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

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Presentation on theme: "Self Drilling Rock Bolt Technology for the Coal Industry Advanced Solutions Ground Support Services Pty Ltd September 2007."— Presentation transcript:

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

2 © 2007 GSS Pty Ltd 2 SDRB Advanced Solutions Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts …it is all about productivity A pick & shovel is cheaper than a Longwall…..but it is not as productive

3 © 2007 GSS Pty Ltd 3 SDRB Advanced Solutions In the future, ……we need to provide a leap forward in roadway productivity Similarly, we don’t use pit props any more……….

4 © 2007 GSS Pty Ltd 4 Operating Costs * Total Cost of Operating a Continuous Miner Unit per year* $6,640,000 Average number of metres driven per Day 100 Number of Shifts per Day 3 Average number of metres driven per shift 33 Total Actual Operating Hours per year 3,072 Operating Cost per Continuous Miner Unit per hour $2,161 Operating Cost per Continuous Miner Unit per minute $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: Average Time to Install a standard rock bolt 150 secs Average Cost of Installing a standard rock bolt based on TIME ONLY $90.06 Average number of standard rock bolts installed per Continuous Miner Unit per year 51,200 Average Cost of TIME to install standard rock bolts per Continuous Miner Unit per year $4,611,072

5 © 2007 GSS Pty Ltd 5 Advanced 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  Need to consider the whole Roadway  SDRBs available for many years in Europe (18 SDRBs)  Pumpable Resin SDRB  Advanced Self Drilling Bolt Technology  Conclusions

6 © 2007 GSS Pty Ltd 6 Existing SDRBs Wiborex Romtech DSI MAI Furen Alwag Stainless CarboTech Williams Hilti Atlas Copco Ischebeck

7 © 2007 GSS Pty Ltd 7 Pumpable Resin SDRB resin fills bearing plate & also locks mesh in place full encapsulation both inside and outside bolt  Full bolt encapsulation maximises roof support  No gloving, no plastic film, no under-mixing or over-mixing  Perfect resin mixing every time  Resin fills bearing plate & locks mesh in place  Minimises water inflow from bolt holes  Minimises bolt corrosion  Full bolt encapsulation maximises roof support  No gloving, no plastic film, no under-mixing or over-mixing  Perfect resin mixing every time  Resin fills bearing plate & locks mesh in place  Minimises water inflow from bolt holes  Minimises bolt corrosion visible resin at collar proves full encapsulation

8 © 2007 GSS Pty Ltd 8 SDRB load transfer capacity Load Transfer Capacity about 2 x solid bolts Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts

9 © 2007 GSS Pty Ltd 9 SDRB 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:

10 © 2007 GSS Pty Ltd 10SDRBSDRB  Refined the bolt design  Improved the equipment  Improved resin  Planning on undertaking a large scale installation  However – need to look at a Total Solution  Refined the bolt design  Improved the equipment  Improved resin  Planning on undertaking a large scale installation  However – need to look at a Total Solution Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts SDRB Progress:

11 © 2007 GSS Pty Ltd 11 Advanced SDRB Solutions  Not about products or systems - about Solutions  Need to consider the whole Roadway  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 miner  Not about products or systems - about Solutions  Need to consider the whole Roadway  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 miner Bolt length is restricted by Roadway opening height

12 © 2007 GSS Pty Ltd 12 Advanced SDRB Solutions  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

13 © 2007 GSS Pty Ltd 13 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?

14 © 2007 GSS Pty Ltd 14 Advanced SDRB Solutions Outer Bar Inner Bar

15 © 2007 GSS Pty Ltd 15 Advanced SDRB Solutions Rock Face Inner Bar Unscrews

16 © 2007 GSS Pty Ltd 16 Telescopic SDRB Drill Bit digs into Rock Face Outer Bar Inner Bar Inner Bar Unscrews

17 © 2007 GSS Pty Ltd 17 Telescopic SDRB Drill Chuck Position Fixed Extension here

18 © 2007 GSS Pty Ltd 18 Telescopic SDRB: Drilling or Extending Drilling: threads locked Extending: threads unlocked Axial Thrust (KN) Resistive Torque (Nm)

19 © 2007 GSS Pty Ltd 19 Telescopic SDRB Position Fixed Distance to roof remains constant 1. Place Bolt in Chuck & fix in position. Begin to rotate – Axial force increases. 1

20 © 2007 GSS Pty Ltd 20 Telescopic SDRB 2. Axial force increases - locking threads - enabling drilling 1 2

21 © 2007 GSS Pty Ltd 21 Telescopic SDRB 3. Axial force decreases as hole drilled - unlocking threads – enabling extension 1 2 3

22 © 2007 GSS Pty Ltd 22 Telescopic SDRB Continued drilling & extension – operator can see full extension of Outer Bar

23 © 2007 GSS Pty Ltd Chuck unlocked & travels to roof as drilling progresses 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

24 © 2007 GSS Pty Ltd 24 Telescopic SDRBs Standard SDRB Telescopic SDRB Length 1.2 to 2.4m 2.0 to 4.6m Load transfer capacity 12 tonnes/100mm 20 tonnes/100mm Tensile Strength* 38 tonnes Drill Time approx 25 secs approx 60 secs Resin Pump Time 30 secs Total Installation Time approx 60 secs less than 120 secs

25 © 2007 GSS Pty Ltd x 2m long telescopic Rib SDRBs (blue) 215 x Standard SDRBs (yellow) 10 x 4m long telescopic Roof SDRBs (blue) Telescopic SDRB Technology 55m of Roadway

26 © 2007 GSS Pty Ltd 26 Conclusions: Telescopic SDRB  Automatically extendable  Very fast bolt installation ~120 secs  Very high load transfer capacity above normal bolt horizon  Minimises Manual Handling  Simplicity:  No drill rods, No drive dollies, No changing drill bits, No resin cartridges & No rotation to mix resin  No Coupling  No Plastic Rods  No Jacks  No pushing rods or cables up holes  Improved Productivity  Automatically extendable  Very fast bolt installation ~120 secs  Very high load transfer capacity above normal bolt horizon  Minimises Manual Handling  Simplicity:  No drill rods, No drive dollies, No changing drill bits, No resin cartridges & No rotation to mix resin  No Coupling  No Plastic Rods  No Jacks  No pushing rods or cables up holes  Improved Productivity Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts Large ‘Swirl Chamber’ for efficient cuttings removal Small annulus to generate high load- transfer capacity Use of pumpable, low viscosity, fast set resin for immediate, high capacity roof support Long Nut for:  bolt alignment  maximising Nut thread strength  drilling rotation  axial thrust  tensioning Injection sleeve for:  large diameter injection nozzle  Nut stop rotation  self-centering & bolt alignment New, custom designed Drill Bit with aggressive profile for fast penetration Welded Drill Bit with stabilising tang for high axial thrust New, micro-alloyed, thick-walled steel hollow bar for:  high strength & good ductility  maximising resin flow  enabling high axial thrust Continuous, coarse profile to provide high load transfer capacity New internal seals to ensure perfect sealing for every bolt every time M27 x 3mm pitch cold-rolled thread for Nut tensioning Full column resin encapsulation for maximum roof support & to minimise corrosion Separate Domed Ball for angled bolts The world’s first automatically extendable SDRB

27 © 2007 GSS Pty Ltd 27 – a revolution in ground support Ground Support Services Pty Ltd September 2007 Telescopic SDRB

28 © 2007 GSS Pty Ltd 28 EndEnd


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