Self Drilling Rock Bolt Technology for the Coal Industry Advanced Solutions Ground Support Services Pty Ltd September 2007

Self Drilling Rock BoltSelf Drilling Rock Bolt TechnologyTechnology

for the Coal Industryfor the Coal Industry

Advanced SolutionsAdvanced Solutions

Self Drilling Rock BoltSelf Drilling Rock Bolt TechnologyTechnology

for the Coal Industryfor the Coal Industry

Advanced SolutionsAdvanced Solutions

Ground Support Services Pty Ltd September 2007Ground Support Services Pty Ltd September 2007Ground Support Services Pty Ltd September 2007Ground Support Services Pty Ltd September 2007

GSS

© 2007 GSS Pty Ltd © 2007 GSS Pty Ltd 22

SDRB Advanced Solutions SDRB Advanced Solutions SDRB Advanced Solutions SDRB Advanced Solutions

…it is all about productivity …it is all about productivity

A pick & shovel is cheaper than a Longwall…..but it is not as productive


SDRB Advanced SolutionsSDRB Advanced SolutionsSDRB Advanced SolutionsSDRB Advanced Solutions

In the future, ……we need to provide a leap forwardIn the future, ……we need to provide a leap forward in roadway productivity in roadway productivity In the future, ……we need to provide a leap forwardIn the future, ……we need to provide a leap forward in roadway productivity in roadway productivity

Similarly, we don’t use pit props any more……….Similarly, we don’t use pit props any more……….


Operating Costs * Operating Costs * Operating Costs * Operating Costs *

Total Cost of Operating a Continuous Miner Unit per year*Total Cost of Operating a Continuous Miner Unit per year* $6,640,000$6,640,000

Average number of metres driven per DayAverage number of metres driven per Day 100100

Number of Shifts per DayNumber of Shifts per Day 33

Average number of metres driven per shift Average number of metres driven per shift 3333

Total Actual Operating Hours per yearTotal Actual Operating Hours per year 3,0723,072

Operating Cost per Continuous Miner Unit Operating Cost per Continuous Miner Unit per hourper hour $2,161$2,161

Operating Cost per Continuous Miner Unit Operating Cost per Continuous Miner Unit per minuteper minute $36.02$36.02

* A continuous miner unit includes all equipment to drive a roadway based on ACARP Report on Roadway Development, by Gary Gibson, 2006

Costs of Operating a Miner & Installing Bolts:Costs of Operating a Miner & Installing Bolts:

Average Time to Install a standard rock bolt Average Time to Install a standard rock bolt 150 secs150 secs

Average Cost of Installing a standard rock bolt based on TIME Average Cost of Installing a standard rock bolt based on TIME ONLYONLY

$90.06$90.06

Average number of standard rock bolts installed per Continuous Average number of standard rock bolts installed per Continuous Miner Unit per year Miner Unit per year

51,20051,200

Average Average Cost of TIMECost of TIME to install standard rock bolts per to install standard rock bolts per Continuous Miner Unit per yearContinuous Miner Unit per year

$4,611,072$4,611,072


Advanced SDRB SolutionsAdvanced SDRB Solutions Advanced SDRB SolutionsAdvanced SDRB Solutions

Not just about supporting the roof

Mines need the Solutions to drive Roadways faster

Need to consider the whole Roadway

SDRBs available for many years in Europe (18 SDRBs)

Pumpable Resin SDRB

Advanced Self Drilling Bolt Technology

Conclusions

Not just about supporting the roof

Mines need the Solutions to drive Roadways faster


SDRBs available for many years in Europe (18 SDRBs)

Pumpable Resin SDRB

Advanced Self Drilling Bolt Technology

Conclusions


Existing SDRBsExisting SDRBsExisting SDRBsExisting SDRBs

Wiborex

Romtech

DSI

MAI

Furen

Alwag Alwag

Stainless

CarboTech

Williams Hilti

Atlas Copco

Ischebeck


Pumpable Resin SDRB Pumpable Resin SDRB Pumpable Resin SDRB Pumpable Resin SDRB

resin fills bearing plate & also locks mesh in place resin fills bearing plate & also locks mesh in place

full encapsulation both inside and outside boltfull encapsulation both inside and outside bolt

Full bolt encapsulation maximises roof support Full bolt encapsulation maximises roof support

