Building Spain’s infrastructure since 2001

17 years, 240 tunnels, 2 million metres of forepoling: the shared history of Robit and Hard & Wear Technologies in a nutshell.

Spain is a mineral-rich country with a vibrant mining industry. It is also a country crisscrossed with several mountain ranges, which means road and rail construction often involves the excavation of tunnels. Ever since 2001, these industries have been served by the dynamic duo of Robit and Hard & Wear Technologies. During that time they have been involved in more than 80 % of all tunnels executed in Spain.

Geologically, the Iberian Peninsula is very diverse, and in tunneling work you need to deal with many kinds of complicated terrains: volcanic ash, sand, clay, gypsum, and granite, to name just a few. Advancing a tunnel in a soft ground or broken rock requires forepoling, also known as the tube umbrella method.

Hard & Wear Technologies SA, a leading supplier of forepoling tools, is the distributor of Robit casing systems in Spain. The Robit umbrella casing system allows easy driving of the casing tubes into the ground.

2018 was another busy year for the dynamic duo in Spain. It included the completion of two tunnels along the Madrid–A Coruña high-speed rail line: one in Padornelo in the Zamora province, and one in Cerdedelo in the Ourense province, adding up to a total of 40,000 metres of forepoling.

Late in the year, contracts were signed for two joint ventures concerning work on two metro stations in the city of San Sebastián, in the Basque Country in northern Spain. Initially the contracts cover a total of 3,000 metres, but this figure is expected to increase greatly.

The outlook for 2019 shows no sign of slowing down. Robit and Hard & Wear Technologies have signed Letters of Commitment for the supply of materials for six more tunnels in the Basque Country, serving a new high-speed rail line between Madrid and the French border.

ALL DRILL AND ROBIT: a partnership bearing fruit in Argentina

The Andes, the longest mountain range in the world, have been an abundant source of mineral riches for centuries – so much so that the largest Spanish-speaking nation in the world was actually named after a metal (argentum). Over the last ten years, the mining industry has seen a massive boom in Argentina.

Gold and copper are some of Argentina’s key mineral exports. Cerro Vanguardia, a major gold mine in the Santa Cruz province in southern Argentina, has been using Robit tools, such as Top Hammer and DTH RC, for six years. Customer satisfaction is crucial for Robit, and Juan Padilla, a senior Robit Drillmaster, knows where you need to look.

Feedback from the field

“The real challenge for us lies out in the field, in the hands of drillers and their supervisors. They work hard to achieve their goals, and my mission is to give them the best support so they can meet them”, Juan explains.

On his latest visit to Cerro Vanguardia Juan went right to the front line to hear the drillers’ feedback on Robit products. “Cerro Vanguardia is keen on continuous improvement, and it made me happy to learn that our tools continue to be an excellent option for them”, says Juan.

2018 has been a good year for Robit in Argentina, thanks to their dealer All Drill. Since its founder Ariel Fernandez was already familiar with and impressed by Robit products, the decision to partner was easy to make.

One of the new deals All Drill and Robit have signed took place in Casposo, a gold and silver mine in the San Juan province. 20 days of rigorous testing convinced the contractor of the quality of Robit’s Top Hammer tools. Cerro Negro, a large gold mine located in southern Argentina, has also opened its doors to Robit products.

Seamless teamwork

”I felt super confident about the opportunity to represent Robit exclusively in the Argentinian mining market. When you have one of the key brands in the world to offer, and you get great support from their Regional Manager Alexei Albuquerque and his team, you have all a dealer needs to close good deals”, says Ariel Fernandez.

Mining has still a lot of growth potential in Argentina, and Robit and All Drill are searching for new opportunities around the country. ”We are proud to say that Robit has become a major player in the Argentinian mining market, with very positive feedback from the end-users. This is a great foundation for planning the future and our next steps. It is a result of hard work, time investment, and trust between All Drill and Robit”, Alexei Albuquerque concludes.

Picture: Drillmaster Juan Padilla replacing a bit at Cerro Vanguardia

TEST REPORT – Altyntau Kokshetau quarry, Kazakhstan

Tested tools: Robit DTH hammer and bits
Test location: Altyntau Kokshetau quarry, Kazakhstan
Client’s challenge: Finding an alternative for their existing QL6 DTH hammer: problems with the upper adapter not solved by the manufacturer
Reported by: Andrey Dak, General Director, LLP Robit Kazakhstan

Report:

At the site, Robit Kazakhstan has tested two QL6 DTH hammers, with 171 mm Robit DTH bits. Representatives of Robit Kazakhstan and Robit Russia as well as competitors’ technical specialists were present at the test. Each of 3 drill rigs had drilling tools from different manufacturers.

As a result, Robit hammers demonstrated excellent results, whereas the tested drill bits did not show the best performance. Therefore, Kazzinc acquired a batch of Robit hammers.

Once in operation, quality issues with the acquired DTH hammers arose: the lifetime of some of the hammers was 30 % less than expected. Lifetime expectation is set by the quarry; we accepted the challenge.

We took a customer-oriented approach and invited a technical specialist from Australia to Altyntau Kokshetau. In addition, two upgraded hammers and redesigned 171 mm DTH bits were sent. Using all the test data, we strove to manufacture the best fit for the customer’s ground conditions. The changes mostly concerned the hammer’s cylinder, make-up assembly, the DTH bit’s check valve and buttons. A second test supervised by our local Robit expert was conducted.

