,000 tonnes per year. There are some 20 seams here, some of which have been extensive-ly worked, while others are untouched. Proven reserves stand at seven million tonnes.

The drilling is carried out by an Atlas Cop- co ROC L6H crawler rig with a 25 bar compressor producing 24 m3/m. And this unit, equipped with a COP 54 DTH hammer, a Secoroc 146 mm ballistic bit and using 5m- long drill tubes, produces good results. The rig is owned by Castlebridge Plant, Scottish Coal’s sister company, which pur-chases and maintains all of the equipment at the mine and hires it to Scottish Coal. The rock at Glentaggart consists mostly of sandstone and mudstone. The sandstone is coarse-grained, open-jointed and hard to very hard, making drilling a challenge since fast penetration is accompanied by high abrasion. But the rig’s large compressed air output, combined with a reduction in tube diame-ter from 102 mm to 89 mm, has increased tube life and dust collection by slowing the uphole velocity of the drill cuttings caused by high penetration rates in the different rock types. Depending on whether the rig is drill-ing in sandstone or mudstone, it achieves a penetration rate of 0.9m/min and 3.5 m/min. Holes are generally drilled on a 6 m x 6 m pattern. The relatively small size of the ROC L6H, compared to the rotary rigs at Scottish Coal’s other mines, is appreciated for its vertical, horizontal and angle drilling flexibili-ty. “It’s a good rig compared to some of the others I have operated,” says its operator, Dean Houston. “It will go places the other rigs simply will not go.”

good operational economy

The boom and the feed arrangement can be readily positioned to drill in various directions from vertical to horizontal. The single-section boom design also permits the operator to position the feed from transport mode to drilling in a few minutes without re-pinning. Toe-holes are simply drilled with the standard boom articulation. Electronic hole inclination and depth control instruments ensure that all blast holes are accurately

On site at Scottish Coal’s Glentaggart operation: The versatile ROC L6H.


acknowledgements


Discussing the day’s performance of the ROC L6H: From left, Dean Houston and Steve Griffiths of Scottish Coal with (right) Atlas Copco’s Mike Wilson.

The remote Glentaggart coal field, about 65 kilometres south of Glasgow.

83

More than a Match for scotland's coal

aligned and drilled to the predetermined hole depth. As a result, the operational economy of the ROC L6H at the site has been high. “We get more production out of it,” con-firms the mine’s Drilling and Blasting Supervisor, Colin Robb. “That’s the main factor. We can drill more holes in less ti-me.” The mine estimates that the rig aver-ages 40 per cent more production per shift than Scottish Coal’s rotary drill rigs, mak-ing it 22 per cent cheaper to run. In addi-tion, fuel consumption is less than 1 litre per metre, making it as fuel efficient as a top hammer rig. “I know both Scottish Coal and Cast-lebridge Plant are very happy with this rig,” Mr Robb says. “It has been meeting and exceeding expectations.” Furthermore, the ROC L6H rig is equip-ped with a ROPS/FOPS cabin for rollover and falling object protection. This suits the requirements of Scottish Coal which has earned five gold awards in the past six years for health and safety from the UK’s Royal Society for the Prevention of Accidents. Castlebridge also acquired a second L6H in October for Scottish Coal’s Broken Cross mine on another part of the same coal field. “We place a lot of importance on safety,” Mr Robb comments. “Besides the cabin, the manoeuvrability of the rig has also made a positive difference especially when working on the slopes. Therefore we can position the rig more safely.


Siilinjärvi, finland

low Grade apatite OreWhen drilling contractor Hartikainen Oy sought a new drill rig fleet for the Siilinjärvi mine, Finland, they had very specific demands. High productivity, reliability, mobility, efficiency and the ability to drill larger, more accurate holes all featured high on the priority list.

Apatite for ExtractionCoprod Solution for Siilinjärvi

The ROC L740CR drilling 15.5 m deep holes has increased the drilling output by double figures.

High Productivity

The Siilinjärvi open pit mine is the biggest in Finland, extracting almost eleven million tons of apatite a year. Excavation began at the site in 1979 at what is the European Union’s only apatite mine. Today the mine has grown to three kilometres in length, is between 200 and 600 metres wide, and 130 metres deep. According to the owner of the pit, Kemira GrowHow – a leading produc-er of agricultural fertilizer, there is enough apatite ore at the site to last 40 years. Siilinjärvi though, has the lowest grade of mineable apatite ore in the world (ten percent apatite in a mineral composition), therefore the need for ultra-efficient extrac-tion is critical to the viability of the opera-tion.

Comparing drill rigs

One of the most important things for the contractor was to find a drill rig that could produce larger diameter holes than most of the other rigs on the market. The need for larger holes is due to the blasting method used at the site: The bench height is typically 14 metres, and the total blast hole depth is 15.5 metres. Waste rock is used to level the uneven surface of the pit so when the drill rig moves to drill the next hole, it first has to drill through 1.5 metres of broken rock. This softer, rela-tively loose rock demands larger holes in order to remain stable and open for charg-ing. Minimizing in-hole deviation was an-other important factor for Hartikainen when se-lecting the drill rigs, for without high drilling and blasting efficiencies, the extraction could become unprofitable. There is a tendancy for in-hole deviation caused by the nature of the rock. The pre-dominant geology of the mine is carboni-titic apatite ore and diabase, distributed in veins. After comparing different manufactu-rer’s drill rigs and then trying a ROC L740CR onsite for a year, the company knew they had found the ideal rig.

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aPatite fOr extraCtiOn COPrOd SOlutiOn fOr Siilinjärvi

The Coprod drilling system used on the ROC L740CR had increased the drilling output by double figures when compared to traditional tophammer and down-the-hole drilling systems. The improvement record-ed at the site quickly led to the Siilinjärvi mine becoming first in the world to take delivery of the upgraded Atlas Copco ROC L740CR. Tuomo Tuohino, Mining Engineer and Project Manager of Kemira GrowHow sums up the performance of the equip-ment: “The Coprod system, in combination with the overall effectiveness of the drill rig, provides us with exactly what we are looking for.”

Coprod Solution

COPROD can make larger holes than tra-ditional tophammer drill rigs, and also produces exceptional hole quality. The upgraded ROC L740CR is equipped with stage3/Tier III engine which meets all the new exhaust emission limits. The rigs deliver exactly the power needed in each phase of the operation, which considerably reduces fuel consump-tion. The ROC L740CR also comes with a large fuel tank, enough to allow 12 hours of continuous operation and dependable start-up thanks to the heavy-duty generator and batteries. The new cabin layout increases cockpit visibility, driver space and comfort, some-thing that has been much appreciated by the crew at Siilinjärvi. Tuomo Tuohino says: “As well as drilling performance, the new ROC L740CR delivers superb operator comfort, a factor that is also plays a part in overall productivity.” Expanding the mine is much easier now with the diesel driven ROC L740CR, than with the old electric driven non Atlas Copco rigs used previously; the mobility of the new rigs making a significant impact to efficiency of the operation. The upgraded version of ROC L740CR has compared to its forerunner a bigger engine (328 kW vs 272 kW), more power-ful rock drill effect (40 kW vs 30 kW), bigger compressor (254 l/s vs 228 l/s) and can drill larger holes (180 mm vs 165 mm). ROC L740CR. is optimized for difficult rock conditions and therefore ideally suited to the Siilinjärvi mine. Both mine owner and contractor were very satisfied with the ROC L740CR they

The Coprod drilling system proved its efficiency when drilling through the 1.5 m deep upper layer of broken rock.

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APAtite fOr extrACtiOn COPrOd SOLutiOn fOr SiiLinjärvi

Acknowledgements


From left: Ensio Hartikainen, Arto Hartikainen, Ilkka Eskola, General Manager Oy Atlas Copco Louhintatekniikka AB, and Kari Tiikkaja, Manager of Mining and Construction, Hartikainen.

ApatiteApatite is a phosphate mineral and the largest apatite deposits are asso-ciated with sedimentary deposits. The mineral is an essential ingredient in phosphate fertilizers, and is also used in the chemical and pharmaceutical industries.

had rented for a year and therefore have decided to buy two additional units. Hartikainen place enormous focus on productivity, and the goal for 2007 is to achieve 260,000 drilled meters and 4.3 million cubic meters of extracted material using just three drill rigs. The rigs there-fore, have to be very reliable, operating two shifts a day, five days a week. In order to ensure the proper mainte-nance of the drill rigs a service and main-tenance agreement with Atlas Copco was selected. The agreement, according to Tuomo Tuohino helps to ensure that the demanding pace of production is met: “Our production schedule in drilling and blasting is very demanding, but so far, availability of the drill rigs has been excellent.”

The Siilinjärvi open pit mine is the biggest in Finland.

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How to spend less on Secoroc products

Atlas Copco Secoroc AB Box 521, SE-737 25 Fagersta, SwedenPhone: +46 223 461 00 E-mail: [email protected]

The way we figure it is this: If you spend your hard-earned money on drill bits that have to be constantly replaced, then sooner or later you’ll start wondering if you can’t get better value elsewhere. In our case, the answer to this problem was to design a comprehensive range of grinding equip-ment.

It really doesn’t matter what kind of drilling you’re into. We have grinding machines for fixed installations and field oper-ations. We can handle tapered, threaded and DTH button bits as well as integrals with chisel inserts.

We also have an ace up our sleeve – a patented diamond grinding wheel. It’s the only one that can give your worn spherical and ballistic buttons a new perfect finish. To start saving money, call your local Atlas Copco representatives today. They may advise you to invest a little first – but hey, we’ve got to make a living too.

DRILLING METHOD GUIDE


The tophammer method The classic tophammer method is renowned for high penetration rates in good drilling conditions. Atlas Copco is developing the method continuously. Exhaustive research into how impact energy can be transmitted into the drill bit in the most efficient way, with the least possible stress, has resulted in anew generation of rock drills. Development has been focused on the key component in the rock drill – the piston. The piston length, mass, and geometry have resulted in even faster penetration. The effect is that more rock is crushed with each blow from the piston. Moreover, a double damping system reduces the load on components to give long service life, at the same time as drillsteel wear is reduced. In other words, the positive results of faster drilling are not counteracted by higher drillsteel costs. An extractor unit is available as a useful accessory for poor rock conditions.

The down-the-hole method The down-the-hole method is areliable way to drill both difficultand easy rock. The rockdrill piston strikes the drill bit directly, while the hammer casing gives straight and stable guidance of the drill bit. This results in minimal deviation and greater holewall stability, even in fissured or otherwise demanding rock. Since the annulus between the drill pipes and the hole wall is comparatively small, a high flushing velocity is maintained, which contributes further to hole quality. Good hole quality enables the burden and spacing to be increased, which saves time and money. Straight holes make charging easier and enable the amount of explosive to be reduced. The reliable DTH method is an easy way to produce deep, straightholes. From an environmental point of view, the noise emissions andvibration from DTH drilling are comparatively low. This is of parti-cular advantage when drilling in densely populated areas.

Different applications need different kind of drilling equipment and performance. The choice of drilling method is nor-mally already made since long. A well proven technique is very seldom considered to be replaced with a new method. This diagram and table is an attempt to start a discussion around what method and equipment that might be the ulti-mate solution for an application. This comparison presents our drilling methods and their advantages.

Drilling method guide

Principle: As the name ”tophammer” implies, the rock drill is situated on the rig and works on top of the drillstring. The impact energy of the rockdrill piston is transmitted to the drill bit in the form of shock waves. The method is fast in good rock conditions.

Principle: The rock drill is situated down the hole in direct contact with the drill bit. This means that power losses are minimal. The hammer’s closeness to the drill bit gives stable guidance and minimal hole deviation.

The COPROD® system The COPROD system combines the speed of tophammer drilling with the precision and long service life of the down-the-hole method. Inside each rigid, threaded pipe section is an impact rod. It is furnished with stop lugs to hold it in place inside the pipe section. The COPROD sections are joined together via the drill pipes. Since the drill pipes transmit rotation force only, stress to the threads is minimal and their service life very long. All negative effects of the transmission of impact energy through the threads are eliminated entirely. The result is high impact power with minimal wear. Since the outer pipes are smooth and flush along the entire length of the drillstring, it is almost impossible for jamming to occur. Practical experience with COPROD has been exceptionally good. The method gives good overall economy, particularly in large scale production drilling and when drilling in fissured or otherwise demanding rock conditions.

Principle: The rock drill is situated on the feed beam on the rig and impact energy is imparted from above. Threadless impact rods are stacked inside the threaded drill pipes. The impact rods are used solely to transmit impact energy and feed force, while the drill pipes transmit rotation. COPROD combines the speed of tophammer drilling with the hole straightness of the down-the-hole method.

DRILLING METHOD GUIDE


Drilling Method Tophammer DTH COPROD

Penetration rate

Straight holes

Hole depth

Productioncapacity(tonnes/shift)

Low fuelconsumption(lit/drillm.)

Economic drillstring life

Low investmentfor drill string

Suitability,difficult drillingconditions

Suitability,good drillingconditions

Operator friendly

Flushingflexibility

Fair Unbeatable in good drilling conditionsLow fuel consumptionLow investment in drillstring

Good Straight holesDeep holesSimplicity for the operator

Very good Unbeatable in difficult drilling conditionsHigh productivityGood penetration rate

Visit www.surfacedrilling.com for more information

Rotary drilling methods The prime difference from other drilling methods is the absence of percussion. Rotary cutting, using fixed type claw or drag bits, is mainly used for soft rock which is cut by shearing. Rotary crushing uses tricone bits relying on crushing and spalling the rock. This is accomplished by transferring downforce, known as pulldown, to the bit while rotating in order to drive the teeth (commonly tungsten carbide type) into the hole bottom as the three cones rotate around their respective axis. The softer the rock the higher the rotation speed.The drill rigs need to be heavy to avoid lifting off the jacks, which means that they are less flexible and not suited for drilling at different angles. Generally, drilling below 152 mm (6 inches) is best accomplished by percussive drilling unless prevailing rock conditions are suited for rotary cutting. Rotary crushing is the prime choice for large diameter holes, above 254 mm (10 inches) in open pit mining, overburden stripping at coal mines, and deep well drilling.

TONS

Principle:Rotation is provided by a hydraulic or electric motor driven gearbox, called a rotary head that moves up and down the tower via a feed system, generating the pulldown required to give sufficient weight on the bit. Flushing of drill cuttings between the wall of the hole and the drill rods is normally made with compressed air.

TOPHAMMER DRILL RIG SPECIFICATION


Main specifi cations

SmartRig™ ROC D7C/D9C

Recommended hole range D7CT38, T45, T51 64-115 mm 2½"-4½"Max hole depth, approx 28 m 92'Recommended hole range D9CT45, T51 76-115 mm 3" - 4½"Hole depth 28 m approx. 92'Hydraulic rock drillCOP 1840-series (ROC D7C)Impact power 18 kW 24.5 HP

COP 2160 (ROC D9C)Impact power, max. 21 kW 28 HPAtlas Copco C 106 screw type compressorROC D7C Working pressure, max 10.5 bar 152 psiFAD 127 l/s 270 cfmROC D9C Working pressure, max 10.5 bar 152 psiFAD 136 l/s 288 cfmEngine ROC D7C/D9C Caterpillar water-cooleddiesel engine Stage 3/Tier III CAT C7Rating at 2200 rpm 168 kW 225 HPBoom variants-11, folding boomFuel tankCapacity 370 l 98 US gal.FeedFeed length, total 7135 mm 23'5"Travel length 4240 mm 15'Feed extension 1400 mm 4'3"Feed rate max. 0.92 m/s 180 ft/minFeed force, max. 20 kN 4400 lbfCoverage area, approx 12 m² 130 sqftTrammingTramming speed, max. 3.1 km/h 2.0 mphTraction force 115 kN 25760 lbfHill climbing ability, 20° (30° with winch)Track oscillation ± 12° Ground clearance 455 mm 17½"Transport dimensionsWeight, excl. options -11 Folding boom 13600 kg 30000 lbWidth 2370 mm 7'10"Length 11610 mm 38'1"Height 3200 mm 10'2"

The new ROC D7C/D9C crawler drill combines the powerand fl exibility of the popular ROC D7 with the intelligenceof RCS – computerized Rig Control System. RCS adjusts impact and feed to the rock conditions so as to achieve smoother drilling and less wear in the drill steel. Designed both for construction and quarrying work, the ROC D7C/D9C has a true 102 mm tophammer capability. For benchheights up to 28 m. Fuel effi cient diesel engine delivers the power needed for quick penetration and effi cient fl ushing.