No gloving, no plastic film, no under-mixing or No gloving, no plastic film, no under-mixing or over-mixing over-mixing

Perfect resin mixing every timePerfect resin mixing every time

Resin fills bearing plate & locks mesh in placeResin fills bearing plate & locks mesh in place

Minimises water inflow from bolt holes Minimises water inflow from bolt holes

Minimises bolt corrosionMinimises bolt corrosion

Full bolt encapsulation maximises roof support Full bolt encapsulation maximises roof support

No gloving, no plastic film, no under-mixing or No gloving, no plastic film, no under-mixing or over-mixing over-mixing

Perfect resin mixing every timePerfect resin mixing every time

Resin fills bearing plate & locks mesh in placeResin fills bearing plate & locks mesh in place

Minimises water inflow from bolt holes Minimises water inflow from bolt holes

Minimises bolt corrosionMinimises bolt corrosion

visible resin at collar proves full encapsulationvisible resin at collar proves full encapsulation visible resin at collar proves full encapsulationvisible resin at collar proves full encapsulation


SDRB load transfer capacitySDRB load transfer capacitySDRB load transfer capacitySDRB load transfer capacityLoad Transfer Capacity about 2 x solid boltsLoad Transfer Capacity about 2 x solid bolts Load Transfer Capacity about 2 x solid boltsLoad Transfer Capacity about 2 x solid bolts


SDRB Underground TrialsSDRB Underground TrialsSDRB Underground TrialsSDRB Underground Trials

Once SDRB is placed in chuck, no manual handling

SDRB remains completely straight throughout drilling cycle

2m hole drilled in 24 secs (83mm/sec)

The water column inside the SDRB gets displaced by the resin

Plate gets pushed firmly up against mesh at about 400 Nm

End of bolt is completely clean

Points to Note:Points to Note:


SDRB SDRB SDRB SDRB

Refined the bolt designRefined the bolt design

Improved the equipment Improved the equipment

Improved resinImproved resin

Planning on undertaking a large scale installation Planning on undertaking a large scale installation

However – need to look at aHowever – need to look at a Total SolutionTotal Solution

Refined the bolt designRefined the bolt design

Improved the equipment Improved the equipment

Improved resinImproved resin

Planning on undertaking a large scale installation Planning on undertaking a large scale installation

However – need to look at aHowever – need to look at a Total SolutionTotal Solution

SDRB Progress:SDRB Progress:SDRB Progress:SDRB Progress:



Not about products or systems - about Solutions


How to support intersections? Long tendon support is often essential But installing long tendons from the miner is

slow Outbye cable bolting sometimes too late

How to support 3m+ ribs? Can only install 1.2m bolts from minerCan only install 1.2m bolts from miner

Not about products or systems - about Solutions


How to support intersections? Long tendon support is often essential But installing long tendons from the miner is

slow Outbye cable bolting sometimes too late

How to support 3m+ ribs? Can only install 1.2m bolts from minerCan only install 1.2m bolts from miner

Bolt length is restricted by Roadway opening height



Why can’t long tendons be installed quickly?

Long cable bolts are slow to install Drill string coupled & uncoupled Mostly manual handling

Why can’t long tendons be installed quickly?

Long cable bolts are slow to install Drill string coupled & uncoupled Mostly manual handling

Rock Bolt length restricted to roadway opening? Coupled bolts - slow Coupled self drilling bolts – still slow

Rock Bolt length restricted to roadway opening? Coupled bolts - slow Coupled self drilling bolts – still slow

Cable Bolt

Coupled Bolt


Advanced SDRB Solutions Advanced SDRB Solutions Advanced SDRB Solutions Advanced SDRB Solutions

Why can’t we have SDRBs that can be installed:

Quickly?

Automatically?

Be longer than the roadway opening?

Provide immediate support?

Provide high capacity roof support?

Why can’t we have SDRBs that can be installed:

Quickly?

Automatically?

Be longer than the roadway opening?

Provide immediate support?

Provide high capacity roof support?