Eventually, thanks to our group’s teamwork and our desire to provide the best service, the performance became excellent again – even exceeding the lifetime expected by the contract. The upgraded DTH bits also showed good results, reaching their expected lifetime. The deal was secured.

Kazzinc decided to continue using Robit drill consumables. Starting from the beginning of 2019, a new contract for a batch of DTH hammers and DTH bits was signed.

ROSH PINAH – boosting quality with Robit tools

Geographically, most of Namibia consists of a desert or near-desert plateau. Underneath this arid ground, however, lies a massive mineral wealth.

Namibia’s economy relies heavily on its mining industry: almost half of the country’s foreign exchange earnings are contributed by this sector. Key exports include diamonds, uranium, gold and silver, as well as a wide variety of base metals such as lead, copper, and zinc.

On the edge on the Namib desert in southern Namibia, the Rosh Pinah underground mine, owned by Canadian-based Trevali, has been producing zinc and lead for 50 years, milling some 2,000 tonnes of ore per day. That kind of production volumes pose a challenge to the supply and service of consumable parts – and that’s where Robit SA was able to help Rosh Pinah improve their performance.

“We signed a consignment stock contract for the “GET” (Ground Engagement Tools) with Rosh Pinah in August. It’s a full-service contract, including a management system”, explains Franco Van Deventer, Sales Director for Robit SA.

The two-year contract covers both development and long hole production drilling, as well as “cut and fill” mining.

Better quality through reporting

“Our management reporting system has marked a significant improvement in quality control. Our monthly feedback reports allow our customer to track the performance of our equipment and compare the efficiency and cost. Before our contract this had not been possible”, Franco says.

Picture: Bird’s eye view of Rosh Pinah. (Image: Hp.Baumeler)

TEST REPORT – Greenbushes, WA, Australia

Tested tools: Robit C51 bits, rods and shanks
Test location: Greenbushes, WA, Australia
Test date(s): Since May 2018
Client’s challenge: Top Hammer drill bit performance in the hard ground conditions of a lithium mine
Reported by: Mark Thwaits, Technical Sales Representative, Robit Australia

Report:

We began trialling at Greenbushes, the world’s largest lithium mine, in the spring of 2018. They are currently using our C51 Retrac bits monthly, principally the 115 mm Drop Centre Retrac (DSR) and Flat Face (FF).

Through frequent site visits we have developed a very positive relationship with our customer where information has become a two-way street. For example, it was our suggestion to try the DSR bit as a substitute to the FF, as we had seen it perform extremely well in similar conditions elsewhere.

We have secured their TH bit business off the strength of Robit’s bits. The life and performance of our bits has been praised by the client. They easily outlast the competition – and with the extremely hard and abrasive ground associated with lithium mines, the increased life of Robit bits has been greatly appreciated.

In today’s intensely competitive market, Australian drilling contractors have become far less inclined to sign contracts, preferring to give monthly business to the supplier who performs and provides value regularly.

Our top-performance bits have allowed us to continually do monthly business with the client, and we continue to trial new products in an effort to supply all their drill string needs, e.g. rods and shanks, at Greenbushes as well as other sites the client operates on.

FIJI – A new dot on the Robit world map

“Tranquillity” is a word that easily comes to mind on Fiji, the island country sitting almost 3,000 kilometres away from its nearest continent Australia. An ever-growing number of visitors are feeling the allure of its white sandy beaches and coral reefs, making tourism a key driver in Fiji’s economy today, along with agriculture and fishing.

Fiji has also been blessed with wealthy mineral resources, with gold and silver representing some of the country’s largest exports. So-called Development Minerals – minerals mined, processed, and used locally in construction, infrastructure, and agriculture – also play an important part in Fiji’s growing economy. This year, the very first Fiji Development Minerals Trade Fair and Conference was held in Suva, the capital city of the republic. The event, hosted by UNDP (United Nations Development Program) and MRD (Mineral Resources Department of Fiji), also helped Robit add a new dot on its global business map.

“It was a great opportunity to network, meet key players in the Development Minerals industry and get a better understanding of the opportunities and challenges facing Fiji’s Development Minerals market”, says Technical Sales Representative Richard Epstein, Robit Australia.

“Fiji is diversifying its economy and improving its civil infrastructure, which should have a positive impact on the quarrying and civil construction industries. This means there is an opportunity to gain a strong foothold in the market. To that end, we are partnering with Vinod Patel, Fiji’s largest hardware and construction materials company to help establish our presence in the market and provide much needed local support”, Richard explains.

Golden prospects

Richard also visited the Vatukoula Gold Mine, the largest and oldest mine in Fiji. It has been operating for over 75 years and has produced over 7 million ounces (approx. 200,000 kg) of gold during this time. “Vatukoula spends about half a million euros per year on Top Hammer drilling consumables, but this is likely to increase in coming years as they have plans to expand development of the mine and double production”, Richard says.

“Robit’s threaded jumbo bits were tested underground at Vatukoula, with promising results. A new gold mine, Lion One, is due to come on line in 2019. Add to that our partnership with Vinod Patel and the contacts we have established through them with key players in the quarrying and extractive industries, and we should be well positioned for future opportunities in Fiji.”

FOREPOLING through the Colombian Andes

“4G”, or Fourth Generation, typically refers to a mobile network. In Colombia, it’s also an abbreviation for the largest and most ambitious road infrastructure program in Latin America.

Colossal investment

Colombia’s 4G program involves 7,000 kilometres of roadway – a more than $ 50 billion investment divided into more than 40 projects. Part of a master plan to place Colombia at the forefront of Latin American economies, its aim is to step up regional development and promote foreign trade by reducing transport times across the country.