Standard equipmentRig Control System RCS, Operator’s cabin (ROPS and FOPSapproved), RHS mechanized rod handlling, Aluminium feed, Double drill-steel support, Angle and hole depth instrument, Fuel saving device, Two-speed traction motors, Dust collector and pre-separator, Feed extension, Air fl ow control switch, Anti-jamming system, Valves for reduced percussion and air pressures for collaring, Retractable dust hood, Heavy duty tracks, Work lights, Electric refuelling pump

Optional equipmentAutomatic feed alignment, Laser plane receiver, Automaticrod adding system, Hydraulic winch, ROC Manager – MWD,Measure While Drilling, Toe-hole drilling kit, Hydraulic support leg, Silencing kit, Hole Navigation System

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2755

5500

3100

4780



Main specifications

Recommended hole range T45, T51 76 -115 mm 3"- 4½"Hole depth, 25 m approx, 82' Hydraulic rock drills Montabert/HC158 Impact power, max. 21 kW 28 HP Compressor Working pressure, max. 10 bar 140 psi FAD 167 l/s 350 cfm Engine Cummins/QSC 8.3 Rating at 2200 rpm 194 kW 260 HP Boom variantType ExtendableFuel tank Capacity 400 l 106 US gal. Feed Feed length, total 7660 mm 25'Travel length 4250 mm 14' Feed extension 1500 mm 4'11"Feed rate max. 0.7 m/s 132 ft/min Feed force, max. 19.6 kN 4400 lbf Pull force max. 19.6 kN 4400 lbfTramming Tramming speed, max. 3.4 km/h 2.1 mph Traction force, max 89.6 kN 20000 lbf Hill climbing ability 30º Track oscillation ± 9º Ground clearance 420 mm 16'5" Transport dimensions Weight, excl. o.e 13 tonnes 28660 lb Width 2.47 m 8'2" Length 9.98 m 32'9" Height 2.87 m 9'5"

ECM 660


This high performing crawler drill is equipped witha 21 kW reverse percussion hydraulic drifter (HC158) and auto drilling system that offers the combinationof high penetration rate, straight holes and long life for consumables. The extendable boom provides for easy and precise hole positioning, and the air conditioned cab for operator’s comfort. The ECM can be used for the hole range 76 -115 mm with T45 or T51 rod in both quarry and construction applications.

Standard equipment 50 hour element kit, 90 deg. Indexed drill guide, ARC T51 X 12’ X 6 for 72 mm coupling, Auto drilling system(montabert), Auto rod thread greaser, Back mirror, Back up alarm, Drifter hour meter, Dust collector with vertical sliding hood, Engine auto throttle, Full length track guard, HC158 reverse percussion hydraulic drifter, JIC hose fittings, Low level indicator for fuel & hyd. oil, One lever ARC control, Safety shutdown device on drill guide, Standard tool set, Three sets manuals and parts books, Triple grouser shoe pads, Two lever drilling controls,Two speed traction motor, Warning horn, Working lights (F:3/R:1), Limited ambient temperature: 52 deg. C.

Selection of Optional equipment Accumulator charge kit, Angle indicator 2-d Lim, Angle indicator 3-d lim, Anti freezing system, Arc lockout system, Arc T45 X 12’ X 6 for 63 mm coupling, Arc T45 X 12’ X 6 For 66 mm coupling, Cold wether kit, Extra parts book, Hyd. pressure test kit, Pre skimmer, Single grouser shoe pads, T51 / 77 mm centralizer, Vaposol (less tank), Vaposol tank (asme)




ROC F7

The ROC F7 is available in two versions: a single boom version ideal for quarries; and a folding boom model versatile enough for all manner of construction sites. The ROC F7 is equipped with a double drill steel support and an ergonomically designed cabin.

Standard equipmentReduced impact pressure mechanism, Anti-jamming system, Automatic feed-force control (RPC), Fuelsaving device, Two-speed traction, Dust collector and pre-separator, Double hydraulic drill steel support, Rod handling system (7+1 rods), Feed extension, Heavy duty tracks, Operator’s cabin, ROPS and FOPS approved, Air fl ow control switch

Optional equipmentHydraulic winch, Hydraulic support leg, Electric refuelling pump, Anti-freeze equipment for compressed air, Air con-ditioner, heater, Electronic hole depth and inclination in-strument, Central lubrication system, Water mist system, TAC tube guides for precision drilling, Thread greasing device

Recommended hole rangeT45, T51 76-115 mm 3" - 4½"Hole depth 28 m approx. 92'Hydraulic rock drillCOP 2160Impact power 21 kW 28.1 HPAtlas Copco XAH2 screw compressorWorking pressure 10.5 bar 152 psiFAD 148 l/s 308 cfmEngineCaterpillar Diesel CAT 3126BRating at 2000 rpm 186 kW 253 HPBoom variants-10, single boom-11, folding boomFuel tankCapacity 400 l 100 US gal.FeedFeed length, total 8100 mm 26'7"Travel length 4770 mm 15'8"Feed rate max. 0.92 m/s 180 ft/minFeed force, max. 20 kN 4500 lbfTrammingTravel speed, max. 3.6 km/h 2.2 mphTraction force 112 kN 25200 lbfHill climbing ability, without winch 20° 20ºHill climbing ability, with winch 35º 35ºTrack oscillation ± 10º ± 10ºGround clearance 405 mm 16"Transport dimensionsLength folding boom version 13000 mm 42'8"Length single boom version 12300 mm 40'4"Width 2490 mm 8'2"Height folding boom version 3200 mm 10'6"Height single boom version 3200 mm 10'6"Weight, optional equipment excludedfolding boom version 15700 kg 34600 lbsingle boom version 15100 kg 33300 lb

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2440

4815

2610

3490




ROC F9/F9LF

The ROC F9 crawler drill rig is very powerful in its class,with true 127 mm tophammer capability, and is availablewith single or folding boom for quarrying and construction.Features the 25 kW COP 2560 rock drill with T51 drill steel for fast penetration and perfect fl ushing, powered by a fuel-effi cient diesel engine.

Standard equipmentAir conditioner, Reduced impact pressure mechanism, Anti-jamming system, Automatic feed-force control, Fuel saving device, Two-speed traction motors, Dust collector and pre-separator, Double hydraulic drillsteel support, Rod-handling system, Feed extension, Heavy-duty tracks, Operator’s cabin, ECM, ROPS and FOPS approved,Air-fl ow control switch, Water mist system excl. tank, Toe-hole drilling kit, Inclination/depth instrument

Optional equipmentHydraulic winch, Hydraulic support leg, Electric refuelling pump, Central lubrication system, TAC tube guides for precision drilling, Thread-greasing device, Rock drill extractor, Heater for cabin

Recommended hole rangeT51 89-127 mm 3½"-5"Hole depth 30 m 98'Hydraulic rock drillCOP 2560Impact power, max. 25 kW 33.5 HPAtlas Copco screw compressorWorking pressure 12 bar 175 psiFAD 213 l/s 450 cfmEngineCaterpillar Diesel Stage 3/Tier III CAT C9Rating at 2000 rpm 224 kW 304 HPBoom variants-10, single boom-11, folding boomFuel tankCapacity 400 l 106 US gal.FeedFeed length, total -10 and -11 8100 mm 26'7" -LF 11230 mm 36'10"Travel length -10 and -11 4770 mm 15'8" -LF 7830 mm 25'8"Feed extension 1300 mm 4'3"Feed rate max. 0.92 m/s 180 ft/minFeed force, max. 20 kN 4500 lbfTrammingTramming speed, max. 3.6 km/h 2.2 mphTraction force 112 kN 25200 lbfHill climbing ability, 20° without winchTrack oscillation ± 10º Ground clearance 405 mm 16"Transport dimensionsWeight, excl. options ROC F9-10 approx. 15600 kg 34000 lb ROC F9-11 approx. 16200 kg 37500 lb ROC F9LF 16600 kg 36600 lbWidth 2490 mm 8'2"Length -10 and -11 12300 mm 40'4" -LF 11300 mm 37'Height 3200 mm 10'6"

ROC F9LF – For selective mining and single pass drillingMaximize drill time. Minimize inproductive rod changing time.The ROC F9 features a drill feed system for 6.1 m (20 foot) drill rods, with a maximum hole depth of 36 m (118 feet).

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25°

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SmartRig™ ROC F9C

The new ROC F9C crawler drill combines the power and fl exibility of the popular ROC F9 with the intelligence ofRCS – the computerized Rig Control System. RCS adjustsimpact and feed to the rock conditions so as to achieve smoother drilling and less wear in the drill steel. Designed both for construction and quarrying work. Features the 25 kW COP 2560 rock drill with T51 drill steel for fast penetration and perfect fl ushing, powered by a fuel-effi cient diesel engine.

Standard equipmentAir conditioner, Reduced impact pressure mechanism, Anti-jamming system, Automatic feed-force control, Fuel saving device, Two-speed traction motors, Dust collector and pre-separator, Double hydraulic drill-steel support, Rod-handling system, Feed extension, Heavy-duty tracks, Operator’s cabin, ECM, ROPS and FOPS approved, Air-fl ow control switch, Water mist system excl. tank, Toe-hole drilling kit, Inclination/depth instrument

Selection of optional equipmentAutomatic feed alignment, Automatic rod adding system, Hydraulic winch, Hydraulic support leg, Thread greasing device, Heater for cabin, Hole Navigation System

Recommended hole rangeT51 89-127 mm 3½"-5"Hole depth 28 m 92'Hydraulic rock drillCOP 2560Impact power, max. 25 kW 33.5 HPAtlas Copco screw compressorWorking pressure 12 bar 175 psiFAD 213 l/s 450 cfmEngineCaterpillar Diesel Stage 3/Tier III CAT C9Rating at 2000 rpm 224 kW 304 HPBoom variants-10, single boom-11, folding boomFuel tankCapacity 400 l 106 US gal.FeedFeed length, total 8100 mm 26'7"Travel length 4770 mm 15'8"Feed extension 1300 mm 4'3"Feed rate max. 0.92 m/s 180 ft/minFeed force, max. 20 kN 4500 lbfTrammingTramming speed, max. 3.6 km/h 2.2 mphTraction force 112 kN 25200 lbfHill climbing ability, 20° without winchTrack oscillation ± 10º Ground clearance 405 mm 16"Transport dimensionsWeight, excl. options ROC F9C-10 approx. 15600 kg 34000 lb ROC F9C-11 approx. 16200 kg 37500 lbWidth 2490 mm 8'2"Length 12300 mm 40'4"Height 3200 mm 10'6"

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30°14°

90°

-6°

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94°

ECM 720Main specifications

ECM 720 provides a perfect balance of high productivity and cost efficiency. The combination of powerful HC 200A rock drill and the Strata Sense drilling control system allows you to drill through various rock con-ditions with high penetration rate and yet drilling straight holes. The extension boom helps quick and accurate collaring. Like the rest of the 700 series, simplicity of the 720 makes it easy to operate and easy to maintain.

Standard equipment Mechanized rod handling, Automatic throttle, Anti-Jamming, Load sense progressive anti jamming system (Strata Sense), Central hydraulic system test port, Variable speed cooling fan control, Tier III emission compliance,2D electronic angle indicator, Boom extension, Feed extension, Dual pinning for L/R horizontal drilling, Water mist system preplumbed for tank, Preseparator, Dust collector, Retractable dust hood, Hydraulic centralizer, Thread greasing device, FOPS and ROPS operator safety cab, Cab air-conditioning, Working lights, Back up alarm,Heavy duty tracks with full length rock guards, Track oscillation

Selection of optional equipment 3D angle indicator, 3D angle indicator with speed and depth, Central lubrication system, 14’ rod changer group, High capacity dust collector, Hydraulic system test kit, Conversion kit T51/T60, Pressurized water mist tank 80 gal, Pressurized water mist tank 120 gal instead of DCT, Cold ambient kits

Recommended hole rangeHole range 115 - 140 mm 4½"- 5½" Hole depth 29.5 m 97' Hydraulic rock drill HC200A Impact power, max. 26 kW 35 HP Compressor Working pressure, max 10.3 bar 150 psi FAD 226 l/s 480 cfm Engine CAT C11 Rating at 1800 rpm 287 kW 385 HP Boom variants Type Telescopic Fuel tank Capacity 587 l ~155 US gal. Feed Feed length, total 8788 mm 28'10" Travel length 5182 mm 17' Feed extension 1524 mm 5' Feed rate max. 0.96 m/s 190 ft/min Feed force, max. 33.8 kN 7600 lbf Pull force, max. 33.8 kN 7600 lbf Tramming Tramming speed, max. 3.2 km/h 2.0 mph Traction force 125.4 kN 28192 lbf Hill climbing ability, 30° Track oscillation ± 10° Ground clearance 432 mm 17" Transport dimensions Weight, excl. o.e 20.5 tonnes 45300 lb Width 2.57 m 8'5"Reaching shortest length Length 10.72 m 35'2"Height 3.94 m 12.11"Reaching lowest height Height 12.17m 39'11"Height lowest 3.33 m 10'11"


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94°




ROC L7

The new ROC L7 drill rig offers an economic alternative with an extraordinary performance in its hole range. Large scale work sites, and quarries with high demand on productivity, are in focus. The standard drill rig is designed to operate within the most demanding production environment. We also provide the short feed version for the contract drilling and more diffi cult operating environments.

Standard equipmentRHS 102 Rod magazine, Stroke length selection in cabin, Engine monitoring, hole inclination and drill depth instrument, Dust collector and pre-separator , Automatic cleaning system, 12 hours fuel capacity, Fuel tank in steel, Hydraulic oil - Mineral, Manual Hydraulic oil fi lling system, Stepless fl ushing regulation in cabin, Triple track chain grouser pads, Electrical outlet 12VDC, Feed lightening

Optional equipmentService winch on feed, Thread greasing device , Diesel driven cabin heater, Sun shade kit for cab, Reversing camera, Compressor regulation heating kit, Fire suppression system Manual / Automatic, Central lubrication system

Recommended hole rangeT51 89-127 mm 4"- 5"Hole depth 36 m 120'Hydraulic rock drillCOP 4050Impact power, max. 40 kW 54 HPAtlas Copco screw compressorWorking pressure 12 bar 171 psiFAD 254 l/s 540 cfmEngineCaterpillar Diesel Stage 3/Tier III CAT C13Rating at 2000 rpm 328 kW 417 HPBoom variantsSingle boomFuel tankCapacity 760 l 201 US gal.FeedFeed length, total 11400 mm 37'Travel length 7500 mm 25'Feed extension 1150 mm 59"Feed rate max. 0.9 m/s 177 ft/minFeed force, max. 40 kN 8992 lbfTrammingTramming speed, max. 1.7/3.5 km/h 1.2/2.2 mphTraction force 124/49 kN 27876/ 11016 lbfHill climbing ability, 20°Track oscillation + 10º/-8 Ground clearance 405 mm 16"Transport dimensionsWeight, excl. options 23700 kg 52250 lb Width 2500 mm 8'2"Length 11500 mm 39'4"Height 3500 mm 11'6"

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A ALong feed 582Short feed 1040

BLong feed 2277Short feed 2659

Long feed Short feed


TOPHAMMER ROCK DRILL SPECIFICATIONS


Technical data

COP 2160/2560 Top hammer rock drills for hole diameter range 89-127 mmUpdated hydraulic rockdrillsCOP 2160 and COP 2560 are among the most powerful rock drills on the market. The main differences from the earlier COP 2150/2550 series are a 10 mm bigger adapter, increased bearing surface, larger driver and an impact piston with a greater diameter at the striking end. The reason for the changes is to give even better impact tolerance for really heavy production work. But there’s another important point: COP 2560 can be used not only with the T51 drill steel but also with the ThunderRod T60 for hole diameters of 102 mm and above. This drill steel has a 40 percent larger cross sectional area than the T51 and is therefore considerably more rigid. The resulting reduced hole deviation allows less dense hole planning and gives rise to significant savings in drilling time. Both models can be delivered with inbuilt extractors, identified by the suffix EX.

