Effects of changing water content of clay-content rocks on field cutter consumption rate of roadheaders: a case study of porous ignimbrites

Abstract

The changing formation characteristics during excavation can cause a higher cutter consumption rate (CCR) of mechanical excavators than theoretically estimated before the project begins. This study investigates the adhesive potential of clay-content porous ignimbrites in increasing water content and their effects on the CCR of roadheaders. For this purpose, the actual field CCR data of roadheaders were recorded for ten cold storage caverns (CSC) projects during the excavation in dry and wet conditions. Then, laboratory tests were carried out on the rock samples collected from project areas. CCRs of roadheaders were theoretically estimated based on the Cerchar abrasivity index of rocks using three different empirical models. The laboratory test results showed that increasing water content reduces the abrasivity and strength of the rocks. The theoretically estimated results also showed that CCR is to be less under saturated conditions. However, actual field data revealed higher CCRs for all CSC projects in wet conditions. Therefore, the adhesion potential of rocks in different water contents was analyzed, and positive relationships were obtained between the field CCR in wet conditions and the adhesion potentials of excavated rocks with 15%, 20%, and 25% water content. New equations were developed to estimate the CCR of roadheaders, especially in excavating rocks that have an adhesive potential to cutters, such as clay-content rocks. It has been concluded that for an accurate CCR estimation, more than theoretical calculations will be required, and changing formation conditions should also be analyzed in detail.