4G has marked a massive boost for the construction industry in Colombia, a country traversed by no less than three branches of the Andes. In addition to 1,400 km of four-lane highways, 4G includes 141 tunnels (125 km in length) and as many as 1,300 viaducts (146 km in length).

One of the 4G projects, called “Autopista Conexión Pacífico 1”, is the construction of a highway between Medellin, Colombia’s second largest city, and Bolombolo, in central northwestern Colombia. It includes two tunnels, Sinifaná and Amagá.

Partnering in a competitive market

Sinifaná, consisting of two parallel tunnels, 1,6 km each with a cross-section of 100 m², is contracted by the Spanish-owned OSSA. They are drilling with Robit tools, supplied by SESCO, Robit’s exclusive dealer of tunneling tools in Colombia. Through SESCO, Robit entered the Colombian market three years ago.

“Entering Colombia was a real challenge since the prices were very depressed. We are by no means the cheapest in the market, but thanks to the durability and fast performance of our tools, we have been able to demonstrate that Robit is the most economical cost-per-meter choice”, says José Cisneros, Sales Director for Robit SAC.

In addition to providing tools, Robit consults the main designers in the projects, and provides training to drillers to ensure optimal use of the various tools. In forepoling, the Robit system can offer key advantages for the driller. It’s easy to install, couplings between sections are very fast to make, and the durability helps minimize downtime.

Impressive performance

“We have seen performance that has not been reached in this country before: 13,000 m for rods, 25,000 m for couplings, 24,000 m for shanks, to name a few. Add to that the superior penetration rate of our drill bits, and our client has been able to reduce execution times up to 40%”, says a pleased José.

The Sinifaná tunnel is expected to be completed in September 2019, and the Amagá tunnel two years later. Once finished, the Pacífico 1 highway will cut the travel time from Medellin to Bolombolo in half.

Picture: The Cauca river crosses numerous towns in the Department of Antioquia, including Bolombolo.

Ylimäki quarries with more than 30 years of experience

Markku Viitanen sits in the cab of the drill rig, wearing protectors on his ears and expertly operating the joystick. An echo sounds out from the surrounding forest as Robit’s drill bit is hammered into the rock. It’s a typical day at the office for Markku. And the quarry, located in Karstula, central Finland, is a typical work site for Markku’s employer, Louhintaliike Ylimäki.

This is Markku’s third day of drilling at the quarry. Red borehole plugs in the snow mark the holes that have already been drilled. The 83-millimetre bore holes are being drilled to a depth of 10–12 metres, down to the bottom level of the quarry. Half of the roughly 1,600 metres to be drilled has already been completed. As a quarrying site, this one is of a moderate size, at 25,000 tonnes. Large sites can be in the range of 100,000 tonnes.

When the boring work is completed, the shot-firing team takes over. An explosive, such as ‘Kemiitti’ – an emulsion explosive developed for open-cut excavations – is loaded into the hole, and a second explosive is placed on top as a guarantee. The area is blasted. A hydraulic hammer is used to break any oversize rocks into a crushable size. At this point, Louhintaliike Ylimäki’s work at this quarry is finished; another contractor will take over the crushing operations.

– Ylimäki’s main areas of operation are western Finland and northern Ostrobothnia, and its main customers are aggregate suppliers and crushing companies,” says civil engineer Matti Pitkäjärvi, who supervises the work at the company’s quarrying sites. Blast rock is also produced at the Karstula quarry, to be crushed for infrastructure construction or concrete or asphalt production, for example.

Industry leader after three decades

Louhintaliike Ylimäki Oy is a family business that was established in 1983. The company started out small, with rented equipment, but over the decades has grown to become the largest rock extractor in the region. With about 20 employees and a solid equipment base, Ylimäki blasted five million tonnes of rock in 2014. A second generation of Ylimäkis – brothers Matti and Mikko – now run the company.

How does a regional operator competing with major national companies survive?

– We’re doing well. We have a lot of long-term, established customer relationships. With adequate and modern equipment, expert staff and reasonable prices, the customers are happy. We don’t have to fight for every site, says Matti.

Annual contract speeds up processes

Louhintaliike Ylimäki has been drilling with Robit bits for a long time. And as Robit’s Sales Manager, Mika Mankinen, recounts, co-operation between the two companies was taken one step further in 2015: they entered into an annual agreement covering not just drill bits, but also shank adapters and drill rods.

– It came down to the price/quality ratio or, to put it in more concrete terms, cost per drilled metre. The Finnish aspect is also an important criterion,” says Matti, elaborating on how the deal came about.

The annual agreement will simplify the purchasing process, and drilling equipment will come at a fixed, competitive price. A volume-based price saves the customer not only money, but the headache of having to negotiate a price separately for every construction site. The process is as simple as can be: Matti makes an order and Robit delivers the agreed amount of products.

– The co-operation between Ylimäki and Robit has for years been practical and smooth. We can always call Mika if new requirements or requests arise during a drilling job, says Matti. – Robit is always able to flexibly respond to changes or development needs, Mika adds.

For this western Finland quarrying company, business is going well. When asked about the bigger challenges facing the company, Matti pauses to think about it.

– In this business in general, the challenge is the unequal distribution of the work load – the ups and downs of the quiet and busy times of the year. But we don’t experience that. Our fleet of equipment is always in use, says a pleased Matti.