COP 2160 COP 2160EX COP 2560 COP 2560EXWeight 187 kg 249 kg 187 kg 249 kg Length 1138 mm 1336 mm 1138 mm 1336 mmImpact power, max 21 kW 21 kW 25 kW 25 kW Impact rate 36 Hz 36 Hz 44 Hz 44 HzHydraulic pressure, max 210 bar 210 bar 230 bar 230 barRotation speed range, max 0-110 rpm 0-110 rpm 0-110 rpm 0-110 rpmRotation pressure, max 200 bar 200 bar 200 bar 200 bar Rotation motor size (OMS 315) -10 -10 -10 -10 Drill steel torque, max 1810 Nm 1810 Nm 1810 Nm 1810 Nm Flushing air pressure 12 bar 12 bar 12 bar 12 bar Lubricating air consump. at 2 bar 5 l/s 5 l/s 5 l/s 5 l/s Shank adapter T45,T51 T45,T51 T51,T60 T51,T60

COP 2560

Hydraulic rock drills

COP 2160EX

COP 2560

TOPHAMMER ROCK DRILL SPECIFICATIONS


Technical data

Technical data

Technical data

COP 1838HE Top hammer rock drill for hole diameter range 76 – 115 mmCOP 1838HE is specially suitable for medium to largehole sizes. Adjustable stroke length makes it possibleto adjust impact rate and energy to actual rock conditionsand hole size. Powerful, stepless variable and reversible rotation motor gives high torque and excellent speed control. The efficient reflex damping system of the COP 1800 series is called “dual damping” due to its high

efficiency and double acting function. As the feed and the boom are not subjected to unnecessary strain, the entire drill string will give you longer service life. The automatic tightening system of the drill string results in straighter holes and optimum penetration. COP 1838HE can also be supplied with built-in hydraulic extractor.

COP 1838HE COP 1838HEXWeight 174 kg 226 kgLength 1098 mm 1296 mmImpact power, max 19 kW 19 kW Impact rate 42-50 Hz 42-50 HzHydraulic pressure, max 230 bar 230 barRotation speed range, max 0-130 rpm 0-130 rpmRotation pressure, max 200 bar 200 bar Rotation motor size (OMS 250) -09 -09 Drill steel torque, max 1500 Nm 1500 Nm Flushing air pressure 10 bar 10 bar Lubricating air consump. at 2 bar 6 l/s 6 l/s Shank adapter T45, T51

A heavy-sized hydraulic top hammer with an impact output of up to 40 kW. It is specially designed for continuous, heavy duty bench drilling. It is equipped with two powerful hydraulic rotation motors which minimizes the risk of jamming. Impact and power levels are easily adjustable to prevailing rock conditions for achieving good hole quality, long drill steel life and an overall high productivity.

COP 4050ME Top hammer rock drill for hole diameter range 89 – 127 mm

COP 4050ME COP 4050MEXWeight, (incl.adapter) 390 kg 420 kgLength, (without adapter) 1293 mm 1546 mmImpact power, max 40 kW 40 kW Impact rate 40-60 Hz 40-60 HzHydraulic pressure, max 230 bar 230 barRotation speed range, max 0-110 rpm 0-110 rpmRotation pressure, max 200 bar 200 bar Rotation motor size (OMS 250) 2× -09 2× -09 Rotation torque, max 3500 Nm 3500 Nm Flushing air pressure 8 bar 8 bar Lubricating air 4 bar 4 bar Shank adapter, male T51

COP 4050ME can also be supplied with a built in extractor device (COP 4050MEX), which further improves drilling capacity and economy by practically eliminating the risk of losing the drill string if it gets stuck. It is obvious that the extractor is an investment which soon pays for itself in difficult ground conditions through fewer disruptions, better hole quality and increased steel life.

COP 1840HE Top hammer rock drill for hole diameter range 76 – 115 mmCOP 1840HE is specially suitable for heavy duty drilling, e.g. when using TDS-type guide tubes to obtain straighter holes. Adjustable stroke length makes it possible to adjust impact rate and energy to actual rock conditions and hole size. Powerful, stepless variable and reversible rotation motor gives high torque and excellent speed control. The efficient reflex damping system of the COP

1800 series is called “dual damping” due to its high efficiency and double acting function. As the feed and the boom are not subjected to unnecessary strain, the entire drill string will give you longer service life. The automatic tightening system of the drill string results in straighter holes and optimum penetration. COP 1840HE can also be supplied with built-in hydraulic extractor.

COP 1840HE COP 1840HEXWeight 184 kg 244 kgLength 1138 mm 1336 mmImpact power, max 19 kW 19 kW Impact rate 42-50 Hz 42-50 HzHydraulic pressure, max 230 bar 230 barRotation speed range, max 0-130 rpm 0-130 rpmRotation pressure, max 200 bar 200 barRotation motor size (OMS 250) -09 -09 Drill steel torque, max 1500 Nm 1500 Nm Flushing air pressure 10 bar 10 bar Lubricating air consump. at 2 bar 6 l/s 6 l/s Shank adapter T45, T51

TOPHAMMER DRILLING TOOLS


Bench and production drilling



Bench and production drilling R/ T38 (1 1⁄2")



Bench and production drilling R/ T38 (1 1⁄2")



R/ T38 (1 1⁄2")Bench and production drilling



T45 (1 3⁄4")Bench and production drilling









T51 (2")Bench and production drilling



T51 (2 ")Bench and production drilling



T51 (2")Bench and production drilling

A bit of evolution




COPROD DRILL RIG SPECIFICATION


Straight and fast drilling in demanding rock used to be a production planner’s dream. However, with the advent of COPROD, the patented tophammer drilling system developed by Atlas Copco, the dream has been translated into reality. COP- ROD provides a drill string that combines the hole straightness of down- the-hole drilling with the speed of the tophammer system. The COP- ROD drill string is a combination of impact rods and drill pipes: the impact rods transmit impact energy and feed force only, while the drill pipes transmit rotational torque and flushing.

Drill PipesThe COPROD sections are joined together via the drill pipes. Since the drill pipes transmit rotation force only, stress to the threads is minimal, and their service life is very long. The normal effects of the transmission of impact energy

through the threads are eliminated, resulting in high impact power with minimal wear. Since the outer pipes are smooth and flush along the entire length of the drillstring, it is almost impossible for jamming to occur.

Impact RodsInside each COPROD section is a floating impact rod. These have no threads, which means that the im-pact shock waves from the rock drill are transmitted directly down to the drill bit, with no energy losses. Each impact rod is furnished with stop Iugs to hold it in place inside the pipe section. The rock drill is mount-ed on the feed beam of the rig, and impact energy is imparted from above.

Straight HolesThe benefits of straight holes in-clude: a more widely spaced drill-ing pattern with fewer holes, saving time and money; trouble-free charg-ing with dramatically reduced explosives consumption; more evenly dis-tributed charges, reducing ground vibration, blasting noise, and risk of flyrock; more regular fragmenta-tion, avoiding the costly secondary blasting needed to pop oversize boulders; smoother bench floors, requiring less extra work; and fewer stuck drill rods, decreasing the time required to remove rods from the hole.

Production EconomyFor total production economy, the speed and precision of drilling, com-bined with the long service life of its components, makes the COPROD system an unbeatable combination.

Practical experience with COPROD drilling has confirmed the theore-tical benefits. The method gives good overall economy, particularly in large-scale production drilling, and when drilling in fissured or other-wise demanding rock conditions.

COPROD ® System

Atlas Copco ROC F9CR production drill rig is fitted with the COPROD system.

COP 2000CR series rock drills are designed for the 90 -127 mm hole range.

Section of COPROD drill string shows the floating impact rod within the drill pipe.

Business end of the ROC F7CR, an engineering masterpiece.



The ROC F7CR is available with a single boom ideal for quarrie. The ROC F7CR is equipped with a double drillpipe support and an ergonomically designed cabin.

Standard equipmentReduced impact pressure mechanism, Antijamming system, Automatic feed-force control (RPC-F), Fuel saving device, Two-speed traction, Dust collector and pre-separator, Double hydraulic drill pipe support,with break-out table, Rod handling system (7+1 sections), Feed extension, Heavy duty tracks, Operator’s cabin, ROPS and FOPS approved, Air fl ow control switch,Air conditioner

Optional EquipmentHydraulic winch, Hydraulic support leg, Electric refuelling pump, Anti-freeze equipment for compressed air, heater, Electronic hole depth and inclination in-strument, Central lubrication system, Water mist system

ROC F7CRMain specifi cations


Recommended hole rangeCR76, CR89 90-127 mm 3½" - 5"Hole depth 28 m approx. 92'Hydraulic rock drillCOP 2150CRImpact power 21 kW 28.1 HPAtlas Copco XAH2 screw compressorWorking pressure 10.5 bar 152 psiFAD 148 l/s 314 cfmEngineCaterpillar Diesel CAT 3126BRating at 2000 rpm 186 kW 253 HPBoom variantssingle boomFuel tankCapacity 400 l 100 US gal.FeedFeed length, total 8100 mm 26'7"Travel length 4770 mm 15'8"Feed rate max. 0.92 m/s 180 ft/minFeed force, max. 20 kN 4500 lbfTrammingTravel speed, max. 3.6 km/h 2.2 mphTraction force 112 kN 25200 lbfHill climbing ability, without winch 20° 20ºHill climbing ability, with winch 35º 35ºTrack oscillation ± 10º ± 10ºGround clearance 405 mm 16"Transport dimensionsLength 12300 mm 40'4"Width 2490 mm 8'2"Height 3200 mm 10'6"Weight, optional equipment excl. 15800 kg 34800 lb

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ROC F9CRMain specifi cations

The ROC F9CR crawler drill rig is very powerful in its class, with true 127 mm tophammer capability, and is available with single boom for quarrying. Features the25 kW COP 2550 rock drill with COPROD drill steel for fast penetration and perfect fl ushing, powered by a fuel-effi cient diesel engine.

Standard equipmentAir conditioner, Reduced impact pressure mechanism, Anti-jamming system, Automatic feed-force control, Fuel saving device, Two-speed traction motors, Dust collector and pre-separator, Double hydraulic drillpipe support, Rod-handling system, Feed extension, Heavy-duty tracks, Operator’s cabin, ECM, ROPS and FOPS approved, Air-fl ow control switch, Water mist system excl. tank, Toe-hole drilling kit, Inclination/depth instrument

Optional equipmentHydraulic winch, Hydraulic support leg, Electric refuelling pump, Central lubrication system

Recommended hole rangeCR76, CR89 90-127 mm 3½"-5"Hole depth 28 m 92'Hydraulic rock drillCOP 2550CRImpact power, max. 25 kW 33.5 HPAtlas Copco screw compressorWorking pressure 12 bar 175 psiFAD 210 l/s 450 cfmEngineCaterpillar Diesel Stage 3/Tier III CAT C9Rating at 2000 rpm 224 kW 304 HPBoom variantsSingle boomFuel tankCapacity 400 l 106 US gal.FeedFeed length, total 8100 mm 26'7"Travel length 4770 mm 15'8"Feed extension 1300 mm 4'3"Feed rate max. 0.92 m/s 180 ft/minFeed force, max. 20 kN 4500 lbfTrammingTramming speed, max. 3.6 km/h 2.2 mphTraction force 112 kN 25200 lbfHill climbing ability, 20° without winchTrack oscillation ± 10º Ground clearance 405 mm 16"Transport dimensionsWeight, excl. options 17300 kg 38100 lb Width 2490 mm 8'2"Length 12300 mm 40'4"Height 3200 mm 10'6"


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2 560 mm



Main specifi cationsMain specifi cations

ROC L7CR

The ROC L7CR drill rig offers an economic alternative with an extraordinary performance in its hole range. Large scalework sites, and quarries with high demand on productivity, are in focus. The standard drill rig is designed to operate within the most demanding production environment. Wealso provide the short feed version for contract drilling.

Standard equipmentRHS 102 Rod magazine, Engine monitoring, Hole inclination and drill depth instrument, Dust collector and pre-separator, Automatic cleaning system, 12 hours fuel capacity, Fuel tank in steel, Hydraulic oil - Mineral, Manual hydraulic oil fi lling system, Stepless fl ushing regulation in cabin, Triple track chain grouser pads, Electrical outlet 12VDC, Feed lightening

Optional equipmentGas charging equipment, Extractor, Service winch on feed, Rock drill stroke length selection in cabin, Diesel driven cabin heater, Cab windows tinted, Cab windows laminated, Wind shield dryer for right window, Sun shade kit for cab,Electrical heated operators seat, Reversing camera, Radio/CD, Canopy lighting, Safety rails on canopy, Beacon, ProCOM, Engine monitoring, Hole inclination and drilldepth instrument with laser receiver, Compressorregulation heating kit, Hydraulic oil - Tropical/Artic/Bio oil, Statoil Hydraway, Bio Pa 46,Diesel driven engine pre-heater, Ether startfor engine, Fire suppression system Manual/Automatic, Central lubrication system,Service lamp inside canopy, Watermist - Pre-plumed, Water mist - 225lpressurised tank, Water mist - 400lnon pressurised tank

Recommended hole rangeCR89, CR102, CR127, CR140 105 -180 mm 4"- 7"Hole depth, max. 36 m 120'Hydraulic rock drillCOP 4050CRImpact power, max. 40 kW 54 HPAtlas Copco screw compressorWorking pressure 12 bar 171 psiFAD 254 l/s 540 cfmEngineCaterpillar Diesel stage 3/Tier III CAT C13Rating at 2000 rpm 328 kW 417 HPBoom variantssingle boomFuel tankCapacity 760 l 201 US gal.FeedFeed length, total 12200 mm 40'Travel length 7500 mm 25'Feed extension 1150 mm 59"Feed rate max. 0.9 m/s 177 ft/minFeed force, max. 40 kN 8992 lbfTrammingTramming speed, max. 1.7/3.5 km/h 1.2/2.2 mphTraction force 124/49 kN 27876/ 11016 lbfHill climbing ability 20°Track oscillation + 10º/-8 Ground clearance 405 mm 16"Transport dimensionsWeight, excl. options 24600 kg 54230 lb Width 2500 mm 8'2"Length 12200 mm 40'Height 3500 mm 11'6"

Visit www.surfacedrilling.com for more information24

40

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B



Long feed Short feed

COPROD ROCK DRILL SPECIFICATIONS


Technical data

Technical data

COP 4050CR Top hammer rock drill for hole diameter range 105 – 180 mm

COP 4050ME-CR and COP 4050HE-CR together with their respective COPROD® drillstrings provide a fast and reli-able means of working in demanding rock formations.These rock drills are equipped with two hydraulic rotation motors with a torque output well suited to their respective hole diameter ranges. High torque reduces the risk of jamming and gives smooth rotary action that eases stress to the equipment. Success of the original COPROD system has stimulated the development of rock drills and additional drillstrings. COP 4050ME-CR is used in the hole range 105-140 mm in combination with the COPROD 89 and 102 drillstrings. In the hole range 140-180 mm COP 4050HE-CR and 127 and 140 is recommended.

