Drill-and-blast excavation

Conventional excavation using shotcrete is a very flexible method of excavation. This is

suitable for difficult, varying ground conditions and is very good for different sizes and for
complex cross-sectional geometries.

The stages for drilling and blasting are predetermined. The blast holes are drilled first, then
loaded with explosives and finally, the explosion takes place. Once the breakout material has
been removed, a process known as mucking, tunnel support is applied in the form of
shotcrete, anchors, lattice arches and reinforcement mats. After one blasting cycle is
complete, the process starts all over again. During the construction of the Brenner Base
Tunnel blasting will take place every three to six hours depending on the geological
composition of the rock.

1. Drilling

Before the blasting takes place, the drilling rig bores the drill holes – determined in advance
in a blasting plan – in the foremost front wall of the tunnel (working face). The more solid the
rock, the more explosives are required.

2. Loading and blasting

The drill holes are now filled with explosives, detonators are attached to the explosive
devices and the individual explosive devices are connected to one another. The devices
should not explode at the same time, but rather one after the other at specified intervals. Only
when the blast master has ensured that nobody is left in the danger zone can the explosion be
triggered by the blasting machine.

-3. Ventilating

The blast causes lots of rock to be flung through the tunnel, dispersing clouds of dust that
then mix with the combustion gases of the explosion. So that the miners can resume work in
the tunnel, the bad air must be removed from the tunnel. This is done by using so-called air-
ducting systems, long steel or plastic pipes, which are attached to the roof of the tunnel and
blow fresh air onto the working face. This gives rise to localized excess pressure and the bad
air is pushed towards the tunnel exit.

-4. Dislodging

Dislodging refers to the stripping away and removal of loose pieces of rock, which were not
completely released from the rock during the blasting procedure. This working step is
completed by a robust tunnel excavator.

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5. Removing rubble

After the loose pieces of rock have been dislodged from the working face, the blasted
material – the rubble or spoil - is carried out of the tunnel. The material is either loaded onto
dump trucks with wheel loaders and taken from the tunnel to an outside landfill or it is
transported from the site of excavation to the landfill on conveyer belts. During the
construction of the Brenner Base Tunnel, the transportation of the excavated material mainly
takes place automatically using conveyor belts.

6. Geological mapping

The working face is now freely accessible and the geologist has a few minutes to map it. In
the process, he determines what type of rock is present and how the rocks lie, i.e. whether
they dip in a flat or steep manner, whether they are folded or even broken. He uses a special
compass as an aid to measure the angle of incidence and direction of incidence of the rock
structures. At the same time, the strength of the rock, the reaction of the rock mass to the
excavation process and any mountain water infiltration are also documented. The mapping
report created from this – with sketches and photos - serves as the basis for the selection of
appropriate supporting measures.

7. Securing

The quickly drying shotcrete used for this purpose in particular enables a cavity-free
connection of the securing mechanism to the rock. Depending on the type of rock, a variety
of securing measures can be implemented: wire mesh, tunnel arches, stakes or so-called bolts,
which can be driven into the rock.

8. Inner shell

Since securing with shotcrete, bolts, etc. only provides a temporary securing solution, a
permanent inner shell is subsequently installed, generally upon completion of the excavation
procedure. A sealing foil is first attached to the shotcrete where water is suspected. The final
concrete coating (inner shell) is only installed after deformations have completely subsided.

-
1. Drilling

Before the blasting takes place, the drilling rig bores the drill holes – determined in advance
in a blasting plan – in the foremost front wall of the tunnel (working face). The more solid the
rock, the more explosives are required.

2. Loading and blasting

The drill holes are now filled with explosives, detonators are attached to the explosive
devices and the individual explosive devices are connected to one another. The devices
should not explode at the same time, but rather one after the other at specified intervals. Only
when the blast master has ensured that nobody is left in the danger zone can the explosion be
triggered by the blasting machine.

3. Ventilating

The blast causes lots of rock to be flung through the tunnel, dispersing clouds of dust that
then mix with the combustion gases of the explosion. So that the miners can resume work in
the tunnel, the bad air must be removed from the tunnel. This is done by using so-called air-
ducting systems, long steel or plastic pipes, which are attached to the roof of the tunnel and
blow fresh air onto the working face. This gives rise to localized excess pressure and the bad
air is pushed towards the tunnel exit.

4. Dislodging

Dislodging refers to the stripping away and removal of loose pieces of rock, which were not
completely released from the rock during the blasting procedure. This working step is
completed by a robust tunnel excavator.

5. Removing rubble

After the loose pieces of rock have been dislodged from the working face, the blasted
material – the rubble or spoil - is carried out of the tunnel. The material is either loaded onto
dump trucks with wheel loaders and taken from the tunnel to an outside landfill or it is
transported from the site of excavation to the landfill on conveyer belts. During the
construction of the Brenner Base Tunnel, the transportation of the excavated material mainly
takes place automatically using conveyor belts.

-
6. Geological mapping

The working face is now freely accessible and the geologist has a few minutes to map it. In
the process, he determines what type of rock is present and how the rocks lie, i.e. whether
they dip in a flat or steep manner, whether they are folded or even broken. He uses a special
compass as an aid to measure the angle of incidence and direction of incidence of the rock
structures. At the same time, the strength of the rock, the reaction of the rock mass to the
excavation process and any mountain water infiltration are also documented. The mapping
report created from this – with sketches and photos - serves as the basis for the selection of
appropriate supporting measures.

7. Securing

The quickly drying shotcrete used for this purpose in particular enables a cavity-free
connection of the securing mechanism to the rock. Depending on the type of rock, a variety
of securing measures can be implemented: wire mesh, tunnel arches, stakes or so-called bolts,
which can be driven into the rock.

8. Inner shell

Since securing with shotcrete, bolts, etc. only provides a temporary securing solution, a
permanent inner shell is subsequently installed, generally upon completion of the excavation
procedure. A sealing foil is first attached to the shotcrete where water is suspected. The final
concrete coating (inner shell) is only installed after deformations have completely subsided.

1. Drilling

Before the blasting takes place, the drilling rig bores the drill holes – determined in advance
in a blasting plan – in the foremost front wall of the tunnel (working face). The more solid the
rock, the more explosives are required.

2. Loading and blasting

The drill holes are now filled with explosives, detonators are attached to the explosive
devices and the individual explosive devices are connected to one another. The devices
should not explode at the same time, but rather one after the other at specified intervals. Only
when the blast master has ensured that nobody is left in the danger zone can the explosion be
triggered by the blasting machine.

3. Ventilating

The blast causes lots of rock to be flung through the tunnel, dispersing clouds of dust that
then mix with the combustion gases of the explosion. So that the miners can resume work in
the tunnel, the bad air must be removed from the tunnel. This is done by using so-called air-
ducting systems, long steel or plastic pipes, which are attached to the roof of the tunnel and
blow fresh air onto the working face. This gives rise to localized excess pressure and the bad
air is pushed towards the tunnel exit.