Widening Hong Kong’s traffic bottlenecks

Hong Kong is one of the world´s most densely populated metropolises. The neighbouring Shenzhen, founded in the 1980s, is the fastest growing city in China. As a reminder of the time when Hong Kong was under British control – no more than 20 years ago – there are still control points between the two cities.

The existing six land control points are major bottlenecks due to the massive traffic. That’s why the Hong Kong government launched a big development project in 2014 to open a seventh road connection. It involves a tunnel excavation where Robit’s tools have been put to the test.

Different rock, different methods

To accommodate the high volume of the traffic, two tunnels are being built side by side, one for each direction. Excavation for the 4.8-kilometre-long tunnels has been started at both ends, using different techniques. TBM is the method of choice at the north end on the Shenzhen side; at the south end the rock is so hard that the drill & blast method yields results faster and more efficiently.

Dragages Hong Kong, the main contractor, organized a bidding tender for the drill & blast work. Robit’s tools, represented by Merman Technology, proved to be the most competitive. The drilling work is performed by Robodrill, using tunneling jumbos and Montabert drifters.

– Before reaching the hard rock, there was a great deal of forepoling. Some of the ground was more challenging and softer than we expected, says Antti Mäkinen, Robit’s Sales Director for Southeast Asia.

– Robit supplied the ring bits, pilots and casings for the forepoling stage, as well as the tools – shanks, couplings, drill rods, and button bits – for drill & blast.

Smooth sailing for all parties

– I’m happy to say this has been a successful project from the very start. Our client has been extremely satisfied with Robit’s services, deliveries and products. I would also like to give my warmest thanks to Mr. Jacky Lee, the CEO of Merman, who has been providing excellent support to our client throughout the entire project.

In a large scale project like this, what have been the biggest challenges so far?

– As far as our tools are concerned, we have faced no problems. The major challenges have more to do with organization than technology, precisely because of the vast scale of it all. Planning the delivery schedules for all the various delivery points has taken a lot of effort, Mäkinen explains.

– Actually, this has been a learning experience for all of us. Cooperation with Dragages and Robodrill has been very fruitful. We frequently visit the work site, evaluate the processes, methods and tools, in a joint effort to make things run ever more smoothly.

The learning experience underneath the hills of northern Hong Kong continues. A staggering 770,000 total drill metres with Robit’s tools is to be completed by the end of 2017. The new Boundary Control Point is scheduled to open a year later.

Billion-euro Tripla project to transform Pasila

The Pasila area holds a major role in the vision for a future Helsinki: there are plans for it to be the new heart of Helsinki. One of the key words for the plan is ‘Tripla’. Upon completion, the billion-euro construction project, massive on Finland’s scale, will connect East and West Pasila. Offices, flats, a shopping centre, a public transportation hub, hotels and other services will emerge within a three-block area. Tripla’s developer is YIT.

Completing Tripla will naturally require comprehensive foundation engineering work. The lowest level of the block will be a parking facility on which the foundation work was begun in April 2015. It was decided that the surrounding retaining wall would be implemented as an RD-pile wall because it can tolerate loads, allows relatively rapid installation and has accurate dimensions even in challenging soil conditions. The difficulty is ensuring the watertightness of the RD-pile wall and significant amounts of slurry can accumulate during the drilling phase.

Strict demands, challenging conditions

It was known from the very beginning that the project was going to be challenging. Developers were faced with backfill full of boulders, combined with construction waste. Much of the backfill was saturated with badly polluted liquids. The nearby busy railway yard posed restrictions of its own.

The quality criteria were also strict. The design age of the structures, including factors such as corrosion resistance and watertightness, were specified to be 200 years instead of the more usual 100 years. The location and incline demands on the RD-pile wall were also relatively strict.

A three-company consortium was responsible for the construction of the retaining wall on behalf of the main contractor YIT. The main contract for the piling was carried out by Keski-Suomen Betonirakenne, the drilling by the Estonian subcontractor Fort Ehitus, with Ilmi Solutions functioning as the consultant. Robit supplied the drill bits for all of the drilling. YIT also uses Robit’s Top Hammer equipment at the worksite.

Inside the bedrock in three phases

There were three main phases in building the retaining wall. During the first phase, the piles were vibrated through the loose clay and sandy soil into the hard ground moraine. During the second phase, the vertically installed piles were emptied with an auger, from the clay layer all the way to the tip of the pile. In the third phase, the piles were drilled through hard or extremely hard moraine into the bedrock to a maximum depth of 1.5 m. Robit’s opening winged bit was selected for down-the-hole drilling. Senior Specialist Kari Juntunen was onsite to supervise on behalf of Robit.

“The alternative for the winged bit would have been a traditional ring bit. The subcontractor took a bit of a risk when selecting the winged bit because there were some tricky spots in the bedrock. We at Robit were still making further improvements to the bit during the project based on tips given to us by the subcontractor. Everything turned out all right in the end and the costs for the customer were lower than they would have been with a ring bit,” says Juntunen.

Trust and seamless collaboration

“The job was completed on schedule with excellent results. I have to take off my hat to the Fort Ehitus guys. We had a strong trust in them to begin with: I had worked with them before on a piling project and became impressed by their expertise,” says Juntunen. According to Jouko Pasanen from Ilmi Solutions, which oversaw the worksite, the co-operation was seamless.

“Despite the challenging worksite we barely ran into any problems. Once my phone rang at nine in the evening. A subcontractor told me that a bit had broken, what should they do? We had agreed that there should always be spare bits available. I promised to be there at six the next morning with a new bit. And I was. The subcontractor thanked me and said that no other supplier could have done it,” says Juntunen with satisfaction.