COP 4050ME-CR COP 4050HE-CRWeight, (incl. adapter) 435 kg 435 kgLength, (without adapter) 1780 mm 1780 mmImpact power, max 40 kW 40 kW Impact rate 40-60 Hz 40-60 HzHydraulic pressure, max 230 bar 230 barRotation speed range 0-95 rpm 0-95 rpm Rotation pressure, max 200 bar 200 bar Rotation motor size (OMS 315) 2• -10 2• -10 Drill steel torque, max 4200 Nm 4200 Nm Flushing air pressure, max 8 bar 8 bar Lubricating air 4 bar 4 bar Tube adapter, male CR 89, CR 102, CR 127, CR140

CIAA AB

COP 2150CR, COP 2550CR Top hammer rock drill for hole diameter range 90 – 127 mm

The COP 2150CR and COP 2550CR together with theirrespective COPROD® drillstrings provide a fast and reliable means of working in demanding rock formations.These rock drills are equipped with two hydraulic rotation motors with a torque output well suited to their respective hole diameter ranges. High torque reduces the risk of jamming and gives smooth rotary action that

eases stress to the equipment. Success of the original COPROD system has stimulated the development of rock drills and additional drillstrings. COP 2150CR is used in the hole range 90 -115 mm in combination with the COPROD 76 or 89 drillstrings. In the hole range 90 -127 mmCOP 2550CR rock drill with COPROD 89 is recommended.

COP 2150CR COP 2550CRWeight, (incl. adapter) 242 kg 242 kgLength, (with adapter) 1661 mm 1661 mmImpact power, max 21 kW 25 kW Impact rate 36 Hz 44 HzHydraulic pressure, max 210 bar 230 barRotation speed range, max 0-100 rpm 0-100 rpmRotation pressure, max 200 bar 200 bar Rotation motor size (OMS 315) 2• -10 2• -10 Drill steel torque, max 4000 Nm 4000 Nm Flushing air pressure 12 bar 12 bar Lubricating air 3 bar 6 bar Shank adapter CR 76, CR 89

Hydraulic rock drills

COPROD DRILLING TOOLS


COPROD COPROD 76 and 89 forCOP 1838CR, 1850CR, 2150CR, 2550CR



COPROD COPROD 89, 102 and 127 for COP 4050CR



Drill bitsCOPROD

DTH DRILL RIG SPECIFICATION


14°30°

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101.25

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90°

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22°Technical data

CM 760D

Recommended hole rangeRecommended 110-130mm 45⁄16"-51⁄8"Optional 102-140mm 4"-51⁄2"DTHHammer 102-127mm 4"-5"Drilltubediam. 76/89/102mm 3"-4"Drilltubelength 4m 13',1½"Holedepth,max. 30m 98.5ft

Compressor Type 2-stageRotaryScrewWorkingpressure 24bar 350psiFAD 297l/s 630cfm

Engine CaterpillarDiesel CATC11TierIIICompliantRatingat1800rpm 287kW 385HP

Fuel tank Totalcapacity 587l 155USgal.

Feed Feedlength,total 6579mm 21'7"Travellength 4293mm 14'1"Feedextension 1219mm 4'Feedrate,max. 0.76m/s 149ft/minFeedforce,max. 43.6kN 9800lbf

Tramming Trammingspeed,max. 3.2km/h 2mphTractionforce 125.4kN 28192lbfHillclimbingability 30°Trackoscillation ±10ºGroundclearance 432mm 17"

Hydraulic Rotation unit Maxspeed 0-120rpmTorquemax,drilling 2820Nm 2080ft.lbfMaxtorque 4067Nm 3000ft.lbf

Transport dimensionsWeight,excl.options 22200kg 49000lbsWidth 2570mm 8'5"Reaching shortest length Length 10680mm 35'½"Height 3300mm 10'8"Reaching lowest height Length 10820mm 35'6"Height 3070mm 10'1"

Visit www.surfacedrilling.com formoreinformation

The CM 760D offers excellent performance and low operating costs when drilling with 4” DTH hammers. A single joystick handles the drill tube changer, and another joystick controls tramming. Operators parti- cularey like the excellent visibility during drilling and tramming. Routine service items are located for ground level service

Standard equipmentMechanizedpipehandling,Automaticthrottle,Centralhydraulicsystemtestport,Variablespeedcoolingfancontrol,Maxenginerpmcontrol,TierIIIemissioncompliance,2Delectronicangleindicator,Feedextension,DualpinningforL/Rhorizontaldrilling,Watermistsystempreplumbedfortank,Preseparator,Dustcollector,Retrac-tabledusthood,Treadgreasingdevice,FOPSandROPSoperatorsafetycab,Cabair-conditioning,Workinglights,Backupalarm,Heavydutytrackswithfulllengthrockguards,Trackoscillation,Variableairvolumecontrolforcollaring,DTHhammerlubricatordevice(pneumatic)

Optional Equipment3Dangleindicator,3Dangleindicatorwithspeedanddepth,Centrallubricationsystem,Auxiliarywinchforloadingpipes,Highcapacitydustcollector,Hydraulicsystemtestkit,Wrenches,Non-pressurizedwatermisttank80gal,Non-pressurizedwatermisttank120galinsteadofDCT,Coldambientkits,DTHhammerlubricatordevice(electric)



Technical data

ROC L6

ROC L6 is a high-capacity down-the-hole crawler for quarry drilling in soft, medium and hard rock, with a power unit that delivers compressed air at a full 25 bar. With the powerful CAT C11 diesel engine the ROC L6 not only provides power but economy.

Standard equipment Airconditioning,Tubehandlingsystem(capacityof8tubes),Fuelsavingdevice,Two-speedtractionmotors,Dustcollectorandpre-separator,Feedextension,Operator’scabin(ROPSandFOPSapproved),AtlasCopcoelectronicholedepth/inclinationinstrument,Reducedairpressureforcollaring,Break-outtable,Retractablesuctionhood,Trackchainswithtriplegrouserpads,Hydraulicsupportleg,Toeholedrillingkit

Optional equipment Centrallubricationsystem,Electricrefuellingpump,Watermistsystems,Trackchainswithsinglegrouserpads,Hydraulicsupportleg,Heavydutyairintakefiltersforengineandcompressor,Coldweatherkitsincludingengineheater,Heatingsystemforcabin,Cabwindowslaminated,Cabwindowstinted,RadioandCDplayer,Sunshadesforcabwindows,Electricheatedoperator’sseat

Recommended hole rangeCOP34/34Q 90-105mm 39/16"-41/8"COP44/44Q 110-130mm 45/16"-51/8"COP54 134-152mm 51/4"-6"COP54HD 140-152mm 51/2"-6"Drilltubediam. 76/89/102mm 3"/3½"/4"Drilltubelength 5m 16'5"Holedepth,max. 45m 148'

Compressor AtlasCopco XRV9screwcompressorWorkingpressure,max. 25bar 363psiFAD 295l/s 625cfm

Diesel Engine Caterpillar CATC11TierIIICompliantRatingat2000rpm 287kW 385HP

Fuel tank Capacity 780l 206USgal.

Feed Feedlength,total 8760mm 28'9"Travellength 5420mm 17'9"Feedextension 1300mm 4'3"Feedrate,max. 0.92m/s 180ft/minFeedforce,max. 20kN 4496lbfTractivepull,max. 30kN 6749lbf

Tramming Trammingspeed,max. 3.4km/h 2.1mphTractionforce 120kN 26980lbfHillclimbingability 20°Trackoscillation +10º-8°Groundclearance 405mm 16"

Hydraulic Rotation unit DHR 48H45 Maxspeed(rpm)1 112Maxtorque(Nm)2 1800 1330lbf/ftMaxflow(l/min) 123 260cfm1Notincombinationwithmaxtorque2atmaxpressureat125bar(1812psi)

Transport dimensionsWeightapprox.excl.options 19000kg 41900lbWidth 2500mm 8'2"Length* 13600mm 44'7"Height* 3110mm 10'2"Length** 10650mm 34'11"Height** 4075mm 13'37"*feedinforwardposition**feeddumpedoncanopy

8760

3030

2820

5450

3550 1900

ROC L6

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25° 25°

2440




Technical data

ROC L6H

ROC L6H is a high-capacity down-the-hole crawler for quarry drilling in soft, medium and hard rock, with a power unit that delivers compressed air at a full 25 bar. With the powerful CAT C13 diesel engine, the ROC L6H provides sufficient power for the most demanding drilling conditions.

Standard equipment Airconditioning,Tubehandlingsystem(capacityof8tubes),Fuelsavingdevice,Two-speedtractionmotors,Dustcollectorandpre-separator,Feedextension,Operator’scabin(ROPSandFOPSapproved),AtlasCopcoelectronicholedepth/inclinationinstrument,Reducedairpressureforcollaring,Break-outtable,Retractablesuctionhood,Trackchainswithtriplegrouserpads,Hydraulicsupportleg,Toeholedrillingkit

Optional equipment Centrallubricationsystem,Electricrefuellingpump,Watermistsystems,Trackchainswithsinglegrouserpads,Heavydutyairintakefiltersforengineandcompressor,Coldweatherkitsincludingengineheater,Heatingsystemforcabin,Cabwindowslaminated,Cabwindowstinted,RadioandCDplayer,Sunshadesforcabwindows,Electricheatedoperator’sseat

Recommended hole rangeCOP44/44Q 110-130mm 45/16"-51/8"COP54 134-152mm 51/4"-6"COP54HD 140-152mm 51/2"-6"Drilltubediam. 76/89/102mm 3"⁄3½"⁄4"Drilltubelength 5m 16'5"Holedepth,max. 45m 148'

Compressor AtlasCopco XRV9screwcompressorWorkingpressure,max. 25bar 363psiFAD 405l/s 858cfm

Diesel Engine Caterpillar CATC13TierIIICompliantRatingat2000rpm 328kW 440HP

Fuel tank Capacity 780l 206USgal.

Feed Feedlength,total 8760mm 28'9"Travellength 5420mm 17'9"Feedextension 1300mm 4'3"Feedrate,max. 0.92m/s 180ft/minFeedforce,max. 20kN 4496lbfTractivepull,max. 30kN 6749lbf

Tramming Trammingspeed,max. 3.4km/h 2.1mphTractionforce 120kN 26980lbfHillclimbingability 20°Trackoscillation +10º-8°Groundclearance 405mm 16"

Hydraulic rotation unit DHR 48H45 Maxspeed(rpm)1 112Maxtorque(Nm)2 1800 1330lbf/ftMaxflow(l/min) 123 260cfm1Notincombinationwithmaxtorque2atmaxpressureat125bar(1812psi)

Transport dimensionsWeightapprox.excl.options 19000kg 41900lbWidth 2500mm 8'2"Length* 13600mm 44'7"Height* 3110mm 10'2"Length** 10650mm 34'11"Height** 4075mm 13'37"*feedinforwardposition**feeddumpedoncanopy

8760

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2820

5450

3550 1900

ROC L6

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36°14°

2140

25° 25°

2440




14°

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98.2

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14°30°

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22°

CM 780D

The CM 780D is a high capacity down-the-hole crawler for drilling with 4”and 5” hammers in aggregate and limestone quarries or in volume mining operations.The simple direct-drive rotary head delivers plenty of torque, a benefit when drilling in poor ground conditions. The rugged CAT C13 Tier III engine delivers the required horsepower and is easy accessible for service.

Standard equipmentMechanizedpipehandling,Automaticthrottle,CentralHydraulicsystemtestport,Variablespeedcoolingfancontrol,Maxenginerpmcontrol,TierIIIemissioncompliance,2Delectronicangleindicator,Feedextension,DualpinningforL/Rhorizontaldrilling,Watermistsystempreplumbedfortank,Preseparator,Dustcollector,RetractabledusthoodThreadgreasingdevice,FOPSandROPSoperatorsafetycab,Cabair-conditioning,Workinglights,Backupalarm,Heavydutytrackswithfulllengthrockguards,Trackoscillation,Variableairvolumecontrolforcollaring,DTHhammerlubricatordevice(pneumatic)

Optional Equipment3Dangleindicator,3Dangleindicatorwithspeedanddepth,Centrallubricationsystem,Auxiliarywinchforloadingpipes,Hydraulicsystemtestkit,Wrenches,Non-pressurizedwatermisttank80gal,Non-pressurizedwatermisttank120galinsteadofDCT,Coldambientkits,DTHhammerlubricatordevice(electric)

Technical data

Recommended hole rangeRecommended 115-152mm 41⁄2"-6"Optional 85-152mm 33⁄3"-6"DTHhammer 102-127mm 4"-5"Drilltubediam. 89-102mm 3½"-4"Drilltubelength 4m 13',1½"Holedepth,max. 30m 98.5ft

Compressor Type 2-stageRotaryScrewWorkingpressure 24bar 350psiFAD 405l/s 862cfm

Engine CaterpillarDiesel CATC13TierIIICompliantRatingat1800rpm 328kW 440HP

Fuel tank Totalcapacity 587l 155USgal.

Feed Feedlength,total 6579mm 21'7"Travellength 4293mm 14'1"Feedextension 1219mm 4'Feedrate,max. 0.76m/s 149ft/minFeedforce,max. 43.6kN 9800lbf

Tramming Trammingspeed,max. 3.2km/h 2mphTractionforce 125.4kN 28192lbfHillclimbingability 30°Trackoscillation ±10ºGroundclearance 432mm 17"

Hydraulic rotation unit Maxspeed 0-80rpmTorquemax,drilling 4236Nm 3125ft.lbfMaxtorque 6100Nm 4500ft.lbf

Transport dimensionsWeight,excl.options 22200kg 49000lbsWidth 2570mm 8'5" Reaching shortest length Length 10680mm 35'½"Height 3300mm 10'8"Reaching lowest height Length 10820mm 35'6"Height 3070mm 10'1"




Recommended hole rangeCOP44/44Q 110-130mm 45/16"-51/8"COP54 134-152mm 51/4"-6"COP54HD 140-152mm 51/2"-6"COP64 156-178mm 61/8"-7"COP64HD 165-178mm 61/2"-7"Drilltubediam. 89/102/ 3½"/4"/4½"/ 114/140mm 5½" Drilltubelength 6m 20'Holedepth,max. 54m 177'Compressor AtlasCopco XRV9screwcompressorWorkingpressure,max. 25bar 363psiFAD 405l/s 858cfmDiesel Engine Caterpillar CATC13TierIIICompliantRatingat2000rpm 328kW 440HPFuel tank Capacity 780l 206USgal.

Feed Feedlength,total 11250mm 3'11"Travellength 8122mm 26'8"Feedextension 1150mm 3'9"Feedrate,max. 0.92m/s 180ft/minFeedforce,max. 30kN 6744lbfTractivepull,max. 40kN 8992lbfTramming Trammingspeed,max. 3.4km/h 2.1mphTractionforce 120kN 26980lbfHillclimbingability 20°Trackoscillation +10º-8°Groundclearance 405mm 16"Hydraulic rotation unit DHR 48H45 Maxspeed(rpm)1 112Maxtorque(Nm)2 1800 1330lbf/ftMaxflow(l/min) 123 260cfmDHR 48H56 Maxspeed(rpm)1 88Maxtorque(Nm)2 2300 1700lbf/ftMaxflow(l/min) 123 260cfmDHR 48H68 Maxspeed(rpm)1 56Maxtorque(Nm)2 3600 2655lbf/ftMaxflow(l/min) 123260cfm1Notincombinationwithmaxtorque2atmaxpressureat125bar(1812psi)Transport dimensionsWeightapproxexcl.options 20000kg 44000lbsWidth 2500mm 8'2"Length 11250mm 36'11"Height 3995mm 13'1"

Technical data

ROC L8

The total solution for drilling in quarries and open pit mines, the ROC L8 DTH crawler drillrig is designed for pre-splitting and large-scale production work. It has ample power to deliver high penetration rates and a rod handling capacity for hole depths up to 54 m.