Outer Bar

Inner Bar



Rock Face

Inner Bar Unscrews


Telescopic SDRB Telescopic SDRB Telescopic SDRB Telescopic SDRB

Drill Bit digs into Rock Face

Outer BarInner Bar

Inner Bar Unscrews



Drill Chuck Position Fixed

Extension here


0

50

100

150

200

250

0 5 10 15 20 25

Telescopic SDRB: Telescopic SDRB: Drilling or ExtendingDrilling or Extending Telescopic SDRB: Telescopic SDRB: Drilling or ExtendingDrilling or Extending

Drilling: th

reads locked

Extending: threads unlocked

Axial Thrust (KN)

Res

isti

ve T

orq

ue

(Nm

)


Telescopic SDRBTelescopic SDRBTelescopic SDRBTelescopic SDRB

Position Fixed

Distance to roof remains constant

1. Place Bolt in Chuck & fix in position. Begin to rotate – Axial force increases.

1



2. Axial force increases - locking threads - enabling drilling

1 2



3. Axial force decreases as hole drilled - unlocking threads – enabling extension

1 2 3



1 2 3 4

4. Continued drilling & extension – operator can see full extension of Outer Bar


5

5. Chuck unlocked & travels to roof as drilling progresses

6 7

6. Drilling continued until hole fully drilled 7. Resin pumped

into Bolt for 30 secs

– Outer Bar fully encapsulated

- Nut then tensioned

- Total Cycle time ~2mins ~3.9m


Telescopic SDRBsTelescopic SDRBs Telescopic SDRBsTelescopic SDRBs Standard SDRBStandard SDRB Telescopic SDRBTelescopic SDRB

LengthLength 1.2 to 2.4m 1.2 to 2.4m 2.0 to 4.6m2.0 to 4.6m

Load transfer Load transfer capacitycapacity

1212 tonnes/100mm tonnes/100mm 2020 tonnes/100mm tonnes/100mm

Tensile Tensile Strength*Strength*

38 tonnes 38 tonnes 38 tonnes 38 tonnes

Drill TimeDrill Time approx approx 2525 secs secs approx approx 6060 secs secs

Resin Pump Resin Pump TimeTime

3030 secs secs 3030 secs secs

Total Total Installation Installation TimeTime

approx approx 6060 secs secs less than less than 120120 secs secs


60 x 2m long telescopic Rib SDRBs (blue)

215 x Standard SDRBs (yellow)

10 x 4m long telescopic Roof SDRBs (blue)

Telescopic SDRB TechnologyTelescopic SDRB TechnologyTelescopic SDRB TechnologyTelescopic SDRB Technology

55m of Roadway 55m of Roadway 55m of Roadway 55m of Roadway


Conclusions: Telescopic SDRB Conclusions: Telescopic SDRB Conclusions: Telescopic SDRB Conclusions: Telescopic SDRB

AutomaticallyAutomatically extendable extendable

Very fastVery fast bolt installation ~120 secs bolt installation ~120 secs

Very highVery high load transfer capacity above normal bolt horizon load transfer capacity above normal bolt horizon

Minimises Manual HandlingMinimises Manual Handling

Simplicity:Simplicity: No drill rods, No drive dollies, No changing drill bits, No resin cartridges No drill rods, No drive dollies, No changing drill bits, No resin cartridges

& No rotation to mix resin& No rotation to mix resin No Coupling No Coupling No Plastic RodsNo Plastic Rods No JacksNo Jacks No pushing rods or cables up holes No pushing rods or cables up holes

Improved ProductivityImproved Productivity

AutomaticallyAutomatically extendable extendable

Very fastVery fast bolt installation ~120 secs bolt installation ~120 secs

Very highVery high load transfer capacity above normal bolt horizon load transfer capacity above normal bolt horizon

Minimises Manual HandlingMinimises Manual Handling

Simplicity:Simplicity: No drill rods, No drive dollies, No changing drill bits, No resin cartridges No drill rods, No drive dollies, No changing drill bits, No resin cartridges

& No rotation to mix resin& No rotation to mix resin No Coupling No Coupling No Plastic RodsNo Plastic Rods No JacksNo Jacks No pushing rods or cables up holes No pushing rods or cables up holes

Improved ProductivityImproved Productivity

The world’s first automatically

extendable SDRB

The world’s first automatically

extendable SDRB


– – a revolution in ground supporta revolution in ground support– – a revolution in ground supporta revolution in ground support

Ground Support Services Pty Ltd September 2007



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Documents

Self Drilling Rock Bolt Technology for the Coal Industry Advanced Solutions Ground Support Services Pty Ltd September 2007