The retaining wall was completed on time before the new year. The work at Tripla is still far from finished, however. The first cars will not be able to park in the garage set off by the retaining wall until 2019.

Drilling of Tripla’s retaining wall
• RD700 pile elements
• D711 x 14.2 RM/RF interlocked piles, 746 pcs
• Robit DTH SF 711/16 winged pilot bit
• Length of piles 5.5–33.5 m
• Altogether 16,335 m of piles
• Drill rig with a 40-m mast

Deep in the heart of the Iron Range

U.S. Route 53 traverses the state of Minnesota, from Duluth at the southwest end of Lake Superior, ending 240 km later at the Canadian border. On its way it crosses the socalled Iron Range, an area rich in iron ore, which has served the raw material needs of the American steel industry since the 19th century.

Today, the ore deposits in the Iron Range are far from depleted. On the contrary, just south of the city of Virginia, a mining company is in the process of expanding an old mine pit. As it happens, Route 53 currently runs right on top of the planned expansion and needs to be relocated. The main element of the relocation project is a new bridge across the neighbouring Rouchleau Mine Pit.

Minnesota’s highest bridge

Abandoned in 1977, the Rouchleau Pit has since served as a tourist attraction. The new bridge will be 335 metres (1,100 ft) long with an elevation of 61 metres (200 ft), making it the highest bridge in elevation in Minnesota.

The construction of the foundations of the bridge started in December 2015 with the installation of 30-inch piles. Drilling deep piles into very hard ground with a high iron content is quite a challenge. Due to strength requirements the holes need to be drilled 12 metres into hard rock – way deeper than at a typical bridge construction site.

Veit USA took the challenge of the drilling work. For the casing advancing system, Veit considered two suppliers.

Tight time schedule

– Veit had heard about Robit through the industry grapevine. They contacted us and presented their two challenges: deep piles in a mine site and a very tight delivery time, says David Delorme, General Manager of Robit Inc.

– We were selected because we were able to supply on a very short notice. We designed a system for the conditions Veit described, and delivered in six weeks – exactly as promised. What about the drilling work itself – how has it been coming along?

– This is the biggest piling job for Robit Inc so far. Despite the technical challenges posed by the rock and the length of the piles, we haven’t faced any major problems, and we are well within schedule, David says.

The installation of the 30-inch piles is set to be completed by mid-March, 2016. Work on the site continues at a swift pace though. The new bridge spanning the Rouchleau Pit should be open to traffic in late 2017 – offering a magnificent new lookout spot for travellers on Route 53.

Bridge construction for Route 53 relocation, Virginia, Minnesota
• 5 x 762 mm (30”) QL200s pilot bit
• 35 x 762/12,7 (30”) mm DTH RoX+ HD (Heavy Duty) ring bit
• Bermingham Reverse Circulation (RC) drill tube system
• Bermingham 50 m lead
• 4 x 25 bar compressor + oiler
• Drill hole depth: 53 m, into hard rock 12 m

Strong hands in the Australian soil and market

Rolling grass plains and awesome rock faces rising up behind them – it’s like a scene out of a western movie. A monotonous pounding can be heard beyond the mountains. Yet we are not in the prairies and the bangs are not from revolver guns. The source of the noise is a Robit Hyper 181 Down-the-Hole (DTH) hammer striking deep into Australian soil, more precisely the mineral deposits of Narrabri.

Lucas Drilling Services, part of the Australian AJ Lucas Group Limited, is more or less halfway through a major coal mine project at the Whitehaven Coal company’s Narrabri North mine. They have drilled around 50 holes down to the bedrock, the deepest ones extending to 240 metres. Around 70 holes remain to be drilled.

Lucas Drilling selected for the project T120XD and Schramm T685 drill rigs equipped with the Robit Hyper 181 DTH hammer. The contractor requested a brand-new 18-inch Robit 181 from the local Robit dealer in Queensland, Dilong Drilling, with whom Lucas Drilling had already successfully collaborated for several years. Angus Simmons, Drilling Supervisor at Lucas Drilling, describes the operation as follows:

“We’ve used our Robit Hyper 181 DTH hammer in a Schramm T130XD drill rig for more than fifty jobs now without a single problem. Some time ago we upgraded our equipment with new Robit Hyper 181 DTH hammers and we’re now using them also in a Schramm 685 rig. We use the Hyper 181 model for hard and brittle basalt and other volcanic types of rock down to depths of 64 metres.”

After that, a 14” DTH hammer will go further down to 200– 220 metres to reach conglomerate of ancient petrified gravel. Finally, a 9” DTH will hammer away the rest, at a depth of between 220 and 240 metres.

AJ Lucas Group, listed on the Australian Securities Exchange (ASX), has more than 60 years of experience in the sectors of energy, water & waste water, resources and public infrastructure. Headquartered in Brisbane, Lucas Drilling has broad experience in engineering services, horizontal directional (HDD) drilling, drilling for oil, gas and coal, surface-to-inseam (SIS) drilling and many other areas of special expertise, making them one of Australia’s largest and most diversified drilling service suppliers.

Dave Crane, sales coordinator with Robit, spared no praise for the quality of work at the Narrabri North mine:

“The workmanship at the mine is solid testimony of Lucas Drilling’s know-how and experience, of Dilong Drilling’s technical support and special expertise as well as of the power and reliability of the Robit Hyper 181 DTH hammer. It’s truly a winning combo!”

Picture: The Schramm drill rig uses three different-sized hammers and drill bits for drilling a 240-metre-deep hole. Lucas Drilling Services relies on Robit’s DTH drilling equipment in demanding conditions.