Standard equipment Airconditioning/heater,Tubehandlingsystem(capacityof8tubes),Reducedairpressureforcollaring,Fuelsav-ingdevice,Two-speedtractionmotors,Dustcollectorandpre-separator,Feedextension,Heavy-dutytracks,Operator’scabin(ROPSandFOPSapproved),AtlasCopcoelectronicholedepth/inclinationinstrument,Break-outtable,Retrac-tablesuctionhood,Trackchainswithtriplegrouserpads,Hydraulicsupportleg

Optional equipment Centrallubricationsystem,Electricrefuellingpump,Watermistsystems,Trackchainswithsinglegrouserpads,Hydraulicsupportleg,Heavydutyairintakefiltersforengineandcompressor,Coldweatherkitsincludingengineheater,Heatingsystemforcabin,Cabwindowslaminated,Cabwindowstinted,RadioandCDplayer,Sunshadesforcabwindows,Electricheatedoperator’sseat

3030

1900

2820

3550

5450

7000

11250

ROC L8

30° 30°

36°14°

2140

25° 25°

2440



B



ROC L8 30

This new version of the proven ROC L series of down-the-hole crawler drills offers extended performance through increased operating pressure and a new genius cylinder feed system. Like the well proven ROC L8 it’s well suited for large-scale production work, pre-split operations, RC-in pit grade control in surface mining operations and large scale quarry operations.

Standard equipmentRHS102tubemagazine,Enginemonitoringandfeedinclination,Holedepthinstrument,Pre-separatoranddustcollectorwithautomaticcleaningsystem,Operator’sROPSandFOPScab,Airconditioning,Windowwipers,Triplegrouserpads,Worklights,Gasspringoperatedcanopydoors,Emergencystops

Optional equipmentToe-holedrillingkitforshortmast,Servicewinch,Threadspraylubrication,Cabheatingsystem,Tintedcabwindows,Laminatedcabwindows,Sunshadekitforcab,Electricheatedoperator’sseat,Reversecamera,Radio/CD,Canopysafetyrails,Revolvinglight(BEACON),Enginemonitoringwithholeinclination/depthinstrumentandlaserreceiver,Coldweatherkitsincludingdieseldrivenengineheater,Watermistflushingsystems,Tropical/arctic/synthetichydraulicoils,Manual/automaticfiresuppressionsystems,Centrallubricationsystem,Fastfillingfuelsystem,Electrichydraulicoilfillingsystem,Hydraulicsupportleg,Canopyservicelamps,RC(reversecirculation)kit.

Technical data

Recommended hole rangeCOP44/44Q 110-130mm 45/16"-51/8"COP54 134-152mm 51/4"-6"COP54HD 140-152mm 51/2"-6"COP64 156-203mm 61/8"-8"COP64HD 165-203mm 61/2"-8"Drilltubediam. 89/102/ 3½"/4"/4½"/5½" 114/140mmDrilltubelength,longmast 6m 20ftDrilltubelength,shortmast 5m 16.4ftHoleDepth,max. 54m 177ftHoleDepth,optional 45m 148ft

CompressorAtlasCopco XRV9screwcompressorWorkingpressure 30bar 435psiFAD 470l/s 995cfm

EngineCaterpillarDiesel CATC15TierIIICompliantRatingat2000rpm 402kW 539HP

Fuel tankTotalCapacity 760l 201USgal.

FeedFeedlength,longmast 11564mm 38'Feedlength,shortmast 9266mm 30'4"Travellength,longmast 7540mm 25'Travellength,shortmast 5400mm 17'7"Feedextension 1150mm 3'9"Feedrate,max. 0.9m/s 177ft/minFeedforce,max. 40kN 8992lbf

TrammingTrammingspeed,max. 1.7/3.5km/h 1.2/2.2mphTractionforce 124/49kN 27876/11016lbfHillclimbingability 20°Trackoscillation +10º-8ºGroundclearance 405mm 16"

Hydraulic rotation unit DHR 48H45Maxspeed 0-136rpmMaxtorque 2070Nm 1527lbf/ft

Hydraulic rotation unit DHR 48H56Maxspeed 0-107rpmMaxtorque 2630Nm 1940lbf/ft

Hydraulic rotation unit DHR 48H68/DHR 48RCMaxspeed 0-68rpmMaxtorque 4120Nm 3039lbf/ft

Transport dimensionsWeight,excl.options 24500kg 54000lbsWidth 2500mm 8'2" Length 12200mm 40'Height 3500mm 11'6"

2440

2140

25º

25º

2440

2140

13º

21º

Longfeed Shortfeed

DTH HAMMER SPECIFICATIONS


Hammer types

Type Std HD Slim*

COP 34 COP 44 COP 54 COP 54 GE COP 64 G

* Reduced hammer OD

Technical data

Hammer COP 34 COP 44 COP 54 COP 54 Gold Express COP 64 Gold

Length excl. thread 954 mm 37.55 in 958 mm 37.72 in 1069 mm 42.08 in 1119 mm 44.1 in 1163 mm 45.78 in

External diameter 83.5 mm 3.28 in 98 mm 3.86 in 120 mm 4.72 in 120 mm 4.72 in 142 mm 5.59 in

External diameter HD 126 mm 4.96 in 126 mm 4.96 in 146 mm 5.75 in

Hammer weight 27 kg 60 lbs 38 kg 84 lbs 57 kg 126 lbs 66 kg 145 lbs 96 kg 212 lbs

Hammer weight HD 67 kg 148 lbs 76 kg 167 lbs 109 kg 241 lbs

Piston diameter 68 mm 2.67 in 78 mm 3.07 in 100 mm 3.93 in 100 mm 3.93 in 120 mm 4.72 in

Piston weight 4.8 kg 10.7 lbs 7.1 kg 16 lbs 12.5 kg 28 lbs 15 kg 33 lbs 20.5 kg 45 lbs

Recommended bit size 92-105 mm 35/8-41/8 in 110-125 mm 45/16++-5 in 134-152 mm 51/4-6 in 134-152 mm 5.3-6 in 156-178 mm 61/8-7 in

Rec. bit size HD 140-152 mm 51/4-6 in 140-152 mm 5.5-6 in 165-178 61/2-7 in

Rec. bit size Slim 130-152 mm 5.1-6.0 in 152-178 mm 6-7 in

Bit shank COP 34 IR DHD340 IR DHD350 IR QL 50 IR QL 60

Top sub thread 23/8" API Reg 23/8" API Reg 23/8" API Reg 31/2" API Reg 31/2" API Reg

Optional thread connection 31/2" API Reg 27/8" API Reg 31/2" API IF

Wrench flat 23/8" API Reg 65 mm 2.6 in 65 mm 2.6 in 65 mm 2.6 in

27/8" API Reg 95 mm 3.7 in 65 mm 2.6 in

31/2" API Reg 95 mm 3.7 in 102 mm 4.0 in

31/2" API Reg (HD) 102 mm 4.0 in 102 mm 4.0 in 102 mm 4.0 in

Feed force 3-12 kN 700-2500 lbs 5-15 kN 1100-3300 lbs 6-17 kN 1300-3700 lbs 6-19 kN 1300-4100 lbs 7-20 kN 1600-4400 lbsFeed force, normal 6 kN 1300 lbs 10 kN 2200 lbs 12 kN 2600 lbs 14 kN 2600 lbs 14 kN 3100 lbs

Working pressure 6-25 bar 87-360 psi 6-25 bar 87-360 psi 6-25 bar 87-360 psi 6-25 bar 87-360 psi 12-30 bar 174-430 psi

Rotation speed 30-90 r/min 25-80 r/min 20-70 r/min 20-70 r/min 25-60 r/min

Standard design – Ideal for water well drilling, blast hole drilling and civil engineering projects.HD design – Designed for abrasive and demanding applications. The HD hammer features a larger overall diameter, in turn allowing for thicker walls and, ultimately, a longer service life. It’s also equipped with reversing back-out buttons, protecting the top sub from wear.Slim design – The Slim version is designed for non to medium-abrasive formations, using a smaller bit diameter than recommended for the standard hammer OD. The Slim design allows an oversized hammer to drill the hole, thereby optimizing performance.

Air

co

nsu

mp

tio

n

Working pressure

0

100

200

300

400

500

600

700

800

900

(l/s)

10 15 20 25 30 (bar)

COP 44 COP 54 COP 64 GOLDCOP 54 GOLD EXPRESSCOP 34

150 450200 250 300 350 400 (psi)

0

500

1000

1500

2000(cfm)

Air consumption/Working pressure

DTH HAMMER SPECIFICATIONS


No wrench flats L = 4 000 mm No wrench flats

API 2 3/8” Reg Pin x Box OD = 76 mm API 2 3/8” Reg Not neededL = 305 mm Wall = 6.3 mm

COP 34, API 2 3/8” Reg 95-105 mm

1 DHR 45 H-1API 2 3/8” Reg Box(*)

API 2 3/8” Reg Pin x Box OD = 89 mm API 2 3/8” Reg Not needed COP 44, API 2 3/8” Reg 110-130 mmL = 305 mm Wall = 6.3 mm


COP 44, API 2 3/8” Reg 110-130 mmAPI 2 3/8” Reg Pin x Box OD = 89 mm API 2 3/8” Reg Not neededL = 305 mm Wall = 6.3 mm

COP 54, API 2 3/8” Reg 134-140 mm1 DHR 48 H 45-1DHR 48 H 45-2API 2 3/8” Reg Box COP 54, API 2 3/8” Reg 134-152 mm(*)

API 2 3/8” x 2 7/8” Reg Pin x Box OD = 102 mm API 2 7/8” RegAPI 2 7/8” x 2 3/8” Reg

L = 305 mm Wall = 6.3 mmL = 140 mm

COP 54HD, API 2 3/8” Reg 140-152 mm(***)

2 DHR 48 H 56-1 API 2 3/8” x 2 7/8” Reg Pin x Box COP 54, API 3 1/2” Reg 134-152 mmDHR 48 H 56-2 L = 305 mm API 2 7/8” x 3 1/2” RegAPI 2 3/8” Reg Box (**) L = 160 mm

COP 54HD, API 3 1/2” Reg 140-152 mm(*)OD = 102 mm API 2 7/8” RegWall = 6.3 mm

API 3 1/2” x 2 7/8” Reg Pin x BoxL = 305 mm

DHR 48 H 56-3DHR 48 H 56-6API 3 1/2” Reg Box(*)

API 3 1/2” Reg Pin x BoxL = 305 mm

COP 64 old, API 3 1/2” Reg 156-171 mm

OD = 114 mm API 3 1/2” Reg Not neededCOP 64 old HD, API 3 1/2” Reg 165-171 mmWall = 6.3 mm

3 DHR 48 H 68-3 API 3 1/2” Reg Pin x BoxDHR 48 H 68-6 L = 305 mmAPI 3 1/2” Reg Box(*)


API 2 3/8” Reg Pin x Box OD = 76 mm API 2 3/8” Reg Not needed COP 34, API 2 3/8” Reg 95-105 mmL = 305 mm Wall = 6.3 mm

COP 44, API 2 3/8” Reg 110-130 mm

API 2 3/8” Reg Pin x Box D = 89 mm API 2 3/8” RegNot needed

L = 305 mm Wall = 6.3 mm COP 54, API 2 3/8” Reg 134-140 mm1 DHR 48 H 45-1

API 2 3/8” Reg BoxCOP 54, API 2 3/8” Reg 134-152 mm

API 2 7/8” x 2 3/8” RegL = 140 mm

COP 54HD, API 2 3/8” Reg 140-152 mm(**)

API 2 3/8” x 2 7/8” Reg Pin x Box OD = 102 mm API 2 7/8” RegL = 305 mm Wall = 6.3 mm

COP 54, API 3 1/2” Reg 134-152 mmAPI 2 7/8” x 3 1/2” RegL = 160 mm

COP 54HD, API 3 1/2” Reg 140-152 mm2 DHR 45 H-1

DHR 45 H-2API 2 3/8” Reg Box(*) (***)

3 DHR 48 H 45-2(*)

ROC F6

ROC L6

ROC L8

Rotation unit Adapter Drill tubes Crossover DTH Hammer Bit



NB (*) Floating adapter should be chosen to prevent fast wear out of threads and cradle wear partsFor further info on bit designs and sizes, see our Secoroc Rock Drilling Tools

NB (*) Floating adapter should be chosen to prevent fast wear out of threads and cradle wear parts(**) Hammer thread is potentially a weak point. Highly recommended to change top sub to 3 1/2” API(***) Only for customers who own ROC 830s or ROC F6s to standardize in same rotation unitFor further info on bit designs and sizes, see our Secoroc Rock Drilling Tools Catalogue

NB (*) Floating adapter should be chosen to prevent fast wear out of threads and cradle wear parts(**) This alternative is NOT highly recommended as the DHR thread is a weak point(***) Hammer thread is potentially a weak point. Highly recommended to change top sub to 3 1/2” APIFor further info on bit designs and sizes, see our Secoroc Rock Drilling Tools Catalogue

G

G

DTH ROTATION UNITS


Rotation units for DTH drilling

DHR seriesHole diameter range 70-254 mm,drilling torque up to 5100 Nm

The Atlas Copco DHR series of rotation units includes a total of 7 airpowered and 12 hydraulically-powered standard motors designed for longer life, superior wear resistance, and enhanced output. All are equipped with both fi xed and moving adapters for all common types and dimensions of thread.

Air-powered versions in the DHR series have powerful vane motors, to ensure top-quality operating reliability and wear resistance. The torque, delivered at a working pressure of 6 bar, is suffi cient for maximum drill capacity, and can be easily increased to 8 bar for greater torque without any risk of overloading. Both rotation speed and direction can easily be changed. The vane motor is integrated with a long-life, well-tested planetary gear.

The hydraulically-operated DHR versions are equipped with reliable, longlife motors of a type for which plane-tary gear is unnecessary. Normal working torque is ob-tained even at a very modest hydraulic pressure. Thepotential working pressure, however, is much greater, offering a good margin for more demanding work situ-ations. Engine speed and rotation direction are easy to set on all motors, and the superior design gives both quiet operation and minimal maintenance. There are two well-proven sizes of reduction gear with various gear combinations to suit all DHR series motor versions. They are extremely strong, and designed for simple and easy mounting. The DHR 48RC version is intended for reverse circulation drilling on ROC L8. It is designed to fi t the drill string components as simple hose connection and underneath air swivel from Metzke Engineering, Australia.

