The challenge

Underground mining infrastructure must function safely and reliably in a demanding environment. In this case, the client needed to protect critical ventilation while allowing underground mining vehicles and maintenance equipment to continue operating above the structures.

The project was further complicated by restricted access, limited working space, difficult logistics and the need to minimise disruption to ongoing mining operations. Conventional construction methods were less suitable in this type of underground environment, where transport, installation and site activities must be carefully controlled.

The client therefore needed a solution that combined structural reliability, practical installation and long-term durability.

The solution

ViaCon supplied a series of corrugated steel structures used as protective covers for underground ventilation tunnels and associated infrastructure.

The structures were designed as modular systems, allowing the components to be transported underground through existing shafts and tunnels and assembled directly at the point of installation. This made the solution practical to deploy within the constraints of an active mine.

To simplify the installation process further, the structures were placed on specially designed steel foundations. This eliminated the need for conventional concrete foundations and removed wet works from the underground construction process.

Once installed, the structures provided robust protection for ventilation infrastructure while also carrying operational loads from underground vehicles and equipment. The soil-steel system combines the corrugated steel shell with the surrounding backfill to create an efficient structural solution with high load-carrying capacity and good tolerance to ground movement.

The ViaCon advantage

The project demonstrates the advantages of corrugated steel structures in underground mining applications.

Compared with more conventional construction methods, ViaCon’s solution offered:

• protection of critical ventilation infrastructure,
• reliable structural performance under underground operational loads,
• lightweight modular components suited to transport through shafts and tunnels,
• rapid assembly in confined underground spaces,
• no need for conventional concrete foundations,
• reduced construction complexity and installation risk,
• minimal disruption to ongoing mining operations,
• long-term durability in demanding underground environments,
• and low maintenance requirements over the service life.

Since 2020, more than 60 structures have been successfully supplied and installed, making corrugated steel structures an established solution within one of Europe’s largest copper mining operations. Supported by regular inspections, measurements and engineering follow-up, the installations continue to demonstrate reliable structural performance, operational safety and long-term stability in demanding underground conditions.