AUSDRILL’S SUCCESS STORY – “Blood, sweat and tears”

Developing DTA’s drilling consumables to their current level of excellence was a long and hard learning curve. Looking back, it was all well worth it. These days Ausdrill is the one to raise the standards to its competitors.

David Hart, Area Manager at Ausdrill Ltd, recalls being one of the first customers to use DTA’s products:

“When I look back on the whole process, I realise now that this could not have been done without some ‘blood, sweat and tears’, and also not without close co-operation between Ausdrill’s and DTA’s personnel. The tight relationship between Ausdrill and DTA was a stroke of luck! DTA was able to make improvements and changes to the products on short notice, and Ausdrill was able to trial those changes just as fast. This made the whole experience less painful than it could have been. There was some frustration, but also satisfaction along the way to producing and developing a product that today will hold its own against the competition. It was a great learning experience!”

At the Super Pit operation we are required to drill approximately 190,000 metres per month. The size and depth of the holes vary, as does their purpose; we have 20,000 metres of grade control holes, 50,000 metres of probe holes and the remaining 120,000 are blast holes. Grade control holes are designed to define the ore body boundaries within each bench prior to blasting. The blast holes are loaded with explosives and the blast fractures the soil into pieces suitable for loading and hauling. Probe holes are designed to define the border
between safe ground areas and potentially unsafe areas, where old underground workings are present.

“Prior to Kalgoorlie becoming the ‘Super Pit’ in the late 1980s, there were many different gold leases owned by different prospectors and lease holders in the area. The majority of the individual gold operations across the Golden Mile (now the site of the Super Pit) were underground operations. The combined length of the underground workings is over 2,000 kilometres, and the size of each mine varies according to the era and methods used at the time. In the 20-plus years that Ausdrill has been working in the Super Pit, I know of one case where a drill rig partly fell into some old underground workings. It couldn’t be retrieved, so it was blasted and dug up with the rock. The operator survived the incident,” Hart says.

Ausdrill uses DTA products at all of their 10 drill and blast sites in Australia and also on some exploration division drill rigs. The most common products are the 4- and 6-inch blast hole hammers and bits used for drilling holes from 115 through to 165 mm. We additionally use a few 7- and 8-inch hammers for drilling hole sizes from 203 to 251 mm and reverse circulation hammers for grade control and RC exploration.

The manufacturing business in Australia is very challenging financially, and many companies have either left Australian shores and set up in India or China to reduce their costs or closed up shop altogether.

“Continuous improvement will be required to keep DTA’s products in the markets and to meet the competition headon,” Hart believes. “A lot of competition stems from the price dumping due to hand-made products from China and India.”

DTA uses robotic machines to contain labour costs, while still maintaining high reliability and proven quality in production. While it is apparent that more and more competitors are entering Ausdrill’s market, the company is determined to stay focused and have fun along the way. It is “cost per metre and reliability” that will win out in the end, Hart concludes.

Picture: KCGM Kalgoorlie Super Pit – Ausdrill has been the production drilling contractor at the Super Pit for many years.

Uptime – from necessity to opportunity

Uptime Earthmoving Solutions Inc. (Uptime) was established in 2016 by engineers and technical people of Delta Earthmoving, Inc. a leading contractor in the Philippines specializing in earthmoving, quarrying and mining.

Delta was executing nine quarrying contracts and one major open pit mining contract, extracting a combined 4.5 million metric tonnes of materials per month, each one requiring drilling operations. Mr. Geoffrey Omengan, Delta’s EVP for asset management then observed that in spite of the operations’ results showing the obvious cost efficiency of Robit products over other brands, the company continued to use an assortment of brands. With this observation, Mr. Omengan envisioned not only expanding the utilization of Robit products but also distributing the brand in the Philippines. Not only would sustainable drilling solutions be provided to Delta but business opportunities would also arise in distributing products which have shown a distinct advantage over other brands based on actual applications. Thus, Uptime
was created with Mr. Geoffrey Omengan at the helm.

On the other end, Binn Lim, Export Manager of Robit Korea, had been waiting for years for the opportunity to introduce the Robit brand to Delta. As fate would have it, Mr. Lim and Mr. Jimmy Omengan, a director of Delta, crossed paths during the Bauma Expo in Munich, Germany in 2016. The two did not waste time discussing the availability of Robit products in the Philippines, which quickly graduated into Uptime’s possible dealership and distribution of Robit products. This would pave the way for further discussions between the two parties and as the adage goes, “the rest is history”.

Less than a year from its establishment, Uptime has gained tremendous momentum in developing Robit as a major player in the Philippine market. The use of Robit products has expanded beyond Delta to other drilling contractors. Furthermore, Uptime was able to confidently conduct drill testings for several significant players in the Philippine mining industry. The results have been encouraging and Uptime foresees a significant growth in the market for Robit.

Picture: Rusialda (Uptime), Binn Lim (Robit Korea), Bryan Lumongtad (Uptime).

Hydro power from the Himalayas

Starting some 4,000 metres high up on a Himalayan glacier, The Alaknanda River winds its way down towards the south through the state of Uttarakhand, gaining momentum, finally meeting with the Bhagirathi river to form the mighty Ganges. Some of that momentum will be harnessed by a hydroelectric plant, now under construction in the Chamoli district in Northern India.

The 444 MW hydropower construction project includes a diversion of the river into a headrace tunnel and a diversion dam of 65 m height across the river. This will create a gross head of 237 m for power generation.