Type DHR 45A DHR 56ALength1 (mm) 870/1026 951/1120Width cradle (mm) 255 270Height (mm) 333 365Height from baseto centre of spindle (mm) 126 138Weight1 (kg) 126/144 235/275Air connection DTH hammer (in) 2 2Drive motors 1 2Air connection motor (in) 3/4 3/4

1with fi xed adapter/fl oating adapter

Operative data, hydraulically powered rotation units

Type DHR DHR DHR DHR DHR 45H 48H45 48H56 48H68 48RCLength1, (mm) 685/842 528/882 534/888 550/904 696/-Weights1, (kg) 111/124 163/239 164/240 166/242 178/-Drill tube connectionAPI Reg Female 23/8” 23/8” 23/8” 23/8” 4”Metzke

3½” 3½” Long pin MaleDrive motors (qty) 1 2 2 2 2Drilling performanceTorque, max (Nm)2 2200 3000 3900 5100 5100Press drop, max (bar) 175 210 210 175 175Speed, max (rpm)3 80 136 107 68 68Flow, max (l/min) 75 150 150 150 1501 With fixed adapter/floating adapter2 With mineral oil. For other oils ask for information3 Not in combination with max torque

Rotation UnitsHydraulically Adapter Recommended Powered type/thread for DTH Hammer

DHR 45H-1 Floating API 23/8" Reg Box 3"- 4"- 5"DHR 45H-2 Fixed API 23/8" Reg Box 3"- 4"- 5"DHR 48H45-1 Floating API 23/8" Reg Box 3"- 4"- 5"DHR 48H45-2 Fixed API 23/8" Reg Box 3"- 4"- 5"DHR 48H56-1 Floating API 23/8" Reg Box 4"- 5"DHR 48H56-2 Fixed API 23/8" Reg Box 4"- 5"DHR 48H56-3 Floating API 31/2" Reg Box 5"- 6"DHR 48H56-6 Fixed API 31/2" Reg Box 5"- 6"DHR 48H68-1 Floating API 22/3" Reg Box 4"- 5"DHR 48H68-2 Fixed API 23/8" Reg Box 4"- 5"DHR 48H68-3 Floating API 31/2" Reg Box 6"- 8"DHR 48H68-6 Fixed API 31/2" Reg Box 6"- 8"DHR 48RC Fixed 4" Metzke Long pin Male RC-hammer

Adapter type/thread

Technical data, air powered

0 20 40 60 80 100 rpm

100

200

300

400

1000

2000

3000

40006 bar 8 bar

DHR 56A

DHR 45A

l/sNmAir requirementTorque

DHR 45A DHR 48RCDHR 48H

ROTARY DRILL RIGS


Large Blasthole Drills

Atlas Copco offers a wide range of large drills for production blast hole drilling in open pit mining. There are a variety of alternatives, including crawler or custom mounted carriers, single or multi pass versions, diesel or electric prime movers. The range covers hole diameters from 4½ up to16¼ inches. (114 – 413 mm).

Technical data

Visit www.cmt.atlascopco.com/ads/ for more information

Installed Power Pulldown force Maximum Hole Diameter Hp (kW) lbf. (kN) inch. (mm)

DM25SP 360 - 460 (270-340) 46,000 (205) 63⁄4 (171)DM30 425 - 525 (315-390) 30,000 (135) 63⁄4 (171)DM45 425 - 525 (315-390) 45,000 (200) 77⁄8 (200)DM50 425 - 525 (315-390) 45,000 (200) 77⁄8 (200)DML 525 - 765 (390-570) 60,000 (270) 9 (229)DMLSP 525 - 765 (390-570) 60,000 (270) 9 (229)T4BH 525 - 760 (390-565) 30,000 (135) 10 (254)PV271 760 (565) 75,000 (335) 105⁄8 (270)PV275 760 (565) 75,000 (335) 105⁄8 (270)DM-M3 630 - 950 (470-705) 90,000 (400) 121⁄4 (311)DM-H2 600 - 950 (445-705) 110,000 (490) 133⁄8 (340)PV351 1,650 (1230) 125,000 (560) 161⁄4 (413)

ROTARY DRILL RIG SPECIFICATION


Main specifications

DM30

The DM30 represents an ideal combination of versatility, economy, and power in rotary blasthole drills.

The DM30 is designed for quarrying and small mining applications. This versatile drill can be easily loaded onto a trailer and moved from one location to another. Strong and powerful, the high-strength cable feed system absorbs drilling shock, improves rotary head life and minimizes inventory requirements. The 136 HP/101 kW spur gear head provides high torque for maximum drilling performance, smooth rod handling, and a powerful impact breakout system. With a precision controlled, pressure balanced cylinder feed system, the DM30 has a 30,000 lb/13,608 kg bit weight and a 10,000 lb/4,536 kg pullback capacity.

Standard equipmentThermal insulated, sound-attenuated cab, Dust collector, Dust hood w/skirting, Halogen night light pkg, Aux. hoist, Engine and air compressor intake filters, Remote tower pinning, Carousel, Remote hydraulic fork chuck for breakout, Hydraulic aux. chain wrench, 230-gal (870L) fuel tank, Leveleing jacks, 68,000 lb (30,845 kg) GVW rated undercarriage, Oscillation yoke, Service walkways w/railing, Back-up alarm, DHD lube, Central lube manifold, Centralizer, Hammer split and split bushings, Lifting bail, Grease gun, Blow gun w/hose, O-ring kit, windshield wipers/washers

Optional equipmentA variety of options is available to meet your drilling needs including (but not limited to): floating spindle sub, water injection w/arctic fox, Automatic and manual lube systems, central service system, diesel-fired preheater, battery and engine oil pan heater, Thunderbird DEI depth and rate of penetration monitor, tramming foot pedal brake, torque limit control, inclinometer.

Recommended hole rangeNominal Hole Size 127 - 171 mm 5" - 63/4" Hole depth, max. STD 27.4 m 90'Hole depth, max. Optional 47.5 150'Pipe length 9.14 m 30 ftFeed system Hydraulic pulldown force 133 kN 30.000 lbf Hydraulic pullback force 44.5 kN 10.000 lbfFast feed/retract speed 0 - 30.5 m/min 0 - 100 ft/min 0 - 85 m/min 0 - 280 ft/minRotary head, two-stage, spur gear Spindle thread Size 101.5 mm 4" API IFRotation motors 101 kW 136 HPTorque, variable 7.322 Nm 5.400 lbf/ftTowerRod changing (2 or 4 pipe) 9.1 m/each pipe 30 ft/eachAuxiliary hoist, (Hyd. motor) 1.134 kg 2.500 lbTower raising & lowering 2 hydraulic cylindersMainframeLeveleing jacks 18.598 kg 41.000 lbJack Pad diameter 457 mm 18" Jack Pad Area 1.642 sq. cm 254.5" sq.UndercarriageModel CAT 320, AC GT 2000 Track length 4.44 m 14 ft 7 inTrack width 2.9 m 9 ft 5 inPowerpackHigh pressure configurationat 350 psi 900 cfmat 2413 kPa 25.5 m3/minDiesel engine options EPA Tier 3Caterpillar C-15Rating at 1800 rpm 403 kW 540 HPCummins QSX15Rating at 1800 rpm 418 kW 560 HPLow pressure configurationat 110 psi 900 cfmat 758 kPa 25.5 m3/minDiesel engine options EPA Tier 3Caterpillar C-15Rating at 1800 rpm 354 kW 475 HPCummins QSX15Rating at 1800 rpm 336 kW 425 HPCooling systemCooling capacity 52 ºC 125 ºF ambientFuel capacity 871 l 230 galHydraulic systemMain pumps, piston pumps 197 l/min 52 gal/minVane Pumps stage 1 133 l/min 35 gal/minVane Pumps stage 2 64 l/min 17 gal/minTransport dimensionsWeight (approx. excl. options) 28.121 kg 60,000 lbsWidth shipping 2.9 m 113" operational 3.6 m 142"Length tower up 7.4 m 292" tower down 12.9 m 506"Height tower up 13.5 m 532" tower down 4.4 m 174"Rock drilling toolsHole range 127 - 171 mm 5" - 63⁄4"COP 44 110 - 130 mm 43⁄8" - 5"COP 54 134 - 152 mm 5¼" - 6"QL 40 105 - 130 mm 4" - 5"QL 50 130 - 152 mm 5" - 6"QL 60 153 - 171 mm 6" - 63⁄4"Bit connection 89 mm 3½"Tricone bits 121 - 171 mm 43⁄4" - 63⁄4"Secoroc Duralloy bit sub adaptor can be used with:Pipe thread (pin end) 89 mm 31/2" BECO 200 mm or 27/8" APIBit thread (box end) 89 mm 31/2" BECO 200 mm or 27/8" AP



DM45

The DM45 is one of a family of drills designed to offer the ideal combination of efficiency, economy, and power in rotary blasthole drills.

The standard DM45 utilizes a diesel engine to drive the air compressor and hydraulic system. Operation of the drill is performed using electric over hydraulic controllers ergonomically located so that the operator faces the drill centralizer while drilling. Both high pressure and low pressure models are available to fit your drilling needs.

Standard equipmentInsulated, FOPS, Sound-attenuated cab, Dust collector, Dust hood w/skirting, Halogen night light pkg, Aux. hoist, Engine and air compressor intake filters, Remote tower pinning, Carousel, Sliding hydraulic fork, Hydraulic aux. chain wrench, 1438 l/380-gal fuel tank, Leveleing jacks, 36,287 kg/80,000 lb GVW rated undercarriage, Oscillation yoke, Service walkways w/railing, No-bump rod changer, Back-up alarm, Jack up indicator lights, Rod support arm, Ether injection, Central lube manifold, Centralizer bushing, Lifting bail, Spindle sub, Blow gun, Manuals, Wipers/washers, Battery select master switch.

Optional equipmentA variety of options is available to meet your drilling needs including (but not limited to): Floating spindle sub, Language name plates, Water injection, 680 gal fuel tank, Auto lube system, Wiggins central service and fast fuel systems, Diesel-fired preheater, 240 V AC cold weather pkg, Variety of Aquila electronic monitoring systems, Thunderbird DEI depth and rate of penetration system monitor, Battery equalizer/converter, Tow hooks, Inclinometer, Torque limit control, Sunshades, 1070 cfm HP and 1050 cfm LP

Main specifications

Recommended hole rangeNominal hole size 114 - 178 mm 4½" - 7" Hole depth, max. 27 - 53 m 90 - 175'Pipe length 9.14 m 30 ftFeed system Hydraulic pulldown force 200 kN 45.000 lbf Hydraulic pullback force 98 kN 22.000 lbfFast feed/retract speed 0 - 44.5 m/min 0 - 146 ft/min 0 - 62.48 m/min 0 - 205 ft/minRotary Head, two-stage, spur gearDrill pipe size 114.3 mm 4-1/2" OD Spindle thread size 88.9 mm 3-1/2" API RegRotation motors 82 kW 110 HPTorque, variable (Nm) 12202 Nm 9.000 lbf/ftTowerRod changing (7 pipe change) 9.1 m/each pipe 30 ft/eachAuxiliary hoist, (hyd. motor) 1.134 kg 2.500 lbTower raising & lowering 2 hydraulic cylindersMainframeLeveleing jacks 26.717 kg 58.900 lbJack pad diameter 762 mm 30 inJack pad area 4560 cm sq 06.8"sqUndercarriageModel Atlas Copco branded tracks Track length 4673 mm 184 inTrack width 600 mm 23.6 inPowerpackHigh pressure configurationat 350 psi 900 cfmat 2413 kPa 25.5 m3/minDiesel engine options EPA Tier 3Caterpillar C-15Rating at 1800 rpm 403 kW 540 HPCummins QSX15Rating at 1800 rpm 418 kW 560 HPLow pressure configurationat 110 psi 900 cfmat 758 kPa 25.5 m3/minDiesel engine options EPA Tier 3Caterpillar C-15Rating at 1800 rpm 354 kW 475 LPCummins QSX15Rating at 1800 rpm 336 kW 425 LPCooling systemCooling capacity 51.6 ºC 125 ºFFuel capacity 852 l 225 galHydraulic systemMain pumps, piston pumps 268 l/min 71 gal/minVane pumps stage 1 158 l/min 42 gal/minVane pumps stage 2 83.3 l/min 22 gal/minTransport dimensionsWeight (approx. excl. options) 28.121 kg 60.000 lbsWidth 3.6 m 142"Length 13.3 m 43'7"Height 4.4 m 174"Rock drilling t oolsHole range 114 - 200 mm 4½" - 77⁄8"Bit connection 76 - 140 mm 3 - 51/2"COP 44 110 - 130 mm 43⁄8" - 5"COP 54 134 - 152 mm 5¼" - 6"QL 40 105 - 130 mm 4" - 6"QL 50 130 - 152 mm 43⁄8" - 6"QL 60 152 - 171 mm 6" - 63⁄4”Tricone bits 149 - 200 mm 57⁄8" - 77⁄8"Secoroc Duralloy bit sub adaptor can be used with:Pipe thread (pin end) 89, 101, 114 mm 31/2, 4, 41/2" BECO 89 mm or 31/2" APIBit thread (box end) 89, 101, 114 mm 31/2, 4, 41/2" BECO 89 mm or 31/2" API



T4BH

With a multitude of configurations from which to choose, the T4BH truck-mounted, rotary blasthole drill meets the tough challenges of the aggregate and construction industries.

This powerful, mobile drill incorporates a comfortable, FOPs cab that provides the operator a non-obstructed view of the drill table and easy access to the drill controls. Fast, efficient drill pipe handling is accom-plished with the carousel-type pipe changer. The high speed/high torque rotary head delivers the fastest drill rates in this class of drill, while consistently deliveringup to 13607 kg/30,000 lb. of force to depths of 45.7 m/ 150 ft. Angle drilling is optional.

Standard equipmentRemote tower pinning, Gear indexing carousel, Sliding fork, Aux. chain wrench, 852 l/225 gal fuel tank, Custom carrier, Ether injection, Back-up larm, Centralizer bushing, Hoist plug, Spindle sub, Manuals.

Optional equipmentA variety of options is available to meet your drilling needs including (but not limited to): Angle drilling pkg, Torque limit control, Central lube manifold, 454 l/120 gallon aux. Fuel tank, Water injection, Remote propel from cab, Drilling efficiency indicator, Cold weather starting aid, Floating spindle sub, 1070 cfm HP and1250 cfm HP

Main specifications

Recommended hole rangeNominal hole size 190.5 - 254 mm 7½" - 10" Hole depth, max. 46 m 150'Pipe length 7.6 or 9.14 m 25 or 30 ftFeed system Hydraulic pulldown force 164.6 kN 37.000 lbf Hydraulic pullback force 73.4 kN 16.500 lbfFast feed/retract speed 14.6 m/min 48 ft/min 33.5 m/min 110 ft/minRotary head, two-stage, spur gear Spindle thread size 101.6 or 102 mm 4" API IFRotation motors 82 kW 110 HPTourque, variable 8.135 Nm 6.000 lbf/ftTowerRod changing (7 pipe change) 7.6 m/each pipe 25 ft/eachAuxiliary hoist, (hyd. motor) 1.134 kg 2.500 lbTower raising & lowering 2 hydraulic cylindersMainframeLeveleing jacks 26.717 kg 58.900 lbJack pad diameter 457 mm 18"TruckModel Crane CarrierTruck engine CAT C11 227 kW 305 HPFront axle capacity 10.886 kg 24.000 lgRear axle capacity 20.412 kg 45.000 lbTransmission: Fuller RTO-11908LL 10 speed forward, 3 speed reversePowerpackHigh pressure configurationat 350 psi 900 cfmat 2413 kPa 25.5 m3/minDiesel Engine Options EPA Tier 3Cummins QSK15Rating at 1800 rpm 418 kW 560 HPCooling systemCooling capacity 51.6 ºC 125 ºFFuel capacity 852 l 225 galHydraulic systemMain pumps, piston pumps 268 l/min 71 gal/minVane Pumps stage 1 158 l/min 42 gal/minVane Pumps stage 2 83.3 l/min 22 gal/minTransport dimensionsWeight (approx. excl. options) 26.308 kg 58.000 lbsWidth⁄ 2.4 m 8 ftLength 10.7 m 35 ftHeight 4.12 m 13 ft 6 inRock drilling toolsHole range 165 - 228 mm 61⁄2" - 9"COP 44 110 - 130 mm 43⁄8" - 5"COP 54 134 - 152 mm 5¼" - 6"COP 64 156 - 171 mm 6 - 63⁄4"QL 40 105 - 130 mm 4" - 5"QL 50 130 - 152 mm 5" - 6"QL 60 152 - 171 mm 6" - 63⁄4"QL 80 203 - 228 mm 8" - 9"Bit connection 127 - 218 mm 5 - 85⁄8"Tricone bits 149 - 200 mm 57⁄8" - 77⁄8"Secoroc Duralloy bit sub adaptor can be used with:Pipe thread (pin end) 89, 101 mm 31/2, 4" BECO 71, 89 mm or 27/8, 31/2" APIBit thread (box end) 89 mm 31/2" BECO 71, 89 mm or 27/8, 31/2" API

SECOROC TRICONE BITS


Secoroc Tricone Bits

Pin Connection

Pin Shoulder

Nozzle NailLock

Lug

ShirttailInserts

GaugeBevelInserts

GaugeInserts

Cutter Cone

Air Exit Slot

Nose Inserts

ShirttailHardfacing

Ball RetainingPin Weld

Nozzle

Air Passageto Bearing

Air Tube

Air Water Separator or Back Flow Valve

Lock Ring

Ball RetainingPin

Outer RollerBearing

Ball Bearing

Inner RollerBearing

Cone (L) and Journal (R)

Thrust Buttons

NomenclatureAtlas Copco BHMT Inc. uses the IADC code along with the Product Line and added feature in the bit’s nomenclature to help describe the bit.

International Association, Drilling Contractors Code: The IADC Code is a three numbered system to classify the hardness and type for all roller cone rock bits. First Digit – Identifies the Bit Type and Major Hardness class:

1 – Steel Tooth for soft formations2 – Steel Tooth for medium formations3 – Steel Tooth for hard formations4 – Insert for soft formations 5 – Insert for soft/medium formations 6 – Insert for medium/hard formations7 – Insert for hard formations8 – Insert for extremely hard formations

The underlined types are the main rock bit types produced by Atlas Copco BHMT, Inc. This range of rock bits will cover EVERY application of a rotary rock bit.

Second Digit – Designates the Hardness Subclass of Major Hardness class. This ranges from 1 to 4, where 1 is classified as the softest subclass and 4 is the hardest subclass.

Third Digit – Designates Bit’s Bearing Features:1 – Roller Bearing2 – Roller Bearing Air-Cooled3 – Roller Bearing with Gage Bevel Inserts4 – Sealed Roller Bearing5 – Sealed Roller Bearing with Gauge Bevel Insets6 – Sealed Friction Bearing7 – Sealed Friction Bearing with Gauge Bevel Inserts8 – Special9 – Special

The underlined types are the main bearing types produced by Atlas Copco BHMT, Inc.

Example: IADC 6-3-2This is a Medium/Hard Air-Cooled Roller Bearing.

Example: 12¼ MAG53CA12¼ Diameter, inchesMAG Product Line53 First two digits of the IADC code (Rock Class ‘5’, subclass ‘3’)C Insert Type (Conical Inserts)A Full Armoured Lug (Nevada Package)

Product Lines:• MAG – Maximum Active Gauge use in soft/medium material.• MAG II – Second generation MAG bits featuring enhanced erosion resistance features and new bearing geometries.• HD – Hard Drilling. Medium hard to hard formation bits.• HD+ – New generation Hard Drilling rotary bits used in medium hard to hard formations, with new carbide grades, aggressive cutting structures, and enhanced bearings.• BH – Standard Product.

Insert Type:• C – Conical • G – Ogive• S – Super Scoop *Chisels and Ovoids are standard inserts and do not have suffixes

SECOROC TRICONE BITS


Tungsten Carbide bit selection and operationFive basic classifications of Atlas Copco BHMT, Inc. rock bits are available for blast hole drilling.

The modifications in cutting structure design from series to series are:

1. The spacing of inserts (or teeth) is greatest for the softer or weaker formations and decreases as the formation hardness increases. 2. The number of rows of inserts and/or the total number of inserts per bit is increased as formation hardness increases.3. The groove depth and amount of intermesh is decreased as formation hardness increases. 4. The insert projection above the cone shell is greatest for the softer formations and is decreased as the formation hardness increases.

40 SeriesThe 40 series bits are typically characterized by large diameter widely spaced super scoop, chisel or conical inserts. This configuration promotes maximum penetration rates in softer formations that have a tendency to stick and ball up the cutting structure.

Applications Soft formations such as shale,siltstone, soft limestone and alluvials.

Suggested Operating Parameters:Weight on bit –1,000 to 5,000 lb/inch of diameterRotation speed – 50 to 150 rpm

50 SeriesThe 50 series bits are typically characterized by more densely spaced chisel or conical inserts. This configuration promotes maximum penetration rates in soft/medium formations that are fractured or have varying degrees of hardness.

ApplicationsSoft/medium formations such as sandstone, shale, granite and some marble.

Suggested Operating Parameters:Weight on Bit – 3,000 to 6,500 lb/inch of diameterRotation Speed – 50 to 150 rpm

60 SeriesThe 60 series bits are typically characterizedby more densely spaced, shorter projecting chisel, conical or ogive inserts. This configuration promotes maximum penetration rates in medium/hardformations.

Applications Medium/ hard formations such as hard limestone, hard shale, basalt and quartzite.

Suggested Operating Parameters:Weight on bit – 4,000 to 7,000 lb/inch of diameterRotation speed – 50 to 120 rpm

70 SeriesThe 70 series bits are typically characterized by a densely spaced, shorter projecting conical or ogive inserts with a conical or ovoid gauge insert. This configuration promotes maximum penetration rates in hard formations.

ApplicationsHard formations taconite, banded iron and quartzite.


80 SeriesThe 80 series bits are typically characterized by very densely spaced, short projecting ovoidinserts. This configuration promotes maximum penetration rates in extremely hard formations.

Applications Extremely hard formations such as chert, hematite ore and quartzite.


secoroc grinding


grinding grinding machines

grind Matic BQ2 grind Matic Manual B

Note:

Note!

Grinding machine Button BitsDTH/COPROD

bitsReaming bits X-type bits

Cross-type bits

Integrals

Grind Matic BQ2

Grind Matic Jazz

Grind Matic Manual B

Grind Matic HG

Grind Matic BQ2-DTH

Grind Matic Manual B-DTH*

Grind Matic X

Grind matic Swing

Grind Matic Senior

grind Matic Jazzrig-mounted, semiautomatic grinding machine for tapered, threaded, dTH and coProd bits.grind Matic Jazz, standard 9500-4100incl. main bit holder for threaded bitsgrind Matic Jazz, dTH 9500-4300incl. main bit holder for DTH / COPROD bits grinding capacityMax. distance 250 mm (10")Max. diameter of drill bit 254 mm (10")Min. diameter of drill bit 35 mm (1 ³⁄8")Min. distance between buttons 3,5 mm (9⁄64")Technical specificationsAir pressure, maximum 7 bar (102 psi)Air pressure, minimum 6 bar (87 psi)Air consumption 25 l/secSpeed, spindle 15 000 rpmOutput, spindle motor 1 kWVoltage 24 VCoolant container 3 literWeight, exclusive of packing 90 kgDimension 800 x 500 x 700 mm (31.5 x 20 x 27.5 in.)Accessories included in delivery Product codeBox wrench, 11 mm 9500-4425Box wrench, 16 mm 9500-4426Protective eyewear 9500-1967Grinding gauge 9500-9104Operators instructions/ Spare parts list 9852 1490 01optional accessoriesAnti-freeze kit 9500-4315Main bit holder for DTH/COPROD bits 9500-4268Main bit holder for threaded bits 9500-4214Mounting bracket for Atlas copco drill rig- with cabin 9500-4388 - without cabin 9500-44563-leg stand 9500-4450Centering tool 9500-4465NOTE!Grind Matic Jazz must be completed with grinding wheels, centering cups, indexing templates and bit holders. Product number begins with 8700-xxxxinstead of 9500-xxxx (product code).

recommended can be used*Can be used for ODEX pilot bits and reamer

secoroc grinding


9213 Secor KAT_1_3.fm Page 86 Thursday, October 16, 2003 4:14 PM

grinding

grind Matic Hg grind Matic BQ2-dTH grind Matic Manual B-dTH

secoroc grinding


Keep up to date with the world of mechanized rock excavation –

Visit Mining & construction on-line atwww.min-con.com

grinding

grind Matic X grind Matic senior grind Matic swing

secoroc grinding

136 Drilling in open pit mining��

grinding diamond grinding wheels for button bits

grinding wheels for steel grinding of button bitsdiamond boron nitride

Full access to Atlas Copco products -everytime, everywhere.

secoroc grinding


grinding diamond grinding cups for button bits

grinding ceramic grinding wheels for button, integral and insert bits

grinding templates

Button bits

integral bits

insert bits

40 30 1020 0

10

5

15

110°

3 m

m

1/

8"

r= 80 mm 3,5/32"

1/4"

1/2"

3/4"

8

9

10

10,95

12,7

14,57

Min.

0,5

Regrind when flatis 173 of button dia.

D

D/3

DRILL RIG OPTIONS


Silenced SmartRigNoise reductionIn many countries, strict noise restrictions are imposed for drilling in urban areas, and close to habitation or other sensitive buildings. This is exactly the situation for which the Silenced ROC D7C was introduced, as the first SmartRig for use especially in areas where noise levels have to be controlled. Silenced SmartRig ROC D9C has now been released to complete the product portfolio.Substantial efforts have been put into redesigning components and soundproofing enclosures, resulting in a 10dB(A) external noise reduction.

Feed enclosureThe most visible difference between the Silenced SmartRig and other computerized drillrigs is its patented feed enclosure, the frame and panels of which are formed from lightweight aluminium. There are four access doors, which are hydraulically operated from the cab. A rubber sliding skirt at its base encloses the drill hole, and this can be hydraulically raised for collaring. The whole enclosure is designedfor quick demounting when not needed.

Lower fuel consumptionThe advanced and more efficient hydraulic system on the Silenced SmartRig requires less power. Because its new engine delivers the right amount of power for each phase of the drilling operation in different rock conditions, fuel consumption can be reduced by upto 30%.

SmartRig automationSmartRig has a PC-based control system that facilitates all kinds of automation in drillrigs. The hardware is designed to operate in every possible weather condition, and the software can be upgraded at site. SmartRig has built-in logging and monitoring functions, together with support for diagnostics and faultfinding. In the cab, the control system replaces hydraulic pipework and gauges with a display unit, considerably increasing the space and reducing the noise for the operator. In addition, the number of hydraulic components on the drillrig has been reduced substantially, and hydraulic efficiency is higher as a result. The need for electrical cables is also diminished.

Increased productivitySmartRig facilitates increased shift capacity through faster positioning, to which can be added the produc-tivity increase from automatic rod adding and auto feed alignment. Altogether, the Silenced SmartRig is a major step forward for the environment, presenting a flexible choice for quarries and civil engineering work sites.

DRILL RIG OPTIONS


Angle and hole depth instrument

a

b

ef

c

d

a

b

c

f

e

d

g

Angle instrument with sightThe electronic angle indication system consisting of an angle sensor on the boom and feed, sight and graphic presentation on an LCD display. The sight makes it possible to drill parallel holes by selecting a reference point before the first hole is drilled. This reference point is then maintained throughout the entire round or as long as the direction of movement is the same. By turning the sight back to the same reference point the entire time regard-less of how the drill rig travels, the instrument calculates how the feed inclination must be changed to maintain the same direction of movement. The angle sensor on the boom mounting allows the instrument to compen-

sate for the turning of the boom the same way as when the sight is turned.

Drilled depth instrumentIn order to maintain control over the drilled depth, drill metres and penetration rate, the system is equipped with a drilled depth sensor.

The drill rig can be equipped with one of the following alternatives:• Angle and depth measurement instruments with sight.• Angle, depth and laser plane instruments with sight.

a Actual inclination front/back b Desired inclination front/back. c Actual inclination left/right d Desired inclination left/righte Resetf Graphic

a Indication of selected measurement methodb Reset of drilled depth counterc Accumulated drilled depthd Desired drilled depth when using automatic drill stope Current drilled depthf Speed Penetration rateg Activation of the laser plane function

Display: Angle instrument with sight Display: Drilled depth instrument

DRILL RIG OPTIONS


Water mist system An optional water injection system on the drill rig, combined with reduced flushing air, produces the so-called water mist system - which can be used for dust protection or hole stabilization. The system is especially useful when starting a hole or drilling through the first metres of soft rock or overburden. Also, in certain types of rock where dust suppression can be a problem for deep holes, water mist can be used as an alternative to the conventional dust collector.

• The water mist system consists of a water tank, safety valve, strainer, two cocks, two valves and one check valve. • The water in the pressure tank is pressurized by the rig’s air system through a hose with an adjustable nozzle. The quantity of water can be finely adjusted using a valve on the water mist system. The system is controlled by a switch located on the drill panel. • The system is depressurized by a blow-down valve when the compressor on the drill rig is deactivated.

In order to meet customer demands, all rigs can be equipped with the water mist system - whether they are top hammer, DTH, pneumatic or hydraulic.

Equipped to operate the water-mist system: an Atlas Copco ROC F7 crawler rig, fitted with a pressurized water tank.

DRILL RIG OPTIONS


Quicklub lubrication pump.

Lubrication systemThe Quicklub lubrication system is designed to provide a relatively simple and inexpensive method of centralizing and automating the lubrication of machinery bearings.

The system dispenses small measured amounts of lubricant at frequent intervals while the machine is operating. With a fully automated system, the lubricant is supplied by an electric pump through one or more distribution blocks to each point covered by the system. Even those hard to reach are assured of being properly lubricated and purged of contaminants.

Up to 300 lubrication points can be served, depending on the length of the hose.

• Reliably distributed lubricant in predetermined amounts.

• Delivers lubricant to the connected lubrication points in a safe manner.

• With three pump elements mounted, the pump can serve three separate lubrication circuits.

• Each lubrication circuit is equipped with a safety valve that holds the pressure within permissible values.

• If there is a block in a lubrication circuit, lubricant will leak from the safety valve.

• Works through lubrication cycles (interval time, propagation time and load time)

• Pumps grease up to NGLI 2 at temperatures between -25 degrees C and +70 degrees C.

• Can be used down to -40 degrees C if special low temperature grease is used.

DRILL RIG OPTIONS


Technical data

COP OIL

Main featuresThe development of lubricating oil for pneumatic and hydraulic tools has been driven by the high demands on environment and reliability. COP OIL is made of carefully selected components that give the highest technical performance. COP OIL has a broad temperature range that gives you optimum operation in the most variable air temperatures. It withstands heavy loads and protects against wear and corrosion. More and more users are recognising the advantages of using environmentally adapted lubricants. In applications where lubricant is contaminating the surroundings, the use of environmentally adapted lubricants will therefore be a strong coming demand. COP OIL is based on renewable raw materials that are readily biodegradable. COP OIL is specially developed for Atlas Copco pneumatic and hydraulic rock drills and down-the-hole hammers.

COP OIL • Excellent lubricating properties. • Reduces the risk of scoring and abrasion. • Protects against corrosion and oxidation. • Insensitive to air temperature variations. Works equally well throughout the temperature range - 35°C to + 45°C (-31oF to +113oF). • Adhesion and larger drop formation contribute to the very good lubricating properties. • Based on > 90% renewable raw materials. • Readily biodegradable according to OECD301

Additives in the oil are: • Approved in accordance with the German authorities ”Blue Angel” • ”Approved” in accordance with the Swedish authorities ”Ren Smörja”

COP OILMineral oil

Readily biodegradable

10 days

28 days

60%

100%

Biodegradability according to OECD 301 COP OILDensity, 15°C: 927 kg/m³Viscosity at 40°C: 65 cStViscosity at 100°C: 13.4 cStIndex of viscosity: 215Flame point 250ºC (482ºF)Lowest flow temperature: - 39ºC (-38ºF)

Part number3115 3125 00 Can 10 litres 3115 3126 00 Can pallet 48 x 10 litres 3115 3127 00 Drum 208 litres

A new oil for Atlas Copco pneumatic and hydraulic rock drills, and DTH hammers that unites technology and environment.