A project this size requires also a number of adits, or access tunnels, to be built. The ground conditions for tunnelling work has proven to be quite challenging: the TBMs would have to drill through loose soil mixed with large – or small – boulders made up of very hard quartzite.

Machino International was selected to supply and install the piperoofing system for the TBM entry adit with Robit’s tools.

– We had heard a lot of positive feedback about Robit’s piperoofing system from previous projects, such as the IL&FS Kiratpur Ner-Chowk highway tunnel and the IRCON railway tunnel at Jammu & Kashmir. Also, Robit’s Sales Manager S.K. Back paid a personal visit on-site to meet our client and made a convincing case for Robit, says Director Vibhore Agarwal, Machino International.

Thanks to the timely supply and high quality of Robit’s ring bits and pilot bits, the goal of installing the 12-metre casing system was reached in time. Once completed, the hydroelectric plant will significantly improve the supply of electricity in the area by providing clean, renewable, low-carbon energy.

Espoo waters to be treated in a massive cave

Playing a round on Espoo Golf’s green fairways, you would never guess that right next to the golf course, under the Blominmäki rock, a massive excavation project is underway: the construction site of a new wastewater treatment plant. Once completed, the plant will process the wastewater of over 400,000 residents.

Espoo is building the new plant to prepare for an increase in its population. The plant will be equipped with the best modern technology which will improve treatment results. Energy efficiency is another design feature: the plant will produce more than half of the electricity it needs itself. It will also produce heat in excess of its needs.

The contract was awarded to Lemminkäinen Infra. Robit will supply all the drill bits and some of the drifter shaft adapters and rods to the construction site.

– Robit’s assets in the competitive bidding process were full service, delivery reliability and uncompromising quality, says Project Engineer Jarkko Meriläinen from Lemminkäinen.

During the first months of the project, Robit and Lemminkäinen worked on product development to find the most suitable drilling tools. Before long, their co-operation resulted in an optimal wear part maintenance cycle during excavation. Robit’s sharpening service ensures that operations can continue uninterrupted.

– It’s not about the unit price of a product, say, a drill bit, but about the life cycle cost. When co-operation with the drillers is smooth and maintenance flows like clockwork, considerable cost savings can be made, comments Robit Sales Manager responsible for the project.

A whopping 900,000 cubic metres of rock will be excavated at Blominmäki in total. The excavation work will be completed during 2017, followed by the actual construction work. The new plant will go on stream in 2020.

New motorway in Macedonia straightens the bends

In Macedonia, the verdant heart of the Balkans, narrow and winding roads hug the mountainsides making journeys by car excruciatingly slow. The situation is about to change, though, through massive investments in infrastructure.

The single largest road building project underway in Macedonia is the 57-kilometre stretch of motorway between Kicevo and Ohrid, a popular lake-side city in the southwest corner of the country. The project employs 1,200 people and 550 machines. The EUR 375 million investment project is financed by Sinohydro, a Chinese state-owned company and the main contractor of the project.

A twin-tube tunnel with two lanes in each tube will be built through the Preseka mountain, totalling four kilometres in length. Traffic will travel in one direction in each of the tubes.

To an extent, the tunnelling work will be carried out the traditional, manual way by around two to three hundred employees, while the rest of the excavation work will be handled by tunnelling jumbos. The local subcontractor for the project is Avtotehna d.o.o. Skopje, which is in charge of procurement and the maintenance of the equipment and machinery. For forepoling, Avtotehna chose Robit’s tools. The criteria for the decision were clear.

– Robit clearly outperformed its competitors in the tests. With Robit’s products, the drilling of one cross section equalling 39 holes took 30 hours in contrast with 48 hours achieved by the best competitor. There are several reasons for this: Robit’s casings are thicker, the casings’ threading is superior, and as a whole, the products are stronger and more reliable, says Vladimir Ovcarov, Manager at Avtotehna.

Robit has guaranteed a constant supply of wear parts.
– It is all about customer service. By listening to the customer and making plans together with them onsite, we are able to estimate what products and how much of them will be needed at the site over the next couple of months, and most importantly, we are also able to deliver on those needs. We dispatch a truckload of products every week, Robit’s Sales Engineer Rasmus Sokura says.

– Competition in this field is stiff. You have to be prepared for surprises and risks and be able to react quickly. We have proven from the get-go that you can always rely on Robit. We have since also managed to gain a foothold in the Balkan mining sector, Rasmus adds.

Avtotehna is also very happy with Robit.
– Our co-operation with Robit has run smoothly. They listen to our wishes and offer flexible, quick service 24/7. This is something that large, rigid organisations have not been able to provide, Vladimir says.

Deep inside the Preseka mountain, tunnelling work will continue for over a year. If the project stays on schedule, the motorway will be completed in 2018, cutting – to the delight of Macedonian motorists – the travel time between Kicevo and Ohrid in half.

ROBIT’S ROX+ 114,3/10 SYSTEM FOREPOLING PRODUCTS IN MACEDONIA:
• Pilot bits
• Ring bits (welded to casing)
• Extension casings and end casings
• Grouting plugs/end caps with ball valves
• Drifter shank adaptors and rods

Picture: Planning and scheduling everyday operations at the jobsite: Avtotehna d.o.o., Sinohydro and Robit.

Munch Museum rises from the sea

Edvard Munch was an incredibly prolific artist. He willed 28,000 of his works – paintings, sculptures, and photographs – to the city of Oslo. It had long been clear that the old Munch Museum was too small to house the collection. A new one is now being built on water in Bjørvika bay in downtown Oslo.