Using Atlas Copco COP OIL ensures that you are doing your best for both the environment and your equipment!

DRILL RIG OPTIONS


COP Grease can be ordered either in a tube for use in the field together with a grease gun, or in a can for use in the workshop.

COP Grease

To keep the rock drill in perfect shape, it is necessary to use the right quality of gear box grease. That´s why we recommend you to use COP Grease – a grease specially developed for Atlas Copco´s hydraulic rock drills. The grease is thoroughly tested to cope with all the trials that the gear box of the rock drill is exposed to, such as damp, vibrations and high temperatures.

COP Grease handles temperatures ranging from 40°C to150°C and short term up to 220°C. It has excellent mecha-nical stability, providing high resistance under vibrating conditions.The smooth consistency ensures minimal temperature elevation in the gear. It has excellent load carrying capacity, is very resistant towards water, and has good rust preventing properties.

COP Grease contains additives to prevent wear and cor-rosion, and to ensure good Extreme Pressure (EP) ability. The additives also improve the oxidation stability, ma-king the grease suitable for use under extended periods of time at high temperatures.

By using COP Grease, you can lower the maintenance cost and increase the life length of your rock drill. You can order COP Grease either in a cartridge for use in the field together with a grease gun, or in a can for use in the workshop.

COP Grease

Items Content P/NCartridge 0,4kg 3115342200Can 18kg 3115342300

Typical inspectionsCharacteristics Methods UnitsThickener - - Lithium- complexNLGI - - 1.5Penetration ASTMD217Worked60times mm/10 305Droppingpoint ASTMD566 ºC >260Baseoilviscosity@40°C ASTMD445 mm2/s 475Baseoilviscosity@100°C ASTMD445 mm2/s 50

Tests and approvalsClassifiedasL-XDDIB1.5accordingtoISO6743-9ClassifiedasK1.5N-40accordingtoDIN51502SKFEmcorWWO,distilledwaterSKFLubricityR2FruntestASKFLubricityR2FruntestB(150°C)

Handling and StorageAvoidskincontact.Washthoroughlywithsoapandwater,afterskincontact.Disposeofusedgreaseproperly.Safetydatasheetavailableforprofessionaluseronrequest.

DRILL RIG OPTIONS


Hole Navigation System

The Atlas Copco satellite-based Hole Navigation System (HNS) for surface drillrigs employs Real Time Kinematic (RTK) GPS for positioning accuracy, to within 10 cm in most situations. With HNS, there is no need to markout holes, and the accuracy is such that all holes can be parallel, or different holes in each round can be drilled in a predetermined direction, according to the blastingpattern. The result is a controllable product, with better fragmentation and fewer boulders.

HNS focus is currently on road construction applications, but the system can be used in any type of surface drilling.Using information on his display, the operator can navigate the rig to the coverage position for the given hole, and the computer will provide the information to place and align the feed exactly over the collaring position.

Where HNS is used in quarries and mines, the drillplan should be provided by an external tool, such as ROC Manager, and transferred to the rig computer system via a PC card. Using ROC Manager, the operator selects a hole in the drillplan, and information on his display guides him to the correct position to start drilling. The time saved by not having to aim visually to set angles, and by being able to drill more than one hole froma single set-up, results in better rig utilization.

ROC ManagerROC Manager is a stand-alone PC-based tool for making drill plans, measuring hole deviation, and logging, presenting and reporting drilling data graphically. This infor-mation can be presented individually or in combination with other parameters, and used both during drilling operations, and by transferring logged data from the rig.

Advanced MWD analysis is also possible as an option. ROC Manager 2.0 supports the IREDES format for data exchange on performance, quality and MWD logs, and on drill plans.

A number of graphical tools are available for presen-tation of data in ROC Manager. These are sometimes customized at site to ensure that local rock conditions such as discontinuities, faults, and boundaries are correctly displayed.

DRILL RIG OPTIONS


Automatic Feed Positioning

Automatic Rod Adding

When drilling the bench, the operator has to be sure that, not only is he drilling in the right position, but he is also drilling at the right angle. It is very important that the drill rig feed is set to an exact pre-defined angle, especially for longer holes, where a small error can cause a large deviation at the bottom of the hole. For example, a 2-degree feed angle error produces a 3.6 cm deviation for every metre drilled, resulting in a 72 cm deviation at the bottom of the hole. The longer the hole, the bigger will be the impact on blasting of even a small deviation. The automatic feed positioning function avoids mistakes during setting of the feed angle, and cancels out operator error. The operator simply has to press a button in his cab, and hold it until the feed is set to the correct angle. Automatic feed positioning reduces set-up time and ensures parallel holes, resulting in better blasting and smoother bench bottoms.

Adding rods to the drill string used to be a time-consuming process. First this process was mechanized by the introduction of carousels, clamps and SpeedRods, and now it has been automated.

The automatic rod adding system, AutoRAS, enables the operator to drill a hole automatically to a given depth, allowing him to leave the cab to carry out other duties such as maintenance checks or grinding bits, while keeping the drill rig in sight.

The drilling is supervised by the drill steel breakdetection system, which shuts down the drilling operation if a breakage is detected. In particular, this ensures that no damage is caused to the drill rig if a rod breaks above the surface of the hole.

The result of using AutoRAS is better rig utilization, evidenced by a couple of extra holes/shift, and more efficient use of the operator’s time by multi-tasking.

Laser PlaneUsing the laser plane as a reference level, all holes are drilled to the same depth, reducing drilling, blasting and crushing costs by way of better frag-mentation, and cancelling the need for secondary blasting. A flatter, more uniform bench surface results, making loading and transportation easier.

DRILL RIG OPTIONS


DCT dust collectors

Protect operators and drill sites from drilling dustDrilling dust poses a serious health hazard, not only to operators, but also to worksites in general. Silicosis can be caused by stone dust containing quartz particles with a granular size less than 0.005 mm. In view of this health risk, many countries have introduced stringent standards and measures concerning dust separation in rock drilling. DCT dust collectors remove virtually 100% of all drilling dust, and, most important of all, separate the microscopic stone particles.

Reduce wear and lower maintenance costsUncontrolled drilling dust can clog motors and filters on adjacent machinery, promoting faster wear through abnormal friction and overheating. This can lead to more servicing and repairs, and a costly decline in production. DCT dust collectors create a dust-free working environment,which in turn contributes to lower maintenance costs, and increased service lives of drilling equipment.

Increase nett penetration ratesField experience has shown that, using DCT dust collectors, nett penetration rates can improve by 5-10%. This is partly because the drill cuttings are removed from the drill hole, reducing recrushing, and improving bit performance. Also, because the operator is able to spend more time at the controls, he is able to maintain constant supervision of the drilling sequence.

Two-stage filtration to separate drill dustAtlas Copco DCT dust collectors operate via a two-stage filtration process that removes virtually 100% of all drilling dust. A coarse separator isolates 90% of dust in the first stage, thus reducing the risk of overload of the filters. Then the remainder is separated in secondary filters to get rid of the highly injurious, microscopicstone dust of particle size less than 0.005 mm.

High reliability DCT dust collectors have very few moving parts. The drive ejector has been positioned behind the filters, creating a partial vacuum in the entire system. As a result there is no dust leakage, even in the event of a suction hose becoming damaged. The drive ejector operates continuously in clean, filtered air, eliminating risk of erosion by drill dust. Steady, high airflow speed in the suction hose counteracts blockage of the suction hose. Compressed air to the ejector does not pass by way of the filters, reducing their load.

Atlas Copco DCT dust collectors offer effective, reliable dust separation with operational simplicity, while improving the working environment and increasing productivity.

DCT dust collectors create a dust-free working environment, wich in turn contributs to lower maintenance costs, and increased service lives of drilling equipment.

SERVICE WORKSHOPS


Mobile Service and Hose WorkshopsFor easy and convenient service of drill rigs and hydraulic hoses

Visit www.facedrilling.com for more information

When you invest in an Atlas Copco drill rig you receive a quality product. Quality gives reliability, availability and high productivity, which is essential to make profit. But the quality of any machine has to be maintained in order to give continuous high performance and good operating economy. And that can only be obtained through regular preventive maintenance and the use of Genuine Parts from Atlas Copco.A service workshop located on site or close by is the key solution to rapid maintenance and repair routines. This is why Atlas Copco have designed and equipped mobile workshops to serve different servicing requirements.

Convenient serviceThe latest enhanced versions of the well regarded Atlas Copco Mobile Workshop and Mobile Hose Workshop contain all of the equipment needed for maintenance and increased availability of rockdrills and drill rigs. They are housed in 20 ft ISO standard steel containers, internally insulated and fitted with non-slip aluminium floor plating. Each workshop container is equipped with heating and has a complete electric and compressed air line system for immediate connection to external electrical and pneumatic power sources.

Basic Mobile WorkshopThe container can be delivered standard equip as a Basic Mobile Workshop without any tools or machinery for those who wish to equip the container themselves. In this version it has a workbench, 2.5 m-long with vice and

lockable pedestal; shelves; tool-board with tool hooks;14 m-long hose roll-up for air pressure; 17 m-long, 230 V electric cable rollup; writing desk with lockable pedestal; powder fire extinguisher; first aid panel; ventilation system; and heating fan.

Mobile WorkshopThe fully equipped version of the Mobile Workshop comes complete with standard tool kit, comprising all hand tools needed for carrying out service and rep-air work; 30 t hydraulic press, with mandrel set; 500 kg extensible hoist beam with manual tackle; and a smalI-part cleaning booth, with exhaust. The Mobile Workshop can then be completed with a number of well thought-out options of special tools, instruments and machinery to optimize efficiency. Mobile Workshops are suitable for installation of drill bit grinding equipment, and the Secoroc Grind Matic Manual B air-powered, handheld portable grinding machine can be supplied.

Mobile Hose WorkshopA new approach to hose maintenance is the Mobile Hose Workshop with the hose assembly centre, a com-plete hose mounting workbench, designed to fulfil all your needs for a safe and professional assembly of hydraulic hoses with up to four reinforcement layers. The centre is delivered with a hose reel, cutting machine, peeling machine, marking machine, hose cleaning equip-ment and hose press. The centre is delivered with all the necessary accessories.

2600

2500 6000

Each container has two main doors at the front that open completely, and on one side they have a window with steel shutter.

View inside fully equipped Mobile Workshop.

View inside fully equipped Mobile Hose Workshop.

General informationThe containers have a base socket provided for forklift transportation. The external dimensions of the containers are 6.0 x 2.5 x 2.6 m, and they weigh around 3 t, depending on equipment. The mobile workshops can be delivered for 230V/50 Hz and 380V/50 Hz, or other voltages on request.

MARKET MATERIAL


Conversion factorsThis unit Times Equals

Lengthmm (millimetres)...................... x 0.001......................= mcm (centimetres)....................... x 0.01........................= mdm (decimetres)........................ x 0.1..........................= mkm (kilometres)......................... x 1000......................= min (inches).................................. x 25.4........................= mmft (feet)....................................... x 0.305......................= myd (yard).................................... x 0.914......................= mmiles.......................................... x 1609.......................= m

PowerkW (kilowatts)............................ x 1000......................= WHorsepower............................... x 735.5......................= WHorsepower, U.K....................... x 745.7......................= Wft.lbf/sec..................................... x 1.36........................= WBtu/h........................................... x 0.29........................= W

Volume1 (litres)...................................... x 0.001......................= m3

ml (millilitres)............................ x 0.001......................= ldm3 (cubic decimetres)............. x 1.0..........................= lcm3 (cubic decimetres)............. x 1.0..........................= mlmm3 (cubic millimetres) .......... x 0.001......................= mlin3 (cubic inches)....................... x 16.39......................= mlft3 (cubic feet)............................ x 28.316....................= lImperial gallon.......................... x 4.546......................= lU.S. gallon................................. x 3.785......................= lOunces (Imp. fluid oz).............. x 28.41......................= mlOunces (U.S. fluid oz)............... x 29.57......................= mlPints (U.S. liq.).......................... x 0.4732....................= lQuarts (U.S. liq.)....................... x 0.9463....................= lyd3 (cubic yards)....................... x 0.7646....................= m3

ForcekN (kilonewton)......................... x 1000......................= Nkp (kilopond)............................. x 9.81........................= Nkgf (kilogramme force)............. x 9.81........................= NIbf (pound force)....................... x 4.45........................= N

Torquekpm (kilopondmetres).............. x 9.81........................= NmIbf in (poundforce inch) ........... x 0.11........................= NmIbf ft (poundforce foot)............. x 1.36........................= Nm

Equals Divided This by unit

This unit Times Equals

Mass (weight)g (grammes).............................. x 0.001.................... = kgt (tonnes, metric)....................... x 1000.................... = kggrains......................................... x 0.0648.................. = goz (ounce).................................. x 28.35.................... = gozt (troy ounce)......................... x 31.10.................... = glb (pounds)................................ x 0.4536.................. = kgtons (long, US).......................... x 1016..................... = kgtons (U.K)................................... x 1016..................... = kgtons (short)................................ x 907....................... = kg

Speedkm/h (kilometre/hour)............... x 0.2777.................. = m/sm/s (metres/second)................. x 3.6........................ = km/hmph (miles/hour)...................... x 0.45...................... = m/smph............................................ x 1.61...................... = km/hft/s (foot/second)....................... x 0.3048.................. = m/sft/s (foot/second)....................... x 18.29.................... = m/minft/s (foot/minute)....................... x 0.3048.................. = m/min

Frequencyblows/minute............................ x 0.017.................... = HzkHz (kiloHertz)........................... x 1000.................... = Hzr/min (rev/minute)..................... x 0.01667................ = r/sdegrees/second......................... x 0.1667.................. = r/minradians/second ......................... x 0.1592.................. = r/s

Pressurebar.............................................. x 100....................... = kPabar.............................................. x 100 000............... = Pakp/cm2........................................ x 0.98...................... = baratm (atmospheres)................... x 1.01...................... = barpsi (pounds/in2)......................... x 6.895.................... = kPapsi............................................... x 0.06895................ = bar

Areamm2 (square mm)..................... x 0.000001............. = m2

cm2 (square cm)........................ x 0.0001................. = m2

in2 (square inches).................... x 645....................... = mm2

ft2 (square feet).......................... x 0.0929................. = m2

yd2 (square yards)..................... x 0.8361.................. = m2

Acres ......................................... x 4047..................... = m2

Square miles............................. x 2.590.................... = km2

Equals Divided This by unit

ROC CARE Value-for-money rig service with extended warranty

Learn more at www.atlascopco.com/surface

Scheduled service. Inspection protocols. Extended warranty. ProCom*. These are the four key ingredients of ROC CARE, the new value-for-money service package for Atlas Copco surface drill rigs.

ROC CARE is tailor-made for the construction and quarry business. It protects all that is essential to your drilling operations. It guarantees regular inspections and service. It extends the warranty on major rig components in order to secure your productivity.

ROC CARE means security and peace-of-mind.

*ProCom is a global, satellite-based system that monitors rig status.


Learn more at www.atlascopco.com/surface

The new ROC L740CR has all the qualities you need for optimal sur facedrilling, featuring a high rock drill ef fect and a strong fuel-ef f icient engine. This master rig will increase your productivity by drilling large and straight holes of supreme quality at great speed.*

The rig features our patented COPROD® system that combines the highpenetration rates of Tophammer drilling with the straightness and accuracyof Down-The-Hole drilling. Add to this its unbeatable ability to handle poor rock conditions, and the new ROC L740CR will help you drill s traight tosuccess.

* Hole range 105 mm - 180 mm (4"- 7" )


Straight to success

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Surface Drilling