There was a long and heated debate about where the new Munch museum should be built and what it should look like. In 2008 the city of Oslo announced an architectural competition, and the following year a proposal called Lambda, by the Spanish architect Juan Herreros, was declared the winner.

Initial controversy

As is often the case with contemporary architecture, Lambda’s bold design and size met with some resistance. It was considered strange shaped and too tall for its surroundings. After years of a political tug-ofwar, the construction work finally started in 2016.

The job site was not the easiest possible either: Lambda was designed to rise directly from the sea. That meant a massive piling project for the contractor Hallingdal Bergboring. Robit, having been in close cooperation with Hallingdal for years, was selected as the provider of drilling tools for the project.

Custom-made drill bits

Old seaports are often challenging for piling jobs. The bottom of Bjørvika was filled with silt, large boulders, wooden piles from old dock, et cetera. The bedrock underneath them, on the other hand, was very hard. For these reasons Robit and Hallingdal designed the optimal drill bits in cooperation.

Location in the city centre was another challenge. The famous Oslo Opera House sits right next to the job site; one had to make sure that its foundations remained unharmed while drilling up to 12 metres into the bedrock. This was achieved by using Robit’s DTH-RoX+ FC (Flow Control) pilot bits.

16 kilometres of piles

For the foundations of the Munch Museum, some 16 kilometres of piles were drilled, 311 piles altogether, the thickest being 711 mm in diameter. Some were drilled on solid ground; others from a drilling platform floating on the bay. In these circumstances, drilling work takes a lot of skill.

– When you’re on the platform, controlling a machine that’s thumping on the rock 50 metres below you, you need to keep your eyes, ears, and touch on full alert, says Hallingdal’s operations manager Sverre Bjella.

Despite the difficult conditions, no major surprises or problems were encountered. The piling project was finished on time in October 2016. In addition to Hallingdal, Robit’s Senior Specialist Kari Juntunen extends his thanks to other parties involved.

– Our agent Norsk Pumpeservice was responsible for the storing and technical service of the drilling equipment, and did a great job. There wasn’t a single gap in the supply of consumables on the job site, Kari says with content.

In October 2016, Princess Mette-Marit laid the ceremonial foundation stone for Lambda. The imposing, glass-faced 12-story building is set to open its doors to the public in 2020.

Robit puts down roots in the Middle East

In late 2016, Robit took a step to expand its foothold in the Middle East by establishing a sales company (Robit Plc – BFC) in Dubai, the largest city in the United Arab Emirates. The new sales company is led by Export Manager Juhani Sivenius.

What are the starting points for the operations in the Middle East?

Considering the size of the market, Robit’s sales in the area have been modest to date. The journey is only just beginning. We are currently focussing on presence to enhance visibility, and on availability, which is indispensable for growth. So we have a lot of footwork to do. We have achieved a few successes, which creates a good foundation for the future.

Tell us more about the successes!

Stevin Rock, the area’s largest quarry located in Ras Al-Khaimah, is my customer. Robit has a two-year agreement for the supply of wear parts for their entire DTH line. Drilling in Tel Aviv’s metro tunnel project in Israel will start during the summer using our forepoling tubes. The Turkish market is already looking good, thanks to my colleague.

What is Dubai like as a business environment?

The culture is quite colourful because of the wide variety of nationalities. Taking care of administrative matters can be a little slow and bureaucratic, but you get to used to it. My goal is to turn the operations in the area around as soon as possible by acquiring end customers and expanding the distributor network.

Picture: Cliff McGowan (DTARobit) giving instructions to Bharadwaj Ventaraman (Delta Corp Global, right).

A new Goliath rising up in Turku

The Finnish shipyard industry has wind in its sails. This is evident at Meyer’s Turku shipyard whose order books are full well into the 2020s. To ensure additional capacity, a new gantry crane – the largest in the Nordic countries – is being erected at the shipyard.

Shipbuilding in Turku began at the mouth of Aurajoki river almost 300 years ago. The newest shipyard was built in Perno in the 1970s, and since then a long line of tankers, cargo vessels and, above all, passenger ships and luxurious cruise ships have left the shipyard to sail the world’s seas.

Right from the start, the shipyard’s skyline has been dominated by a 600-tonne gantry crane rising to 105 metres. It is used to lift the ship sections, the size of small blocks of flats, manufactured at the shipyard into the basin to be joined together.

Lifting capacity doubled

As the shipyard saw its order book fill up and the ships growing in size, the need for additional capacity became apparent. That is why the construction of a new, even sturdier crane is now being planned. It will have a lifting capacity of 1,200 tonnes, i.e. twice that of the old crane. The new crane will be 122 metres high, thus also increasing the lifting height by more than 10 metres.

Three DTH hammers have been busy at the shipyard before the crane construction begins. In the past, the plates coming from the steel mill were stored outdoors; now a hall is being built specifically for them. Hundreds of piles measuring 170 and 220 mm have been drilled for its foundations in demanding conditions.

– We chose the suitable methods in collaboration with the contractor to make sure that everything goes as planned. And we succeeded: the piling proceeded within schedule and the deliveries arrived on time, says Robit’s Senior Specialist Kari Juntunen.

Old and new work side by side

In summer 2017, the piling work for the foundations of the new gantry crane has been started, and the erection of the crane will begin at the turn of the year. The old crane will not be scrapped – it will just be moved a little further backwards on the rails. As of summer 2018, the skyline of the Turku shipyard will be dominated by not just one but two Goliaths.